Abstract
A layered modeling method is proposed to resolve the problems resulting from the complexity of the error model of a multi-axis motion control system. In this model, a low level layer can be used as a virtual axis by the high level layer. The first advantage of this model is that the complex error model of a four-axis motion control system can be divided into several simple layers and each layer has different coupling strength to match the real control system. The second advantage lies in the fact that the controller in each layer can be designed specifically for a certain purpose. In this research, a three-layered cross coupling scheme in a four-axis motion control system is proposed to compensate the contouring error of the motion control system. Simulation results show that the maximum contouring error is reduced from 0.208 mm to 0.022 mm and the integration of absolute error is reduced from 0.108 mm to 0.015 mm, which are respectively better than 0.027 mm and 0.037 mm by the traditional method. And in the bottom layer the proposed method also has remarkable ability to achieve high contouring accuracy.
This is a preview of subscription content, log in via an institution to check access.
Similar content being viewed by others
References
KOREN Y. Cross-coupled biaxial computer control for manufacturing [J]. ASME Journal of Dynamic System, Measurement and Control, 1980, 112: 225–232.
CHENG M Y, LEE C C. Motion controller design for contour following tasks based on real-time contour error estimation [J]. IEEE Transactions on Industrial Electronics, 2007, 54(3): 1686–1695.
YANG Jiang-zhao, LI Ze-xiang. A novel contour error estimation for position loop-based cross-coupled control [J]. IEEE/ASME Tran Mechatronics, 2011, 16(4): 643–655.
YEH Syh-Shiuh, HSU Pau-Lo. Estimation of the contouring error vector for the cross-coupled control design [J]. IEEE/ASME Tran Mechatronics, 2002, 7(1): 44–51.
ZHU Shao-wei, DING Guo-fu, QIN Sheng-feng, LEI Jiang, ZHUANG Li, YAN Kai-yin. Integrated geometric error modeling, identification and compensation of CNC machine tools [J]. International Journal of Advanced Manufacturing Technology, 2012, 52: 24–29.
UCHIYAMA Naoki. Robust contouring control for biaxial feed drive systems [J]. International Journal of Machine Tools & Manufacture, 2008, 48: 1234–1241.
SUN Dong, TONG Ming-Chau. A synchronization approach for the minimization of contouring errors of CNC machine tools [J]. IEEE Trans Automation Science and Engineer, 2009, 6: 720–729.
CONWAY J R, ERNESTO C A, FAROUKI R T, ZHANG M. Performance analysis of cross-coupled controllers for CNC machines based upon precise real-time contour error measurement [J]. International Journal of Advanced Manufacturing Technology, 2012, 52: 30–39.
PENG Chao-chung, CHEN Chieh-li. Biaxial contouring control with friction dynamics using a contour index approach [J]. International Journal of Machine Tools & Manufacture, 2007, 47: 1542–1555.
GONG Shi-hua, HUANG Yu. Adaptive control of cam contour error in camshaft grinding process [J]. Electric Drive & Automatic Control, 2010, 32(4): 1–3. (in Chinese)
ZHANG D L, CHEN X S, DU R. A CNC program module based on polar coordinate system [J]. International Journal of Advanced Manufacturing Technology, 2013, 68: 1767–1773.
SHIN Joong-ho, YANG Hyun-dai, KWON Soon-man. Kinematical system of breadth cam profile design [J]. Journal of Central South University, 2011, 18: 451–457
LO Chih-Ching. A tool-path control scheme for five-axis machine tools [J]. International Journal of Machine Tools & Manufacture, 2002, 42: 79–88.
FRANCISCO J, GERARDO C, ISMAEL A V. Relative coupling strategy [C]// IEEE International Electric Machines and Drives Conference. Madison, 2003, 2: 1162–1166.
ZHU Lin-sen, TANG Yang-ping, BIN Hong-zan, FENG Qing-xiu, XIONG Cai-hua. Study on symmetrical machining technology [J]. International Journal of Advanced Manufacturing Technology, 2008, 36: 844–851.
Author information
Authors and Affiliations
Corresponding author
Additional information
Foundation item: Project(51005086) supported by the National Natural Science Foundation of China; Project(2010MS085) supported by the Fundamental Research Funds for the Central Universities, China; Project(DMETKF2013008) supported by the Open Project of the State Key Laboratory of Digital Manufacturing Equipment and Technology, China
Rights and permissions
About this article
Cite this article
Zhang, Dl., Zhang, X., Xie, Jm. et al. Contouring error modeling and simulation of a four-axis motion control system. J. Cent. South Univ. 22, 141–149 (2015). https://doi.org/10.1007/s11771-015-2504-z
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11771-015-2504-z