Abstract
The gear generation process is strongly dependent on the accuracy of the multi-axis relative motion, which is controlled by the electronic gearbox (EGB). This research mainly focuses on helical gear hobbing and on EGB control error analysis, estimation and compensation in the generation process of a gear hobbing machine. First, a simple approach for estimation of the helical gear pitch error and the spiral line contour error is proposed. Then, in conjunction with this estimation method, an EGB cross-coupling controller (ECCC) architecture, which is connected by the EGB and the cross-coupling controller, is presented. Simulation results show that the proposed ECCC has higher control accuracy than an uncoupled controller, and its control accuracy can be further improved using friction compensation. Finally, experiments are conducted on an YS3118 six-axis hobbing machine. The helical gears machined using this machine have high precision. In addition, the proposed ECCC architecture can be implemented easily on most motion systems that are in current use.
Similar content being viewed by others
References
Bouzakis, K. D., Lili, E., Michailidis, N., and Friderikos, O., “Manufacturing of Cylindrical Gears by Generating Cutting Processes: A Critical Synthesis of Analysis Methods,” CIRP Annals-Manufacturing Technology, Vol. 57, No. 2, pp. 676–696, 2008.
Dinsdale, J., Jones, P. F., Thorneycroft, M., and Loxham, J., “The Electronic Gearbox-Computer Software Replaces Mechanical Couplings,” CIRP Annals-Manufacturing Technology, Vol. 31, No. 1, pp. 247–249, 1982.
Leadbeater, P. B., Clarke, M., Wills-Moren, W. J., and Wilson, T. J., “A Unique Machine for Grinding Large, Off-Axis Optical Components: The OAGM 2500,” Precision Engineering, Vol. 11, No. 4, pp. 191–196, 1989.
McKeown, P. A., “High Precision Manufacturing and the British Economy,” Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, Vol. 200, No. 3, pp. 147–165, 1986.
Boston, W. T., Carl, J. A., and Connolly, J. L., “Method and Apparatus for Correcting Hysteresis Synchronous Motor Hunting,” US Patent, No. 5235263A, 1993.
Ramesh, R., Mannan, M., and Poo, A., “Tracking and Contour Error Control in CNC Servo Systems,” International Journal of Machine Tools and Manufacture, Vol. 45, No. 3, pp. 301–326, 2005.
Tomizuka, M., “Zero Phase Error Tracking Algorithm for Digital Control,” Journal of Dynamic Systems, Measurement, and Control, Vol. 109, No. 1, pp. 65–68, 1987.
Tsao, T. C. and Tomizuka, M., “Adaptive Zero Phase Error Tracking Algorithm for Digital Control,” Journal of Dynamic Systems, Measurement, and Control, Vol. 109, No. 4, pp. 349–354, 1987.
Park, H. S., Chang, P. H., and Lee, D. Y., “Trajectory Planning for the Tracking Control of Systems with Unstable Zeros,” Mechatronics, Vol. 13, No. 2, pp. 127–139, 2003.
Koren, Y., “Cross-Coupled Biaxial Computer Control for Manufacturing Systems,” Journal of Dynamic Systems, Measurement, and Control, Vol. 102, No. 4, pp. 265–272, 1980.
Koren, Y. and Lo, C. C., “Variable-Gain Cross-Coupling Controller for Contouring,” CIRP Annals-Manufacturing Technology, Vol. 40, No. 1, pp. 371–374, 1991.
Lo, C. C., “Cross-Coupling Control of Multi-Axis Manufacturing Systems,” Ph.D. Thesis, Department of Mechanical Engineering, University of Michigan, 1992.
Yeh, Z. M., Tarng, Y., and Lin, Y., “Cross-Coupled Fuzzy Logic Control for Multiaxis Machine Tools,” Mechatronics, Vol. 7, No. 8, pp. 663–681, 1997.
Chin, J. H. and Lin, T. C., “Cross-Coupled Precompensation Method for the Contouring Accuracy of Computer Numerically Controlled Machine Tools,” International Journal of Machine Tools and Manufacture, Vol. 37, No. 7, pp. 947–967, 1997.
Shih, Y. T., Chen, C. S., and Lee, A. C., “A Novel Cross-Coupling Control Design for Bi-Axis Motion,” International Journal of Machine Tools and Manufacture, Vol. 42, No. 14, pp. 1539–1548, 2002.
Yeh, S. S. and Hsu, P. L., “Estimation of the Contouring Error Vector for the Cross-Coupled Control Design,” IEEE/ASME Transactions on Mechatronics, Vol. 7, No. 1, pp. 44–51, 2002.
Cheng, Y. M. and Chin, J. H., “Machining Contour Errors as Ensembles of Cutting, Feeding and Machine Structure Effects,” International Journal of Machine Tools and Manufacture, Vol. 43, No. 10, pp. 1001–1014, 2003.
Chin, J. H., Cheng, Y. M., and Lin, J. H., “Improving Contour Accuracy by Fuzzy-Logic Enhanced Cross-Coupled Precompensation Method,” Robotics and Computer-Integrated Manufacturing, Vol. 20, No. 1, pp. 65–76, 2004.
Barton, K. and Alleyne, A., “Cross-Coupled Ilc for Improved Precision Motion Control: Design and Implementation,” Proc. of American Control Conference, pp. 5496–5502, 2007.
Cheng, M. Y. and Lee, C. C., “Motion Controller Design for Contour-Following Tasks based on Real-Time Contour Error Estimation,” IEEE Transactions on Industrial Electronics, Vol. 54, No. 3, pp. 1686–1695, 2007.
Barton, K. L. and Alleyne, A. G., “A Cross-Coupled Iterative Learning Control Design for Precision Motion Control,” IEEE Transactions on Control Systems Technology, Vol. 16, No. 6, pp. 1218–1231, 2008.
Su, K. H. and Cheng, M. Y., “Contouring Accuracy Improvement using Cross-Coupled Control and Position Error Compensator,” International Journal of Machine Tools and Manufacture, Vol. 48, No. 12, pp. 1444–1453, 2008.
Chen, C. S. and Chen, L. Y., “Cross-Coupling Position Command Shaping Control in a Multi-Axis Motion System,” Mechatronics, Vol. 21, No. 3, pp. 625–632, 2011.
Uchiyama, N., “Contouring Controller Design based on Iterative Contour Error Estimation for Three-Dimensional Machining,” Robotics and Computer-Integrated Manufacturing, Vol. 27, No. 4, pp. 802–807, 2011.
Chen, C. S. and Chen, L. Y., “Robust Cross-Coupling Synchronous Control by Shaping Position Commands in Multiaxes System,” IEEE Transactions on Industrial Electronics, Vol. 59, No. 12, pp. 4761–4773, 2012.
Huo, F. and Poo, A. N., “Improving Contouring Accuracy by using Generalized Cross-Coupled Control,” International Journal of Machine Tools and Manufacture, Vol. 63, No. pp. 49–57, 2012.
Liu, Y., Han, J., Xia, L., and Tian, X., “Hobbing Strategy and Performance Analyses of Linkage Models for Non-Circular Helical Gears based on Four-Axis Linkage,” Strojniški Vestnik-Journal of Mechanical Engineering, Vol. 58, No. 12, pp. 701–708, 2012.
Xi, X. C., Poo, A. N., and Hong, G. S., “Tracking Error-based Static Friction Compensation for a Bi-Axial CNC Machine,” Precision Engineering, Vol. 34, No. 3, pp. 480–488, 2010.
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Tian, XQ., Han, J. & Xia, L. Precision control and compensation of helical gear hobbing via electronic gearbox Cross-Coupling controller. Int. J. Precis. Eng. Manuf. 16, 797–805 (2015). https://doi.org/10.1007/s12541-015-0105-2
Received:
Revised:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s12541-015-0105-2