Analysis and control of vibration in machine tools

Lim, Kim Yew (2017) Analysis and control of vibration in machine tools. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

The aim of this report is to analyze the characteristic of vibration on machine tools, to design a controller and an observer, and to validate the performance of control system. Precision and accuracy play important role in enhancing the performance and quality of the control system. However, vibration, is known as disturbance force that occur on machine tool can reduce the accuracy of the system. Hence, a compensator is required to design for mitigating the vibration effect to the system. In this project, a cascade P/PI controller and an inverse model based disturbance observer were chosen as compensator to control the vibration effect. Firstly, the behavior of the system was evaluated by finding its transfer function. Then, a cascade P/PI controller and disturbance observer were designed in MATLAB Simulink environment by applying the principle of traditional loop shaping method with taken into consideration on phase margin, gain margin, Nyquist diagram and bandwidth. Numerical analysis was carried out using MATLAB Simulink software. Two parameters were analyzed; disturbance rejection in root mean square tracking error and maximum amplitude of tracking error. The tracking performance of the control system was analyzed with and without input disturbances signals, then a comparison was made between them. A sinusoidal input reference was applied for this project. XYZ stage was used as positioning system whereas band limited white noise and cutting forces were utilized as emitting disturbance signal. To validate the performance of controller, an experimental analysis was conducted on the test setup. Based on the result obtained, a cascade P/PI controller with an add-on module, disturbance observer had reduced the disturbance efficiently by 21 %. Further improvement was recommended by adding the speed feedforward to enhance the robustness of control system.

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