MANUFACTURING

TECHNOLOGY

ADAPTIVE CONTROL
SYSTEMS FOR MACHINING
BY
K.SRIPATHI
M.RENUKA
P.MAHESH NAIDU
(MVGR COLLEGE OF ENGINEERING)

Introduction

Adaptive control systems is a logical extension of the CNC

mechanism.

The control systems which automatically selects the required values

of process control variables based on line-process measurements
are mainly referred as ADAPTIVE CONTROL SYSTEMS.

Adaptive control is basically a feedback system that takes CNC as a

internal unit.

Why adaptive control ?

It is mainly introduced to overcome the limitations of CNC.

A common drawback of CNCS is that the control variables are

totally dependent on programmers knowledge and experience.

Considering the most adverse conditions and also reducing tool

failure is highly impossible by a CNC.

CNC controls only the relative position between tool and workpiece and not the metal-cutting process itself.

Schematic representation
CNC systems

Drive commands
Position feedback

Feed
rate ,speed
corrections

Adaptive
controller

strategy
constraints
IP

Machine tool
Machining
process

Measured variables

Sensors

Functions of adaptive control

There are 3 functions that it can perform. They are :

Identifying the current performance by taking measurements of

inputs and outputs.(IDENTIFICATION)

Depending on that, a decision procedure is carried out to

determine what changes are needed to improve system
performance.(DECISION)

Considering the above factors ,the system modifies to the actual

conditions.(MODIFICATION)

Types of adaptive control

ADAPTIVE
CONTROL

TECHNOLOGICAL
ADAPTIVE
CONTROL
GEOMETRICAL
ADAPTIVE
COMTROL

ADAPTIVE
CONTROL
CONSTRAINT
ADAPTIVE
CONTROL
OPTIMIZATION

ADAPTIVE CONTROL CONSTRAINTS :

The

principle of ACC system is to sense the constraint

variable and to adjust the cutting speed and feed
according to this measurement and a programmed
strategy.

The

objective in this system is to manipulate feed and/

or speed so that these measured process variables are
maintained at or below their constraint values.

The most useful constraints in practical ACC systems are

the cutting force F, the cutting power P, and the torque T.

ADAPTIVE CONTROL OPTIMIZATION :

ACO refers to systems in which the performance is optimized

according to a prescribed IP.

The IP is usually an economic function such as maximum

production rate or minimum machining cost.

It is basically a sophisticated closed loop control system ,

which automatically works in optimum conditions, even in the
presences of work piece and tools materials variations.

Advantages :

Increased production rates.

Increased tool life

Highest metal removal rates consistent to the existing conditions.

It is more advantageous where there are wide variations in the

depth of cut during machining.

Dimensional accuracy and better surface finish can be obtained.

Disadvantages :
Inspite of the economic advantage's, there are some limitations of
AC systems. They are :

Unavailability of suitable sensors that have a reliable operation in

a manufacturing environment.

Interface of AC systems with CNC units is another major

problem.

Force and torque sensors in ACC systems are difficult to install.

There exists some stability problems due to oscillations in the

ranges of cutting parameters.

IMAGE SHOWING TURNING

OPERATION

Applications :
Adaptive control for turning :
An adaptive control (AC) system is described for turning on a
lathe.
In this system, a programmed cutting force is compared with the
actual cutting force; the difference provides correction to the feed.
It is demonstrated that the effective AC loop gain depends on both
depth-of-cut and spindle speed and thereby influence system
stability.
A method

to maintain a constant system gain is proposed.

Conclusion :
For a machining operation adaptive control is the best method for
controlling the process, there are still some major theoretical and
practical problems which must be solved before wide-spread
industrial use can be expected. With developments more AC
systems can be utilized in production plants.

THANK YOU

Queries ???