Design and Validation of an Adaptive Force Control Algorithm with Parameter Estimation Unit for Electromechanical Feed Axis

Production technology is characterized by the use of electromechanical feed axes, for which the concept of cascade control has become established. The concept is based on linear control engineering. It is not suitable for the control of process forces, which is associated with nonlinearities. Here, adaptive control algorithms from the field of higher control engineering represent a promising approach for improvements of manufacturing strategies and processes in terms of stability, quality, and efficiency. This can also ensure in reducing the number of parts rejected due to bad quality and thus aiding as a significant economic benefit. In this paper, the development of an adaptive control concept that automatically reacts to different and changing environmental conditions during the process is presented. The digital, parameter-adaptive controller consists of a recursive online parameter estimation unit, the controller design procedure, which is based on the setting rule for the symmet ric optimum, and the control algorithm. The functionality of the adaptive control concept is demonstrated in simulation and validated by means of experiments on a test setup. It is real-time capable and implemented directly on the machine control together with all calculation algorithms.