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In the area of production engineering, there are several ongoing efforts to improve manufacturing strategies and processes in terms of stability, quality, and efficiency. Control of process forces is one such appropriate measure for ensuring stable process conditions. This can also ensure in reducing the number of parts rejected due to bad quality and thus aiding as a significant economic benefit. However, control of process forces in production machines with electromechanical feed axes is still a developing field and offers space for potential improvement. Control concepts at the process level, which enable a combination of force control and position control still need to be developed. The concept of hybrid force and position control is presented in this article as a possible approach. Different methods of implementation along with the effects are examined in the simulation. A reduced‐order model of an electromechanical feed axis is used for this purpose. The potential of the hybrid force and position control as well as the limits and possible applications are explained based on the simulation results.

In the field of modern production systems, the process-parallel measurement of time-varying process forces and torques for high-level process monitoring is becoming increasingly important. Commonly utilized methods are based on additional sensors placed close to the working area. Unfortunately, this often leads to a higher complexity and additional costs due to the necessity of external hardware. An alternative approach is to evaluate the already available machine-internal signals of the subordinate drive systems. The process forces act on the load side of the machine axes in the form of disturbance forces and influence the drive-internal signals such as motor current or motor speed. To extract these disturbances, additional superimposed forces (e.g. friction and acceleration forces) and the influence of the feedback control as well as the mechanical system must be considered. Therefore, in the present paper, the application of various observer-based approaches for the estimation of load side disturbances on speed- controlled mechatronic drive systems will be examined. The investigations are performed on a simulation model of a speed-controlled machine axis. After an introduction, three different disturbance observers will be presented. Subsequently, the paper describes the structure of the simulation model including its parameterization based on test rig measurements. Afterwards, the performance of the disturbance observers will be investigated and compared taking selected influencing factors like changing controller and inertia parameters into account. The paper closes with a summary and an outlook.

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