Design and control of a novel hybrid feed drive for high performance and energy efficient machining

Okwudire, Chinedum E.; Rodgers, Jason

doi:10.1016/j.cirp.2013.03.139

Cited by 28 publications

(14 citation statements)

References 13 publications

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“…The idea behind the HFD is to: (i) drive the machine table using the LMD during rapid traverse to achieve very high speeds and accelerations with low energy consumption; (ii) drive the table using a low-lead SD during cutting to achieve the required cutting speeds with low energy consumption; (iii) use the LMD to compensate for vibrations and errors introduced by the SD during cutting; and (iv) ensure that the switch between the LMD and SD can be achieved rapidly and energy efficiently at any position of the table within its travel. Figure 1 shows the CAD model of a HFD prototype whose design is detailed in [8]. An air core linear motor is employed to drive the table because it does not need to support large cutting forces for which iron core motors are better suited, hence cogging forces are minimized.…”

Section: Overview Of Hfd Conceptmentioning

confidence: 99%

“…Note that using a toggle mechanism ensures that no energy is required to keep the nut halves separated. Figure 2(a) shows a slightly simplified version of the controller proposed for the cutting mode of the HFD, when the LMD and SD are coupled together [8]. x r is the reference position while x 1 and x 2 represent the (equivalent) linear displacements of the rotary and linear motors, respectively.…”

Section: Overview Of Hfd Conceptmentioning

confidence: 99%

“…The resultant heat generated has to be removed by cooling systems to prevent thermal issues, thus driving up the cost and energy consumption of the machine [5]. To reduce the energy/heat issues related to linear motors, Okwudire and Rodgers [8] have recently proposed a hybrid feed drive (HFD). Much like hybrid electric vehicles, their proposed HFD synergistically combines a LMD and SD to achieve speeds and accuracies similar to LMDs while consuming much less energy [8,9].…”

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Energy Efficiency and Performance Optimized Control of a Hybrid Feed Drive

Duan

Okwudire

2015

Volume 2: Materials; Biomanufacturing; Properties, Applications and Systems; Sustainable Manufacturing

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Linear motor drives (LMDs) are well known to provide significant advantages in terms of positioning speed and precision over traditional screw drives (SDs), making them better suited for high-speed, high-precision machine tools. However, their use in such machine tools is limited by their tendency to consume a lot of electrical energy and cause thermal issues that help drive up costs. A hybrid feed drive (HFD) has been proposed as a possible solution to this dilemma. The HFD combines LMD and SD actuation to achieve speeds and accuracies similar to LMDs while consuming much less energy. This paper explores control strategies to further improve the performance of the HFD without unduly sacrificing its efficiency. First, it highlights two performance limitations of the controller proposed for the HFD in prior work, namely, imperfect tracking and suboptimal feedback gains. Then it compares two approaches for achieving perfect tracking with regard to performance and energy efficiency. Finally, it presents an approach for optimizing the feedback gains of the HFD to achieve the best positioning performance. Simulations and experiments are used to demonstrate significant gains in precise positioning using the methods proposed in this paper, while maintaining superb energy efficiency relative to an equivalent LMD.

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Section: Overview Of Hfd Conceptmentioning

confidence: 99%

Section: Overview Of Hfd Conceptmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Energy Efficiency and Performance Optimized Control of a Hybrid Feed Drive

Duan

Okwudire

2015

Volume 2: Materials; Biomanufacturing; Properties, Applications and Systems; Sustainable Manufacturing

View full text Add to dashboard Cite

show abstract

“…A combination of different actuation principles, on the other hand, improves the energy efficiency of actuators and combines the advantages of both principles. In this context, for example, hybrid drives are being designed which provide lower energy consumption than regular linear motor direct drives and combine their higher speed and accuracy with the higher damping of screw drives (Okwudire and Rodgers 2013). Chen et al (2014) present the design of a novel three-degrees-of-freedom linear magnetic actuator which increases the damping and static stiffness of flexible structures during machining.…”

Section: Reconfigurable Machine Toolsmentioning

confidence: 99%

Sustainable Solutions for Machine Tools

Uhlmann

Lang

Prasol

et al. 2017

Sustainable Production, Life Cycle Engineering and Management

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Environmental, economic and social changes of any significant proportions cannot take place without a major shift in the manufacturing sector. In today's manufacturing processes, economic efficiency is realised through high volumes with the use of specialised machine tools. Change in society, such as in the form of mobility and digitisation, requires a complete overhaul in terms of thinking in the manufacturing industry. Moreover, the manufacturing industry contributes over 19 % to the world's greenhouse gas emissions. As a consequence of these issues, a demand for sustainable solutions in the production industry is increasing. In particular, the concept of "cost" in manufacturing processes and thus the "system boundaries" within the production of the future has to be changed. That is, a great number of aspects to the machine tool and production technology industries can be improved upon in order to achieve a more sustainable production environment. Within this chapter, the focus lies on microsystem technology enhanced modular machine tool frames, adaptive mechatronic components, as well as on internallycooled cutting tools. An innovative machine tool concept has been developed recently, featuring a modular machine tool frame using microsystem technology for communication within the frame, which allows for a high level of flexibility. Furthermore, add-on upgrading systems for outdated machine tools-which are particularly relevant for developing and emerging countries-are poised to gain in importance in the upcoming years. The system described here enables the accuracy of outdated machine tools to be increased, thus making these machine tools comparable to modern machine tool systems. Finally, the cutting process requires solutions for dry machining, as the use of cooling lubricants is environmentally damaging and a significant cost contributor in machining processes. One such solution is the use of internally cooled cutting tools.

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“…In order to find ways to overcome these problems, under the funding of the doctoral scientific research foundation of Shandong Jiaotong University, the latest theory of mechanism [4][5][6][7][8][9][10] was applied to design the working devices of the construction machinery, and some of multi-DOF controllable loading mechanism was invented [11][12], which are mechanical loaders that can realize flexible control of bucket trajectory, and use link mechanism instead of hydraulic transmission. This kind of loading mechanism not only low in energy consumption, high in reliability and flexible in action, but also in full electric control, which is very suitable for the manufacture of a super small loader.…”

Section: Introductionmentioning

confidence: 99%

The inverse kinematics analysis and simulation study on the controllable loading mechanism

Zhang

Cai

2018

MATEC Web Conf.

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Abstract. The multi-DOF controllable loading mechanism adopts the electric drive system to replace the hydraulic drive system of traditional loader, not only has higher transmission efficiency and has better mechanical and electrical integration level, but also overcome the shortcomings of high cost of manufacture and maintenance.The inverse kinematics model of this type of loading mechanism was built by means of closed loop vector method. According to the performance index of the loading mechanism, the inverse kinematics model was solved by means of MATLAB software, and the input motion law of the two driving lever at different period of time is obtained, and a small prototype is built, which provides the basis for control system programming of this new type of leading mechanism. To some extent, this research lays a foundation for further development of this type of loading mechanism.

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Design and control of a novel hybrid feed drive for high performance and energy efficient machining

Cited by 28 publications

References 13 publications

Energy Efficiency and Performance Optimized Control of a Hybrid Feed Drive

Energy Efficiency and Performance Optimized Control of a Hybrid Feed Drive

Sustainable Solutions for Machine Tools

The inverse kinematics analysis and simulation study on the controllable loading mechanism

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