Bayesian networks modeling for thermal error of numerical control machine tools

The interaction between the heat source location, its intensity, thermal expansion coefficient, the machine system configuration and the running environment creates complex thermal behavior of a machine tool, and also makes thermal error prediction difficult. To address this issue, a novel prediction method for machine tool thermal error based on Bayesian networks (BNs) was presented. The method described causal relationships of factors inducing thermal deformation by graph theory and estimated the thermal error by Bayesian statistical techniques. Due to the effective combination of domain knowledge and sampled data, the BN method could adapt to the change of running state of machine, and obtain satisfactory prediction accuracy. Ex- periments on spindle thermal deformation were conducted to evaluate the modeling performance. Experimental results indicate that the BN method performs far better than the least squares (LS) analysis in terms of modeling estimation accuracy.

Recent Developments of Modulation and Control for High-Power Current-Source-Converters Fed Electric Machine Systems

The pulse-width-modulated(PWM)current-source converters(CSCs)fed electric machine systems can be considered as a type of high reliability energy conversion systems,since they work with the long-life DC-link inductor and offer high fault-tolerant capability for short-circuit faults.Besides,they provide motor friendly waveforms and four-quadrant operation ability.Therefore,they are suitable for high-power applications of fans,pumps,compressors and wind power generation.The purpose of this paper is to comprehensively review recent developments of key technologies on modulation and control of high-power(HP)PWM-CSC fed electric machines systems,including reduction of low-order current harmonics,suppression of inductor–capacitor(LC)resonance,mitigation of common-mode voltage(CMV)and control of modular PWM-CSC fed systems.In particular,recent work on the overlapping effects during commutation,LC resonance suppression under fault-tolerant operation and collaboration of modular PMW-CSCs are described.Both theoretical analysis and some results in simulations and experiments are presented.Finally,a brief discussion regarding the future trend of the HP CSC fed electric machines systems is presented.

Experimental Investigation of Capacity Control Scheme on System Performance for a Machine Tool Cooler

Highly accurate manufacture in machining industry can only be obtained with precise temperature control of the coolant （oil or water）.Machine tool with more accurate,stable and advanced the precision of the working component cannot be developed without appropriate cooling.However,the machine tool coolers are facing the control hunting of cooling temperature and the dramatic variation of heat load in high-accuracy machining.The main objective of this study is to evaluate the influence of the hot-gas by-pass scheme and suction regulation for capacity control of a machine tool cooler system.In this study,experimental investigation on both hot-gas by-pass scheme and suction valve regulation for capacity control has been proposed.Effects of using capillary tube and thermostatic expansion valve along with different capacity control scheme have been investigated extensively in an environmental testing room.Cooling performance and power consumption of the cooler system have been measured and analyzed as well by comparing with different opening percentage of throttling valve under specific coolant temperature.The experimental results reveal that the power consumption will reduce slightly by capacity control using the hot-gas by-pass scheme but the coefficient of performance （COP） of the overall system will decrease.Lower coolant temperature will result in higher compressor power consumption as well.While conducting suction valve regulating for capacity control,energy-saving at 10%-12% can be obtained by using thermostatic expansion valve under different evaporator load.It also reveals that suction valve regulation along with adequate choice of thermostatic expansion valve can provide alternative choice for steady capacity control and substantial energy-saving.The proposed cooler systems with different capacity control schemes are not only more cost-effective than inverter driven system,but also can perform energy-saving and precise temperature control specific for high-accuracy machine tool cooling.

Real-Time Data and Visualization Monitoring of Computer Numerical Control Machine Tools Based on Hyper Text Markup Language 5

In order to ensure the safety,quality and efficiency of computer numerical control(CNC)machine tool processing,a real-time monitoring and visible solution for CNC machine tools based on hyper text markup language(HTML)5 is proposed.The characteristics of the real-time monitoring technology of CNC machine tools under the traditional Client/Server(C/S)structure are compared and analyzed,and the technical drawbacks are proposed.Web real-time communication technology and browser drawing technology are deeply studied.A real-time monitoring and visible system for CNC machine tool data is developed based on Metro platform,combining WebSocket real-time communication technology and Canvas drawing technology.The system architecture is given,and the functions and implementation methods of the system are described in detail.The practical application results show that the WebSocket real-time communication technology can effectively reduce the bandwidth and network delay and save server resources.The numerical control machine data monitoring system can intuitively reflect the machine data,and the visible effect is good.It realizes timely monitoring of equipment alarms and prompts maintenance and management personnel.

DRIVE AND CONTROL OF VIRTUAL-AXIS NC MACHINE TOOLS

The structure features and driving modes of virtual axis NC machine tools are studied. Accor ding to different application requirements,the three axis control method,the five axis control method and the sixfreedom control method are put forward.These results lay a foundation for the product development of the virtual axis NC machine tools

METHOD FOR SUPPRESSING CUTTING CHATTER IN NUMERICAL CONTROL MACHINE TOOLS

A new method for suppressing cutting chatter is studied by adjusting servo parameters of the numerical control （NC） machine tool and controlling the limited cutting width. A model of the cutting system of the NC machine tool is established. It includes the mechanical system, the servo system and the cutting chatter system. Interactions between every two systems are shown in the model. The cutting system stability is simulated and relation curves between the limited cutting width and servo system parameters are described in the experiment. Simulation and experimental results show that there is a mapping relation between the limited cutting width and servo parameters of the NC machine tool, and the method is applicable and credible to suppress chatter.

Bayesian zero-failure reliability modeling and assessment method for multiple numerical control(NC) machine tools

A new problem that classical statistical methods are incapable of solving is reliability modeling and assessment when multiple numerical control machine tools(NCMTs) reveal zero failures after a reliability test. Thus, the zero-failure data form and corresponding Bayesian model are developed to solve the zero-failure problem of NCMTs, for which no previous suitable statistical model has been developed. An expert-judgment process that incorporates prior information is presented to solve the difficulty in obtaining reliable prior distributions of Weibull parameters. The equations for the posterior distribution of the parameter vector and the Markov chain Monte Carlo(MCMC) algorithm are derived to solve the difficulty of calculating high-dimensional integration and to obtain parameter estimators. The proposed method is applied to a real case; a corresponding programming code and trick are developed to implement an MCMC simulation in Win BUGS, and a mean time between failures(MTBF) of 1057.9 h is obtained. Given its ability to combine expert judgment, prior information, and data, the proposed reliability modeling and assessment method under the zero failure of NCMTs is validated.

Global Control Simulation of Electric Vehicle Based on Finite State Machine Theory

Finite state machine theory (FSM) is introduced and applied to global control of electric vehicle. Theoretical adaptation for application of FSM in control of electric vehicle is analyzed. Global control logic for parts of electric vehicle is analyzed and built based on FSM. Using Matlab/Simulink, BJD6100-HEV global control algorithm is modeled and prove validity by simulation.

Carbon Emission Modeling and Analysis in Manufacturing Process for Numerical Control Machine Tools

Reducing carbon emissions( CEs) is the urgent demand all over the world. In order to realize the low-carbon numerical control( NC) machining, the evaluation model of a part's manufacturing carbon emission with NC machine tools was built by considering the influences of the cutting tool geometrical parameters.The manufacturing CEs were produced by electric power,cutting tools,and cutting fluid consumed in manufacturing process. The parameters of cutting tools affected not only the CEs,but also the machining quality. Then the actual constraint models of the machine performance,machining quality were given in order to optimize the cutting parameters and achieve the low-CEs. Finally,a case was given to analyze the influences of the cutting tool angles on the manufacturing CEs. The results show that the CEs decrease as the rake angle and edge angle increase under the constraints of the machine specifications and machining quality.

Studies of layout of world machine tools industry based on patent analysis

As the foundation of an industrialized country nowadays,machine tools industry is regarded as the engine of industrial development of a country.The developed countries,such as USA,Germany and Japan,have widely deployed the technology of using the patent in order to keep their strength in various fields.This research examins the CNC machine tools industry in the world by using the patent analysis method.It first gives an overview about the world patent application in CNC machine tools industry from 1963 to 2010 and divides the development of the industry into five stages.It also lists the patent application of the world top 20 countries,where the top 5 countries are compared.The patents of the world top 10 companies of machine tools manufacturers are mapped according to the international patent classification(IPC),and the future trends of world machine tools industry are discussed.Finally conclusions and suggestions are presented.

Artificial Neural Networks for Controlling the Temperature of Internally Cooled Turning Tools

By eliminating the need for externally applied coolant, internally cooled turning tools offer potential health, safety and cost benefits in many types of machining operation. As coolant flow is completely controlled, tool temperature measurement becomes a practical proposition and can be used to find and maintain the optimum machining conditions. This also requires an intelligent control system in the sense that it must be adaptable to different tool designs, work piece materials and machining conditions. In this paper, artificial neural networks (ANN) are assessed for their suitability to perform such a control function. Experimental data for both conventional tools used for dry machining and internally cooled tools is obtained and used to optimise the design of an ANN. A key finding is that both experimental scatter characteristic of turning and the range of machining conditions for which ANN control is required have a large effect on the optimum ANN design and the amount of data needed for its training. In this investigation, predictions of tool temperature with an optimised ANN were found to be within 5°C of measured values for operating temperatures of up to 258°C. It is therefore concluded that ANN’s are a viable option for in-process control of turning processes using internally controlled tools.

STUDY ON THE FEEDFORWARD COMPENSATION OF THE MOTIONERRORS OF NC MACHINE TOOLS

A feedforward compensation naethod of the motion errors of NC machine tools imple- mented with software is proposed , with which the motion errors can be compensated whithout changing the original computer control systems of the NC machine tools. The experimental results show that the circular interpolation profile machining errors decrease by a factor of 2/3 after com- pensated.

Development of a PC-based Open Architecture Software-CNC System

As a key te..hnology in the field of advanced manufacturing, an open architecture controller is studied. In order to develop an open architecture software-CNC system on personal computer （PC） according to open modular architecture controllers （OMAC）. First, the software and hardware platform is chosen and software realization methodology for the CNC system is determined. Second, static modeling methods of an open architecture controller inclusive of object-oriented （OO） programming technology, dynamic link library （DLL） technology and system modules partition are investigated. Third, the dynamical behavioral modeling and the data flow representation of open architecture controller are discussed, which are both described in hierarchy fmite state machine （FSM） model. Fourth, a reusable software module model is established to develop software function module library. Finally, a 3-axis milling machine tool test-bed, named for HIT-CNC, is successfully designed by means of the constructed software function module library and the system configuring method. The experimental results show that, besides increasing the degree of reusability and openness, application of above-mentioned method- ology leads to significant decrease of development time as well as maintenance cost.

Dynamic Feedforward Control of a Novel 3-PSP 3-DOF Parallel Manipulator

Parallel manipulators with less than six degrees of freedom （DOF） have been increasingly used in high-speed hybrid machine tools. The structural features of parallel manipulators are dynamic, a characteristic that is particularly significant when these manipulators are used in high-speed machine tools. However, normal kinematic control method cannot satisfy the requirements of the control system. Many researchers use model-based dynamic control methods, such as the dynamic feedforward control method. However, these methods are rarely used in hybrid machine tools because of the complex dynamic model of the parallel manipulator. In order to study the dynamic control method of parallel manipulators, the dynamic feedforward control method is used in the dynamic control system of a 3-PSP （prismatic-spherical-prismatic） 3-DOF spatial parallel manipulator used as a spindle head in a high-speed hybrid machine tool. Using kinematic analysis as basis and the Newton-Euler method, we derive the dynamic model of the parallel manipulator. Furthermore, a model-based dynamic feedforward control system consisting of both kinematic control and dynamic control subsystems is established. The dynamic control subsystem consists of two modules. One is used to eliminate the influence of the dynamic characteristics of high-speed movement, and the other is used to eliminate the dynamic disturbances in the milling process. Finally, the simulation model of the dynamic feedforward control system of the 3-PSP parallel manipulator is constructed in Matlab/Simulink. The simulations of the control system eliminating the influence of the dynamic characteristics and dynamic disturbances are conducted. A comparative study between the simulations and the normal kinematic control method is also presented.The simulations prove that the dynamic feedforward control method effectively eliminates the influence of the dynamic disturbances and dynamic characteristics of the parallel manipulator on high-speed machine tools, and significantly improves the trajectory accuracy. This is the first attempt to introduce the dynamic feedfordward control method into the 3-PSP spatial parallel manipulator whose dynamic model is complex and provides a study basis for the real-time dynamic control of the high-speed hybrid machine tools.

CPS Modeling of CNC Machine Tool Work Processes Using an Instruction-Domain Based Approach

Building cyber-physical system(CPS) models of machine tools is a key technology for intelligent manufacturing. The massive electronic data from a computer numerical control(CNC) system during the work processes of a CNC machine tool is the main source of the big data on which a CPS model is established. In this work-process model, a method based on instruction domain is applied to analyze the electronic big data, and a quantitative description of the numerical control(NC) processes is built according to the G code of the processes. Utilizing the instruction domain, a work-process CPS model is established on the basis of the accurate, real-time mapping of the manufacturing tasks, resources, and status of the CNC machine tool. Using such models, case studies are conducted on intelligent-machining applications, such as the optimization of NC processing parameters and the health assurance of CNC machine tools.

Development of tool-path generation module for 5-axis control machining of impellers

An impeller is difficult to machine because of severe collision due to the complex shape,overlapping and twisted shape of the impeller blades.So,most computer aided manufacturing(CAM)software companies have developed CAM module for manufacturing impeller according to their CAM software.But these dedicated modules are difficult to use for inexperienced users.The purpose of this work is to develop a tool-path generation module for impellers.For this purpose,it is based on Visual Basic language and used CATIA graphical environment.The result of simulation for generated tool-path by the module is satisfactory.And it has slow processing speed compared to other commercial modules,but it is easy to use.

Micro electrical discharge machining of small hole in TC4 alloy

Aiming at machining deeply small holes in TC4 alloy,a series of experiments were carried out on a self-developed multi-axis micro electrical discharge machining(micro-EDM)machine tool.To improve machining efficiency and decrease relative wear of electrode in machining deeply small hole in TC4 alloy,many factors in micro-EDM,such as polarity,electrical parameters and supplying ways of working fluid were studied.Experimental results show that positive polarity machining is far superior to negative polarity machining;it is more optimal when open-circuit voltage,pulse width and pulse interval are 130 V,5μs and 15μs respectively on the self developed multi-axis micro-EDM machine tool;when flushing method is applied in micro-EDM,the machining efficiency is higher and relative wear of electrode is smaller.

Application of direct torque control to electric screw presses for speeding up torque response and reducing starting current

Fast response and stable torque output are crucial to the performance of electric screw presses. This paper describes the design of a direct torque control （DTC） system for speeding up torque response and reducing the starting current of electric screw presses and its application to the J58K series of numerical control electric screw presses with a dual-motor drive. The DTC drive system encompasses speed control, torque reference control, and switching frequency control. Comparison of the DTC dual-AC induction motor drive with corresponding AC servo motor drive showed that for the J58K-315 electric screw press, the DTC drive system attains a higher maximum speed （786 r/min） within a shorter time （1.13 s） during a 250 nun stroke and undergoes smaller rise in temperature （42.0 ℃） in the motor after running for 2 h at a 12 min-1 strike frequency than the AC servo motor drive does （751 r/min within 1.19 s, and 50.6 ℃ rise）. Moreover, the DTC AC induction motor drive, with no need for a tachometer or position encoder to feed back the speed or position of the motor shaft, enjoys increased reliability in a strong-shock work environment.

Kinematic Modelling and Control Simulation for 1PS+3TPS Type Hybrid Machine Tool

A structure scheme for a novel hybrid machine tool (HMT) is proposed in this paper. In the scheme,a 4-DOFs 1PS+3TPS type spatial hybrid mechanism is utilized as main feed mechanism,with assistance of a two direction movable worktable,multi-coordinates NC machining can be realized. In the main feed mechanism,fixed platform is connected with moving platform by three TPS driving links and one PS driving link,one translation DOF and three rotation DOFs can be achieved by it. This type HMT enjoys some advantages over its conventional counterparts:large workspace,good dexterity,etc. Closed form inverse displacement analysis model and inverse kinematic model for main feed mechanism are established. A fuzzy PID control scheme for machining control of HMTs with high tracking precision is proposed aiming at highly nonlinear,tightly coupled and uncertain characteristic of HMTs. Simulation researches for fuzzy PID control of HMTs are carried out. Simulation Results demonstrate the effectiveness and the Robostness of the fuzzy PID controller.

Design of Five-Axis Ultrasonic Assistant Compound Machine Tool

A compound machine tool was designed, which combined rotary ultrasonic assisted grinding, electrical discharge machining(EDM) and multi-axis milling. Experimental results indicated that its positioning accuracy was less than 5.6 μm and its repetitive positioning accuracy was less than 1.8 μm; the vibration amplitude of ultrasonic grinding system was uniform and stable, and the EDM system worked well and stably.A smooth surface of K9 optical glass component was achieved by the grinding method.