ADAPTIVE CONTROL SYSTEMS

INTRODUCTION
• Adaptive control (AC) machining originated
out of research in the early 1960s sponsored
by the U. S. Air Force at the Bendix Research
Laboratories.
• Initially adaptive control systems were based
on analog control devices.
• Today, AC uses microprocessor based controls
and it is typically integrated with an existing
CNC system.
 INTRODUCTION
• Adaptive control denotes a control system that
measures certain output process variables and
uses these to control speed or feed.
• Some of the process variables that have been
used in adaptive control machining systems
include deflection or force, torque, cutting
temperature, vibration amplitude and
horsepower.
 INTRODUCTION
• The motivation for developing an adaptive
machining system lies in trying to operate the
process more efficiently.
• The typical measures of performance in
machining have been metal removal rate and
cost per volume of metal removed.
• Adaptive control possesses attributes of both
feedback control and optimal control.
GENERAL STRUCTURE OF ADAPTIVE
CONTROL SYSTEMS
 WHERE TO USE ADAPTIVE CONTROL

• AC is not appropriate for every machining

situation.
• Generally, the following characteristics can be
used to identify situations where AC can be
beneficially applied:
1.The in-process time consumes a significant
portion of the machining cycle time.
2.The cost of operating the machine tool is high.
 WHERE TO USE ADAPTIVE CONTROL

3. The typical jobs are ones involving steel,

titanium and high strength alloys.

4. There are significant sources of variability in

the job for which AC can compensate. In
effect AC adapts feed and/or speed to these
variable conditions.
 SOURCES OF VARIABILITY IN
MACHINING
• Variable geometry of cut in the form of
changing depth or width of cut.
• Variable work piece hardness and variable
machinability.
• Variable wok piece rigidity.
• Tool wear
• Air gaps during cutting (AC automaticaly
increase the feed rate where air gaps are found
in material).
FUNCTIONS OF ADAPTIVE CONTROL

• The three functions of adaptive control are:

1. Identification function

2. Decision function

3. Modification function
 IDENTIFICATION FUNCTION
• The identification function is concerned with
determining the current value of this
performance measure by making use of the
feedback data from the process.
• Since the environment will change overtime,
the performance of the system will also
change.
• Accordingly the identification is one that must
proceed over time or less continuously.
 DECISION FUNCTION
• Once the system performance is determined, the
next function is to decide how the control
mechanism should be adjusted to improve process
performance.
• The decision procedure is carried out by means of
a pre-programmed logic provided by the designer.
• Depending upon the logic the decision may be to
change one or more of the controllable process.
 MODIFICATION FUNCTION
• Modification is concerned with a physical or
mechanical change in the system and it is a
hardware function rather than a software
function.
• The modification involves changing the
system parameters or variables so as to drive
the process towards a more optimal state.
• Actual changes to the system are made in the
modification function.
TYPES OF ADAPTIVE CONTROL

There are basically two groups of adaptive

control.
a. Geometrical adaptive control.

b. Technological adaptive control.

 GEOMETRICAL ADAPTIVE
CONTROL
• This type of adaptive control is concerned with
monitoring the shape and dimension of a
machined component.
• It relies on some in process gauging instrument
to relay information with a very short time
response.
• The index of performance of such a system is
the final dimension and shape of the
component.
TECHNOLOGICAL ADAPTIVE
CONTROL SYSTEM

Under the umbrella of technological AC two

distinct systems are grouped:

Adaptive control constraint (ACC)

Adaptive control optimization (ACO)

 ADAPTIVE CONTROL
OPTIMIZATION (ACO)
• In this form of AC, an index of performance
is specified for the system.
• Performance index is a measure of overall
process performance such as production rate
or cost per volume of metal removed.
• The objective of the adaptive controller is to
optimize the index of performance by
manipulating speed and/or feed in the
operation.
• Index of performance is
IP= MRR/TWR
where MRR=material removal rate
TWR=tool wear rate
• The trouble with this performance index is that
TWR cannot be measured online with today’s
measurement technology.
• Because of the sensor problems encountered in
the design of ACO systems, nearly all AC
machining is of the second type, ACC systems.
ADAPTIVE CONTROL CONSTRAINT (ACC)

• The systems developed for actual production

were somewhat less sophisticated than the
research ACO systems.
• The production AC systems utilize constraint
limits imposed on certain measured process
variables hence known as ACC systems.
• The objective is to manipulate feed/speed so
that these measured process variables are
maintained at a below their constraint limit
values.
Programmed feed rate based on maximum depth and
width encountered during machining of the whole job
P = K1 K2 K3 a fk N D
Where K1, K2, K3 are constrains
Spindle power (P), depth of cut (a), feed Rate (f), RPM
(N) and Milling tool diameter (D),

Using maximum motor power, feed rate will be

varied. Cutting force (F) is limiting with
proportional depth of cut(a) and feed rate (f)
F = K 1 a fk
OPERATIONS OF AN ACC SYSTEM
• Profile or contour milling on NC machine tool.
• Feed is used as controlled variable.
• Cutter force and horse power are used as
measured variables.
• It is common to attach an AC to an NC
machine tool.
• The adaptive control retrofit package consists
of a combination of hardware and software
components.
• Hardware components are:
1. Sensors mounted on the spindle to measure
cutter deflection.
2. Sensors to measure spindle motor current.
3. Control unit and display panel to operate the
system.
4. Interface hardware to connect the AC system
to existing NC or CNC control unit.
• Software in the AC package consists of a
machinability program which can be called as
an APT MACRO statement.
• An air gap over-ride feature which monitors the
cutter force and determines if the cutter is
moving through air or through metal.
• This is usually sensed by means of a low
threshold value of cutter force.
• If the actual cutter force is below this threshold
level the controller assumes that the cutter is
passing through the air gap , the feed rate is
doubled or tripled to minimize the time wasted
travelling across the air gap.
 BENEFITS OF ADAPTIVE
CONTROL SYSTEMS
• Increased production rates.
• Increased tool life by reducing tool loads and
vibration.
• Maintain high level of workpiece precision
• Greater part protection.
• Less operator intervention.
• Easier part programming.
 LIMITATIONS
• The adaptive control systems are high cost.
• These are not suitable for all machining
operation.