Modelling, Identification and Control of Thermal Deformation of Machine Tool Structures, Part 4: A Multi-Variable Closed-Loop Control System

Abstract

A multi-variable closed-loop control system is proposed to compensate for the thermal deformation of machine tool structures. The control system recognizes the fact the relative thermal displacement between the tool and workpiece is not accessible for direct measurement. Using the generalized thermoelastic transfer functions of the structure, which provide satisfactory input-output dynamic dependencies, the heat input to the structure and thermal displacements are estimated in real time. Artificial heating elements are used as the actuation mechanism of the control system, since they provide an economical solution for retrofitting existing conventional machine tools, and can also be combined with NC controllers to effect the desired compensation of the expansion and bending modes of deformation. Computer simulation test results indicated that even when the random temperature measurement and power actuation errors are taken in consideration, an accuracy of better than 2.5 μm and a control cycle of the order of 1 second are achievable.