Simulation based optimization for controller parameterization of machine tool axes – advanced application

The quality of the controller parameterization of a drive system has direct influence on the obtained performance. Nevertheless, the commissioning is mainly done today by the application of basic tuning rules or not comprehensible automatisms. This often leads to not optimal performance. An alternative approach is to parameterize the typical controller cascade, which is widely used in standard industrial controllers, in one step by using the so-called “simulation-based optimization” (SBO). Significant advantages are the opportunity of defining specific restrictions concerning the desired controller parameterization and the possibility for directly processing non-linear systems without approximations. Furthermore, friction, additional filters in the cascade or controller structure extensions like the Advanced Position Control (APC) can be considered. Therefore, in the present paper, the application and the results of the SBO for different drive systems will be presented. After an introduction, the paper describes the basic principles of the simulation based optimization including the application for controller parameterization. Subsequently, the results for indirect velocity control of a test rig are discussed. After that, the findings for the commissioning of a direct position controller of an industrial servo press are presented. The paper closes with a summary and an outlook.