Hardware-in-the-loop simulation for estimation of position control performance of machine tool feed drive

One of the most important measures for improving the performance of a machine tool is to set its controller parameters appropriately. The setting of these parameters is typically done by an expert when the machine tool is initially installed. Although parameter tuning is crucial when there is a change in the operation conditions, it is a challenge faced by non-experts as improper settings can result in critical problems in the machine tools. Simulation software, which estimate the control performance and identify appropriate parameters, can be used for the easy customization of these parameters. However, it is difficult to accurately model a commercial controller owing to its complex structure and several hidden functions. This paper proposes a novel method that utilizes Hardware-In-the-Loop (HIL) simulation for estimating the position control performance of machine tool feed drives. HIL improves the simulation accuracy by integrating a real commercial controller into the simulation loop. The simulation error caused by the inaccuracy of the controller model is out of existence in the HIL simulation. The procedure of configuring the HIL simulation, from modeling and parameter identification of the machine tool feed drives, to organizing data exchange between the real controller and feed drive model, is extensively explained. The accuracy of the proposed HIL simulation is experimentally evaluated and applied for the estimation of position control performance, based on the controller parameters. The estimation of step response, failure mode, and effect analysis, as well as the evaluation of the control algorithm, are also performed using the HIL simulation. The results demonstrate that the HIL simulation can not only be used for the estimation of control performance but also for performance enhancement of machine tools.