Adaptive Control

According to dictionary adapt means’ to change (one self) so that one’s behavior conforms to
new or changed circumstances. In the context of CNC machine tools, adaptive control implies
that the CNC system is responsive to adapt itself to operate at those machining parameters that
result higher productivity.

Staring in the early 1950s, the design of auto pilots for high performance aircraft motivated an
intense research activity in adaptive control. High-performance aircraft undergo drastic changes
in their dynamics when they fly from one operating point to another that cannot be handled by
constant gained feedback control. A sophisticated controller, such as an adaptive controller, that
could learn and accommodate changes in the aircraft dynamics was needed.

An adaptive controller is formed by combining an online parameter estimator, which provides

estimates of unknown parameters at each instant, with a control law that is motivated from the
known parameter case. The way the parameter estimator, also referred to as adaptive law in the
book, is combined with the control law gives to two different approaches:

 In the first approach, referred to as indirect adaptive control, the system performance
parameters are estimated online and used to calculate the controller parameters. This
approach has been also referred to as explicit adaptive control, because the design is
based on an explicit system performance model. It is also called adaptive control
optimization or ACO.
 In the second approach, referred to as direct adaptive control, the system performance
model is parameterized in terms of controller parameters that are estimated directly
without intermediate calculations involving system-performance parameters estimates.
This approach has been also referred to as implicit adaptive control because the design is
based on the estimation of an implicit system-performance model. It is also called
Adaptive Control with constraints or ACC.

When the part programs are written, the programmer checks the machinability hand books to get
the appropriate cutting speed, feed and depth of cut for the particular machining operation taking
the cutting tool and workpiece material combination and required surface finish. These values
and are useful as starting values, the actual machining time for the part may not be optimal. An
MCU having Adaptive control will actually modify these values continuously based on the
actual performance in the real time by measuring certain parameters.

Adaptive Control Optimisation (ACO) in adaptive control optimization, the system-

performance model P (PI) is parameterized with respect to some known parameter vector PI as
shown fig.1. For example, in case of CNC machine tools, the system-performance model, PI
may represent some parameter that identifies a performance index (PI) as follows:

MRR
PI =
TWR

Where MRR represents material removal rate and TWR represents the tool wear rate. In metal
cutting, MRR is dependent upon the cutting speed, feed rate and depth of cut. Tool-wear rate
depends upon the cutting-process parameters as well as the other dynamic characteristics of the
machine –tool-cutting tool- workpiece system. The tool wear rate cannot be measured directly
from the process, and hence some parameters are measured such as cutting power, cutting
forces, vibration signature of the cutting tool, acoustic emission from worm cutting tool and
cutting tool temperatures and are fed into process parameter estimator program.

Figure 1: adaptive control with optimization

The online parameter estimator generates an estimate PI (t) of PI at each time t by processing
the system performance inputs u and outputs y. this index compared to desired value by another
program in the system software which recalculates the cutting process variables like feed rate
and speed rate so as to keep performance index at highest level without violating any of the
constraints. The process variables are thus continuously changed so as to obtain optimum value
of the performance index.

From the above discussion on AC systems, it can be observed that these systems may be
advantageously used:

 To increase productivity
 To maintain high levels of workpiece precision
 To raise the level of automation by reducing operator intervention
 To increase cutter life by reducing tool loads
 To increase workpiece accuracy and CNC machine life maintain low levels of vibration

Adaptive Control with constraints (ACC) in this system, the control is simplified by
incorporating certain safe limits for any of the relevant process parameters in the form of
constraints. A few examples are

 Use the available spindle power to maximum

 Limit the defection of cutter
 Limit the cutting force
 Limit the vibration amplitude of the cutter

Typical process variables measured are cutting forces, torques, spindle motor power/ current,
tool wear, tool deflection, cutting temperature, vibrations, etc. The type of variable measured
depends upon the convenience of the measurement and how closely it affects the system
performance. A number of sensors and transducers are integrated into the CNC control systems.
The choice of either contact type (Cutting forces, vibration signature, etc.) or non-contact type
(temperature, acoustic emission, etc.) instruments could be used. Generally, a single parameter is
not able to provide a very clear performance measure. Hence, a number of parameters are
measured and then they are fused to come up with a more reasonable performance indicator.
 Figure 2: adaptive control with constraints

The measured vale is compared with the permissible value which has been incorporated in the
adaptive control software. It is ensured that at no time the measured value exceeds the permitted
one. The program calculates those values of machining parameters which give the desired
extreme objective, say maximum metal-removal rate. The programmed values of machining
parameters like that of feed rate are continuously replaced by the new calculated values. The real
time effect of operating values is checked by the new calculated values. The real time effect of
the operating values is checked by measuring the constraints values is accordingly adjusted so as
to remain within the imposed constraints.