System construction of a four-side primary permanent-magnet linear motor drive mechanical press

Abstract

A primary permanent-magnet linear motor (PPMLM) has a robust secondary structure and high force density and is appropriate for direct-drive mechanical press. The structure of a four-side PPMLM drive press is presented based on our previous research. The entire press control system is constructed to realize various flexible forming processes. The control system scheme is determined in accordance with the mathematical model of PPMLM, and active disturbance rejection control is implemented in the servo controller. Field-circuit coupling simulation is applied to estimate the system’s performance. Then, a press prototype with 6 kN nominal force is fabricated, and the hardware platform of the control system is constructed for experimental study. Punch strokes with 0.06 m displacement are implemented at trapezoidal speeds of 0.1 and 0.2 m/s; the dynamic position tracking errors are less than 0.45 and 0.82 mm, respectively. Afterward, continuous reciprocating strokes are performed, and the positioning errors at the bottom dead center are less than 0.015 mm. Complex pulse trajectories are also achieved. The proposed PPMLM drive press exhibits a fast dynamic response and favorable tracking precision and is suitable for various forming processes.

Keywords

mechanical press / direct drive / primary permanent-magnet linear motor (PPMLM) / servo system / active disturbance rejection control (ADRC) / prototype experiment

References

[1] Osakada K, Mori K, Altan T, Mechanical servo press technology for metal forming. CIRP Annals, 2011, 60(2): 651–672

[2] Behrens B A, Krimm R, Reich D, Linear drives in metal forming machines and peripherals-recent developments. Journal of Manufacturing Processes, 2016, 22: 192–198

[3] Xu J, Guo B, Shan D B, Development of a micro-forming system for micro-punching process of micro-hole arrays in brass foil. Journal of Materials Processing Technology, 2012, 212(11): 2238–2246

[4] Sato K. High-precision and high-speed positioning of 100 G linear synchronous motor. Precision Engineering, 2015, 39: 31–37

[5] Nasiri-Gheidari Z, Tootoonchian F. Electromagnetic design optimization of a modular linear flux-reversal motor. Electric Power Components and Systems, 2016, 44(18): 2112–2120

[6] Zeng Z Q, Lu Q F. Investigation of novel partitioned-primary hybrid-excited flux-switching linear machines. IEEE Transactions on Industrial Electronics, 2018, 65(12): 9804–9813

[7] Ullah N, Basit A, Khan F, Enhancing capabilities of double sided linear flux switching permanent magnet machines. Energies, 2018, 11(10): 2781

[8] Chung S U, Kim J W, Woo B C, Design and experimental validation of doubly salient permanent magnet linear synchronous motor for precision position control. Mechatronics, 2013, 23(2): 172–181

[9] Liang J T, Ming Z F. Servo X-Y biaxial feed system of flux switching permanent magnet linear motor. Review of Scientific Instruments, 2019, 90(7): 074703

[10] Nakagava T, Higuchi T, Sato R, Linear motor drive CNC press using learning control. CIRP Annals, 1999, 48(1): 199–202

[11] Matsumoto R, Hayashi K, Utsunomiya H. Experimental and numerical analysis of friction in high aspect ratio combined forward-backward extrusion with retreat and advance pulse ram motion on a servo press. Journal of Materials Processing Technology, 2014, 214(4): 936–944

[12] Jeon J Y, Matsumoto R, Utsunomiya H. Two-step die motion for die quenching of AA2024 aluminum alloy billet on servo press. Materials Transactions, 2014, 55(5): 818–826

[13] Matsumoto R, Sawa S, Utsunomiya H, Prevention of galling in forming of deep hole with retreat and advance pulse ram motion on servo press. CIRP Annals, 2011, 60(1): 315–318

[14] Maeno T, Mori K, Hori A. Application of load pulsation using servo press to plate forging of stainless steel parts. Journal of Materials Processing Technology, 2014, 214(7): 1379–1387

[15] Song Q Y, Guo B F, Li J. Drawing motion profile planning and optimizing for heavy servo press. International Journal of Advanced Manufacturing Technology, 2013, 69(9–12): 2819–2831

[16] Liang J T, Ji X P, Gong W J, Design and analysis of a novel stator permanent magnet linear motor drive mechanical press. In: Proceedings of 2018 IEEE International Conference on Mechatronics and Automation (ICMA). Changchun: IEEE, 2018

[17] Han J Q. From PID to active disturbance rejection control. IEEE Transactions on Industrial Electronics, 2009, 56(3): 900–906

[18] Gao Z Q. On the centrality of disturbance rejection in automatic control. ISA Transactions, 2014, 53(4): 850–857

[19] Tong L, Lin M Y. Study on a high thrust force bi-double-sided permanent magnet linear synchronous motor. Advances in Mechani-cal Engineering, 2016, 8(3): 1–10

[20] Ting C S, Chang Y N, Shi B W, Adaptive backstepping control for permanent magnet linear synchronous motor servo drive. IET Electric Power Applications, 2015, 9(3): 265–279

[21] Huang W T, Hua W, Yin F B, Model predictive thrust force control of a linear flux-switching permanent magnet machine with voltage vectors selection and synthesis. IEEE Transactions on Industrial Electronics, 2019, 66(6): 4956–4967

[22] Du C, Yin Z G, Zhang Y P, Research on active disturbance rejection control with parameter autotune mechanism for induction motors based on adaptive particle swarm optimization algorithm with dynamic inertia weight. IEEE Transactions on Power Electronics, 2019, 34(3): 2841–2855

[23] Zhang X H, Zhu Q, Sun Y K, Three-degree-of-freedom positioning control of magnetically levitated permanent magnet planar motor using active disturbance rejection control scheme. Advances in Mechanical Engineering, 2017, 9(7): 1–13

[24] Amjad J H, Ibraheem K I. Speed control of permanent magnet DC motor with friction and measurement noise using novel nonlinear extended using novel nonlinear extended state observer-based anti-disturbance control. Energies, 2019, 12(9): 1651

[25] Vera-Tizatl P, Luviano-Juarez A, Santos-Cuevas L, Tracking control of tomographic image acquisition robotic system based on active disturbance rejection theory with adaptive gains. Proceedings of the Institution of Mechanical Engineers, Part I: Journal of Systems and Control Engineering, 2020, 234(1): 81–95

RIGHTS & PERMISSIONS

Higher Education Press