Model-based Feedback Control of an Ultrasonic Transducer for Ultrasonic Assisted Turning Using a Novel Digital Controller

Ultrasonic turning has time variant parameters due to temperature effects and changing load conditions during the process. This results in a change of the resonance frequency and vibration amplitude. To realize constant vibration amplitudes it is necessary to control the ultrasonic transducer by a suitable feedback controller. One approach to drive such a system is to use the resonance frequency as operating point in connection with an amplitude feedback controller. The advantages of resonant driven low damped systems are low voltages and high values of effective power. This paper presents a digital system used for parameter identification and model-based feedback control of the ultrasonic turning tool. During the turning process the system load depends on several factors like chip formation, material inhomogeneity, warming and tool wear. To achieve a stable process and a uniform surface of the work piece the feedback controller has to guarantee constant vibration amplitudes of the ultrasonic tool. The controller used in this paper consists of a digital resonance controller and a current amplitude controller with a frequency of 500 Hz. The current amplitude and phase between the excitation voltage and current are determined by phase sensitive demodulation (PSD). To determine the feedback parameters a model-based approach is used.