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Iterative learning contouring controller based on trajectory generation with linearly interpolated contour error estimation and Bézier reposition trajectory for computerized numerical control machine tool feed drive systems

In industrial applications, highly accurate mechanical components are generally required to produce advanced mechanical and mechatronic systems. In machining mechanical components, contour error represents the product shape quality directly, and therefore it must be considered in controller design. Although most existing contouring controllers are based on feedback control and estimated contour error, it is generally difficult to replace the feedback controller in commercial computerized numerical control machines. This article proposes an embedded iterative learning contouring controller by considering the linearly interpolated contour error compensation and Bézier reposition trajectory, which can be applied in computerized numerical control machines currently in use without any modification of their original feedback controllers. While the linearly interpolated contour error compensation enhances tracking performance by compensating the reference input with an actual value, the Bézier reposition trajectory enables smooth velocity transitions between discrete points in the reference trajectory. For performance analysis, the proposed controller was implemented in a commercial three-axis computerized numerical control machine and several experiments were conducted based on typical three-dimensional sharp-corner and half-circular trajectories. Experimental results showed that the proposed controller could reduce the maximum and mean contour errors by 45.11% and 54.48% on average, compared to embedded iterative learning contouring controller with estimated contour error. By comparing to embedded iterative learning contouring controller with linearly interpolated contour error compensation, the maximum and mean contour errors are reduced to 20.54% and 26.92%, respectively.