Energy saving control in five-axis machine tools using contouring control

Machine tools operate around the clock in industrial applications all over the world, and hence there is a requirement not only for high-speed and high-precision operation but also for reduced energy consumption. This paper presents a novel controller design that aims to reduce energy consumption in five-axis machine tools, which typically consist of three translational and two rotary axes. The proposed design is based on a contouring controller that has been proposed for use in high-precision machining in machine tool systems. The design also takes into consideration the relative orientation error between a tool and the workpiece in five-axis machining. The synchronous controller is also used to reduce synchronous error between two parallel actuators, which is a cause of significant mechanical damage. The experimental results demonstrate the effectiveness of the proposed controller, which reduces energy consumption by about 13 %.