A Novel Hybrid Active Control Method for Improving Rotational Accuracy of Ultra‑Precision Hydrostatic Spindles
DOI:
https://doi.org/10.64229/76yz5d88Keywords:
Ultra-Precision Spindle, Hydrostatic Bearing, Hybrid Active Control, Piezoelectric Actuator, Observer-Based Coordinated Control, Rotational AccuracyAbstract
To address radial and angular rotation errors and the difficulty of suppressing high-frequency disturbances in high-speed ultra-precision hydrostatic spindles, a novel hybrid active control method is proposed. The approach is built on a reduced-order hydrostatic chamber–rotor dynamic model and uses pressure regulation for low-frequency, large-amplitude error compensation while employing high-bandwidth piezoelectric actuators for fast local correction of synchronous and higher-harmonic components. A state-observer-based estimator and a coordinated control strategy are designed so the two actuator classes complement each other in the frequency domain, improving overall bandwidth and robustness. Numerical simulations and a proposed experimental testbed demonstrate significant suppression of synchronous errors and harmonic content, reduction of steady-state radial/tilt errors, and enhanced disturbance rejection and tolerance to model uncertainty. Practical implementation issues, limitations, and directions for future improvement are discussed.
References
[1]Thanh, N. N., & Erkan, İ. (2020). An active control for hydrostatic journal bearing using optimization of servo control parameters. Precision Engineering, 64, 142–153.
[2]Wang, Y., & Zhang, J. (2019). The stability's influencing factors and active control of hydrostatic spindle in ultra‑precision machining. Advances in Engineering Research, 179, 45–52.
[3]Aoyama, T., & Kakinoki, Y. (2018). Control of active lubrication for hydrostatic journal bearing by optimization. Advances in Mechanical Engineering, 10(4), 1–12.
[4]Kümmerle, J., & Verl, A. (2022). Investigating the dynamic characteristics of the hydrostatic bearing spindle with active control technology. Journal of Tribology, 144(7), 071803.
[5]Li, H., & Shin, Y. C. (2021). Dynamic characteristics of spindle with water‑lubricated hydrostatic bearings for ultra‑precision applications. Precision Engineering, 70, 1–11.
[6]Chen, Y., & Gao, W. (2021). Attaining ultraprecision machining by feed drive system stability control using piezoelectric actuators. Applied Sciences, 11(18), 8491.
[7]Müller, A., & Verl, A. (2010). Rotary‑axial spindles for ultra‑precision machining: Design and active compensation. CIRP Annals, 59(1), 399–402.
[8]Kobayashi, T., & Shinagawa, Y. (2014). A study on active magnetic bearings for machine tool's high‑speed spindles. Proceedings of the 7th International Symposium on Magnetic Bearings, 1–6.
[9]Yoshimoto, S., & Hamaguchi, T. (2000). Error correction in hydrostatic spindles by optimal bearing tuning. Precision Engineering, 24(1), 95–100.
[10]Jiang, X., & Wang, Y. (2018). Analysis of error motions of axial locking‑prevention hydrostatic thrust bearing spindle. Proceedings of the Institution of Mechanical Engineers, Part J: Journal of Engineering Tribology, 232(10), 1285–1296.
Downloads
Published
Issue
Section
License
Copyright (c) 2025 Jiaheng Sun (Author)
This work is licensed under a Creative Commons Attribution-NonCommercial-ShareAlike 4.0 International License.
