Cognitive Electric Drive Regulation Systems for Heavy Metal Fabrication Machinery

Abstract

The research sought to empirically evaluate the functionality of an advanced electric drive control system in high-capacity metalworking machinery. The approach involved substituting the relay control circuit of a vertical milling machine with a multi-tiered digital system featuring a frequency converter and a programmable logic controller. Ongoing surveillance of parameters and dynamic regulation were executed utilising encoders, strain gauge sensors, and an artificial neural network that adjusted the coefficients of the proportional-integral-derivative controller. The findings demonstrated a notable superiority of the intelligent system compared to conventional and static digital controllers across all operational modes. Specifically, the variation in rotation speed remained within 0.43-0.52 radians per second under fluctuating load, whereas the fixed controller exhibited values of 1.29-1.77 radians per second, and the relay system surpassed 2.8 radians per second. The duration of transition was minimised to 0.41-0.79 seconds, which is superior to the 1.01-1.39 seconds for a fixed regulator and 2.30-2.48 seconds for relay control. The mean current ranged from 7.44 to 8.42 amperes, with peak values not surpassing 10.94 amperes, signifying a 35-40% decrease in load relative to relay control. The Pearson correlation coefficient of 0.995 between current variability and response time shows a strong association between energy stability and the system's dynamic sensitivity. The system's predictive and adaptive characteristics facilitated accurate control without requiring manual recalibration. The acquired data substantiates that intelligent control frameworks offer enhanced speed stability, energy efficiency, and responsiveness to variations, establishing a foundation for their application in a high-performance industrial setting. The findings can assist design engineers, automation system creators, and technical supervisors in updating metal-cutting machinery and minimising energy usage while maintaining precision.