Supervisory Control of Drilling

Abstract

A supervisory process control approach to machining is presented in this paper, and demonstrated by application to a drilling operation. The supervisory process control concept incorporates optimization and control functions in a hierarchical structure. This approach utilizes feedback measurements to parameterize the constraints of a process optimization problem whose solution determines both strategies and references for process control. For this particular drilling operation, a three-phase strategy (utilizing a combination of feed, speed, and torque control) evolved due to inherent variation in constraint activity as a function of hole depth. A controller comparison study was conducted which demonstrates the advantages of this approach compared to (1) uncontrolled “conventional” drilling, (2) feed and speed controlled drilling, and (3) torque and speed controlled drilling. Benefits of reduced machining time, improved hole quality, and the elimination of tool breakage are demonstrated, and the potential economic impact is highlighted for an example production application.