Automatic preload adaptation for rack-and-pinion drives to maximize performance and energy efficiency

Abstract Electrically preloaded rack-and-pinion drives are typically utilized in machine tools to precisely move heavy loads over long travel distances. In the state of the art, the preload torque is commonly set to a constant value during commissioning. This poses a conflict of objectives between maximizing performance and minimizing energy consumption. To resolve this, this publication presents a novel approach to automatically adapt the preload torque during operation. For this purpose, the established preload control is extended by a simple control law that adapts the preload torque to the current operating state within the permissible limits. This way, higher preload torques are only applied, if the resulting higher system stiffness is beneficial for the drive performance. Otherwise, the preload torque is reduced to save energy. The automatic preload adaptation is experimentally validated on a test system with industry standard components. This involves both system-theoretical analyses and practical test scenarios.