Frequency Domain Design of a Reset-Based Filter: An Add-On Nonlinear Filter for Industrial Motion Control

TL;DR

This paper presents a novel nonlinear reset-based filter with a feedthrough term that enhances phase control and reduces nonlinearities, improving industrial motion control performance without compromising robustness.

Contribution

It introduces a modified CgLp filter with a feedthrough term, a backward calculation tuning method, and an add-on structure for existing controllers, demonstrated on an industrial wire bonder.

Findings

Enhanced phase control with minimal nonlinearities

Improved vibration suppression in industrial machinery

Validated effectiveness through a real-world case study

Abstract

This study introduces a modified version of the Constant-in-Gain, Lead-in-Phase (CgLp) filter, which incorporates a feedthrough term in the First-Order Reset Element (FORE) to reduce the undesirable nonlinearities and achieve an almost constant gain across all frequencies. A backward calculation approach is proposed to derive the additional parameter introduced by the feedthrough term, enabling designers to easily tune the filter to generate the required phase. The paper also presents an add-on filter structure that can enhance the performance of an existing LTI controller without altering its robustness margins. A sensitivity improvement indicator is proposed to guide the tuning process, enabling designers to visualize the improvements in closed-loop performance. The proposed methodology is demonstrated through a case study of an industrial wire bonder machine, showcasing its effectiveness in addressing low-frequency vibrations and improving overall control performance.