Method, system and apparatus for on-demand integrated adaptive control of machining operations

An adaptive control system for controlling a machining operation on a workpiece by a machining tool, said system comprises:

• a sensor for measuring a present value of a spindle load on a spindle drive;
• and
• an adaptive controller for comparing the present value of the spindle load to a present value of a target spindle load, said adaptive controller includes:
• a computing element configured to determine a first feed rate value of a machining tool, and
• a number generator configured to generate a first feed rate dither adjustment value, the first feed rate dither adjustment value used for adding noise to the first feed rate value;
• said adaptive controller configured to control the feed rate of the machining tool relative to the workpiece to maintain the present value of the spindle load approximately equal to the present value of the target spindle load using one or more of the first feed rate value, the first feed rate dither adjustment value, and a second feed rate dither adjustment value.

A method of controlling a machining operation on a workpiece by a machining tool, said method comprises:

• measuring a present value of a spindle load developed by a spindle drive rotating a machining tool;
• comparing the present value of the spindle load to a present value of a target spindle load;
• determining a first feed rate value for the machining tool using the comparison;
• generating a first feed rate dither adjustment value;
• combining the first feed rate dither adjustment value with the first feed rate value such that noise is added to the first feed rate value based on the first feed rate dither adjustment value;
• and
• controlling the feed rate of the machining tool relative to the workpiece to maintain the present value of the spindle load approximately equal to the present value of the target spindle load using one or more of the first feed rate value, the first feed rate dither adjustment value, and a second feed rate dither adjustment value.