Adoption of Active Power H-bridge Filter to Vibration
Compensator for Machining Processes
Adopcia aktívneho silového H-mostíkového filtra
ku kompenzátoru vibrácii pre procesy obrábania
Saša Sladić, Branimir Barišić, Nicole Ungurean
Abstract
Machine tool technology is getting more and more
sophisticated in order to achieve high quality and high
accuracy of machine tools and fixtures. Different alloys and
their properties are generally well known but new ideas for
the improvement tool quality are arising. It has been shown
that a decrease of vibration during machine tool or other
part production increases its precision. This article is about
the adoption of known engineering solutions (active power
filter- APF) for machining part fixtures during machining
processes. The results are extended to other problems where
the same circuit-algorithm could be used (e.g. vibration
compensation in refrigerators or air conditioners). The acti-
ve power filter was realized with a microprocessor system
(based on TMS320F240). Results were analyzed and further
expanded by the software (Simplorer) in order to predict
vibration control on different frequencies and for different
machining processes. Such a comparison is important in the
sense of the price of vibration compensators because inte-
grated electrical circuits with the same algorithm were
developed for almost three decades and they have witnessed
a break through in mass production because of modern PC
production.
Keywords: vibration control, simulation, mechatronic
concepts
Abstrakt
Technológia prípravy nástrojov sa stáva viac a viac so-
fistikovanejšou, účelom je dosiahnutie vysokej kvality a
presnosti nástrojov a prípravkov. Zliatiny a ich vlastnosti sú
všeobecne dobre známe, vzniká ale nová myšlienka zlepšo-
vania kvality nástrojov. Bolo dokázané, že zníženie vibrácii
počas výroby nástroja, resp. inej jeho časti zvyšuje jeho
presnosť. Článok popisuje adoptáciu známeho inžinierskeho
riešenia (aktívneho silového filtra APF) pri výrobe príprav-
kov. Výsledky sú rozvinuté aj na iné problémy, kde by sa
mohol uplatniť rovnaký obvodový algoritmus (napr. pri
kompenzácii vibrácií v chladničkách resp. klimatizáciách).
Aktívny silový filter bol realizovaný mikroprocesorovým
systémom (založenom na TMS320F240). Výsledky boli
analyzované a následne zovšeobecnené softvérovou apliká-
ciou (Simplorer) s účelom predvídania kontroly vibrácií pre
rozdielne frekvencie a rozdielne procesy obrábania. Takéto
porovnanie je dôležité z hľadiska ceny vibračného kompen-
zátora, nakoľko integrované elektrické obvody s podobným
algoritmom boli vyvinuté pred skoro troma desaťročiami
a s príchodom modernej výpočtovej produkcie boli svedka-
mi nasadenia do masovej produkcie.
Kľúčové slová: vibračná kontrola, simulácia, mechatro-
nický koncept
80
1 Introduction
In turning operations, vibrations are a common problem
[1] as they affect the productivity and performance of the
machine tool. Furthermore, acoustic noise is generated and
tool life is reduced depending on the vibration intensity [2].
This problem is particularly emphasized in micro machi-
ning. Different alloys and their properties are generally well
known [3] but new ideas in order to improve tool quality are
arising [4]. The race in improved product quality, between
different producers has resulted in the need for active
compensation of vibration (vibration control) with more
precise fixtures [4].
For a quick view of active compensation, it is important
to mention the sliding mode algorithm that started its
development with Russian space program in the 60s [5] and
it is still developing [6]. Simply bang-bang regulation or
the sliding mode algorithm, both names for holding a
certain variable near a reference value, was used widely in
the 80s and 90s for power factor compensation [7], [8]. This
method enables the same wires to transport more electrical
energy in an electrical network. Could it be used for
improving cutting, grinding or drilling? It has been shown
that a decrease of vibration during machine tool or other
part production increases its precision [4], [9], [10], [11].
Usage of active compensation hasn’t been widely exploited
in fixture systems because standard solutions enable satis-
factory results, and industry mostly shows no interest.
Accordingly, [4] booth factors have been changed recently
and known solutions have to be adapted to new applica-
tions.
The main change in the adopted system is expected to be
in actuators and in sensors. There is a lot research in the
area of actuators [2], [12]. In low power applications such
as the PC hard drive (HDD) vibration compensator [13], as
in high power applications, different mechatronic systems
have been proposed involving electromagnetic [14] or
piezoelectric actuators [2], [15]. In high power vibration
compensation, tuned mass dampers (TMD) [16] or seismic
isolation is usually proposed [17]. Passive solutions have
also been applied for fixture solutions in the past but a need
for a more structured and scientific approach to the develop-
ment of fixtures has recently appeared [4]. The goal is the
reduction of vibration in order to compensate noise or to
achieve higher precision during machining processes. In
order to present a low coast solution for vibration control
the H-bridge active power filter has been presented. Later,
the same system will be analyzed in light of vibration
control.
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82
 exists the same as in the electronic system but here it has
additional meaning of force because it sets an actuator in the
motion. The analogy is obvious if the Faraday law of in-
duction (9) is compared with second Newton law of motion
(10) as follows:
V di
= (9)
L dt
2
F dv d s
= = 2
= a. (10)
m dt dt
Fig. 8 Lathe TU 360
Obr. 8 Sústruh TU 360
Measurements were conducted on a lathe (turning ma-
chine) shown on figure 8.
Frequencies which are usually compensated in electro-
nic systems (section 2) are 50, 150, 250, 350 Hz, which
means odd harmonic components of the mains signal (50
Hz). In literature it can be found that frequencies generated
by cutting are of several hundreds of hertz up to 1500 Hz
[2]. However, it’s maximum appears at 350 Hz which is
almost equal to that seen in the power filter application.
That means that the power factor compensator and the
vibration compensator could be implemented on the same
microprocessor system or with the same integrated circuit
(which could be appropriate for industrial application) so
the similar results in sense of compensating waveforms
could be achieved [18].

4 Sensor and actuator selection
It can be noted that current waveform is similar in
waveform to the rotor vibration during acceleration of the
electromotive drive (sections 2 and 3). During part machi-
ning similar oscillation occurs and similar results (dyna-
mics) are needed. Consequently, the same microprocessor
system or integrated circuit can be used for both problems.
The segment that differs at different applications includes
sensors and actuators. As it was shown in section 2 the
active power filter has a current sensor and an inductor as
an actuator. The fixture device would have a very accurate
displacement sensor and electromagnet actuator as proposed
in Sturos et al. [14], which is an inductor with a movable
magnet connected to machining part. Analogy between
mechatronic systems is obvious. For the fixturing device a
piezoelectric sensor would be appropriate [1], [2], [12],
[19]. These materials (sensors and actuators) offer an
expansion deformation roughly proportional to the voltage,
up to 0.1% (1µm/mm) at typically 150 V. In electromotive
drives the semiconductor or optical sensors also can be used
[11] in order to sense vibration.
5 Proposed active part fixture device
The similarity of problems and tools used in power
factor correction and vibration control results in the adop-
tion of the systems shown in figures 3. and 5. for use in a
vibration compensating device or machining part fixture
shown on figure 9.
Depending on the machining process vibration in cutting
direction [19] or in some other direction, compensation can
be made. The simulation of a proposed circuit was conduc-
ted following the analogy presented in the electronic sys-
tem. In this way, current becomes speed and it is connected
with displacement, voltage in the vibration compensator
Fig. 9 Proposed vibration compensator for machine tool
applications derived from active power filter
Obr. 9 Navrhnutý vibračný kompenzátor pre aplikácie
výroby nástrojov odvodený z aktívneho silového filtra
In spite of the fact that both systems need to be more
precisely mathematically described, an analogy between
them could be observed in light of these two simple
equations (9 and 10). The vibration compensator has both
electrical and mechanical time constants so it can be ex-
pected that its time constant will be larger than the electrical
time constant. The dynamics of both systems could be ana-
lyzed also as a function of filter capacitor voltage (VC1),
which can be controlled, so in the sense of simulation both
systems were assumed to have equal time constants.
Figure 10. shows simulation of vibration control in pro-
gram Simplorer followed by amplitude spectra of vibration
displacement before and after compensation (figures 11 and
12). Figure 13 presents vibration compensation for other ty-
pe (frequency spectrum) of vibration followed by frequency
spectrums of vibration displacement on figures 14 and 15.
All results were shown on the same amplitude scale. In this
way vibration reduction can be noted easily.
83
 Fig. 10. Simplorer simulation results for vibration control;
filter capacitor voltage – measure of force (1), compensated
vibrations – motion of compensated device (2), vibration
before compensating (3), vibration produced by
compensating device – actuator (4)
Obr. 10 Výsledky simulácie kontroly vibrácii v aplikácii
Simplorer; napätie kapacitátora filtra – meranie sily (1),
kompenzované vibrácie – pohyb kompenzovaného
zariadenia (2), vibrácie pred kompenzáciou (3), vibrácie
vytvorené kompenzačným zariadením – aktivátor (4)
Fig. 11 Amplitude spectra of vibrations before
compensation
Obr. 11 Amplitúdové spektrum vibrácií pred kompenzáciou
Fig. 12 Amplitude spectra of vibrations after compensation
Obr. 12 Amplitúdové spektrum vibrácií po kompenzácii
Fig. 13 Simplorer simulation results for vibration control;
filter capacitor voltage – measure of force (1), compensated
vibrations – motion of compensated device (2), vibration
before compensating (3), vibration produced by
compensating device – actuator (4)
Obr. 13 Výsledky simulácie kontroly vibrácii v aplikácii
Simplorer; napätie kapacitátora filtra – meranie sily (1),
kompenzované vibrácie – pohyb kompenzovaného
zariadenia (2), vibrácie pred kompenzáciou (3), vibrácie
vytvorené kompenzačným zariadením – aktivátor (4)
Fig. 14 Amplitude spectra of vibrations before
compensation
Obr. 14 Amplitúdové spektrum vibrácií pred kompenzáciou
84
Fig. 15 Amplitude spectra of vibrations after compensation
Obr. 15 Amplitúdové spektrum vibrácií po kompenzácii
Fig. 16 Sliding mode algorithm presented in program
Matlab/Simulink for fixture application on lathe
Obr. 16 Algoritmus s kĺzavým módom vytvorený
v Matlab/Simulink pre aplikáciu prípravku na sústruhu.
Two different types of vibration waveforms are tested in
order to show frequency invariance of system. That is its
main advantage comparing with passive methods of com-
pensation.
Figure 16. shows an adopted sliding mode algorithm for
vibration control applications.
Fig. 17 Microprocessor system with single phase H-bridge
which can be used as active power filter or vibration
compensator
Obr. 17 Mikroprocesorový systém s jednofázovým
H-mostíkom, ktorý môže byť použitý ako aktívny silový filter
alebo kompenzátor vibrácií
Figure 17. shows the microprocessor system dSPACE
suitable for implementation of different mechatronic sys-
tems.
5 Conclusion
An adoption of an electronic circuit for power factor
compensation was presented. Its new application is
vibration control. The presented single phase circuit can
compensate vibrations in one direction. For compensation
of vibrations in two or three dimensions, two or three such
circuits have to be used (or one multiphase circuit). This
article describes an electromagnetic actuator, but also
pneumatic actuators can also be used for larger tool ma-
chines. One could notice that both the power factor correc-
tor and the vibration compensator as well generate addition-
nal oscillations. The frequency of such oscillations is higher
than original ones and can be controlled. In booth cases
vibrations are reduced and translated to ultrasonic area of
frequencies (15 to 20 kHz) where we will hear no noise.
These new vibrations (or oscillations) have generally lower
amplitude so the circuit has a positive effect on machine
process. The analogy between the active power filter (power
factor corrector) and the vibration compensator is important
because power factor correctors are already mounted in
almost all PCs. That means that they are (or could be)
inexpensive. So it can be predicted that the same (or simi-
lar) solutions could be used for cost effective vibration com-
pensation. The result would be silent washing machines,
silent refrigerators, or silent air conditioners. Compensation
of vibrations or fixing parts during machining can be
implemented by the same algorithm, which means the same
integrated circuit at a very low price. Further development
of vibration compensating devices is probably going to be
concentrated on actuators adapted to special applications
(e.g. cuttng, drilling, etc.) employing even simpler circuits
than one presented.
Saša Sladić, Eng., MsC
Branimir Barišić, Eng., PhD
Technical University of Rijeka, Technical Faculty,
Vukovarska 58, 51000 Rijeka, Croatia,
tel.: +385-51-651489, fax: +385-51-651416
e-mail: sladics@riteh.hr,
barisic@riteh.hr,
Nicolae Ungeruanu, Eng., PhD
North University of Baia Mare,
Dr. V. Babes 62/A, 430083 Baia Mare, Romania,
tel.:+407-20027597
e-mail: unicu@ubm.ro
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