ORIGINAL RESEARCH article
Front. Mech. Eng.
Sec. Mechatronics
Optimization of Time-Varying Load Dynamic Response of Industrial Robot PLC System Based on Improved Model Reference Adaptive Control
Provisionally accepted
- 1Shanghai Jianqiao University, Shanghai, China
- 2Shanghai Xindao Electronic Technology Co., LTD, Shanghai, China
- 3Shanghai Borong Zengyi Control Technology Co., LTD, Shanghai, China
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In the process of industrial automation, industrial robots are widely used in complex operations such as welding, assembly, and handling. The dynamic response performance under time-varying load conditions directly affects production efficiency and control quality. To improve the dynamic response speed and control accuracy of industrial robot Programmable Logic Control (PLC) systems under time-varying loads, an improved Model Reference Adaptive Control (MRAC) strategy that combines Fuzzy Correction Adaptive Law (FCAL) and Particle Swarm Optimization (PSO) algorithm is designed. It combines an Extended Kalman Filter (EKF) load observer with a composite control law to adapt to the discrete characteristics of PLC and optimize multi-task scheduling. Experiments show that in three scenarios: automotive welding, electronic assembly, and metal cutting, the production efficiency of this system is increased by 20.7% to 23.8% compared with traditional PLC methods, and the dynamic response time is shortened from 0.8 s to 0.3 s. The product qualification rate increases from 1.9% to 3.9%, and the positioning error of the assembly robot drops from ±0.1 ms to ±0.05 ms. The torque fluctuation of the cutting robot motor drops from 1.0 N·m to 0.58 N·m, the load observation error does not exceed 0.05 N·m, and the angular velocity overshoot is less than 1.2%. Through the deep integration of adaptive control strategy and PLC system, the dynamic response speed and control accuracy of industrial robots under time-varying load conditions are effectively improved, and production efficiency, product qualification rate, and energy consumption indicators are improved. This study provides reliable technical support for the field of flexible manufacturing.
Keywords: Dynamic response, Industrial robot, MRAC, PLC, Time-varying load
Received: 29 Dec 2025; Accepted: 13 Feb 2026.
Copyright: © 2026 Li, Lian, Yang and Liu. This is an open-access article distributed under the terms of the Creative Commons Attribution License (CC BY). The use, distribution or reproduction in other forums is permitted, provided the original author(s) or licensor are credited and that the original publication in this journal is cited, in accordance with accepted academic practice. No use, distribution or reproduction is permitted which does not comply with these terms.
* Correspondence: Lihua Liu
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