Novel control approaches for the next generation computer numerical control (CNC) system for hybrid micro-machines

It is well-recognised that micro-machining is a key enabling technology for manufacturing high value-added 3D micro-products, such as optics, moulds/dies and biomedical implants etc. These products are usually made of a wide range of engineering materials and possess complex freeform surfaces with tight tolerance on form accuracy and surface finish.In recent years, hybrid micro-machining technology has been developed to integrate several machining processes on one platform to tackle the manufacturing challenges for the aforementioned micro-products. However, the complexity of system integration and ever increasing demand for further enhanced productivity impose great challenges on current CNC systems. This thesis develops, implements and evaluates three novel control approaches to overcome the identified three major challenges, i.e. system integration, parametric interpolation and toolpath smoothing. These new control approaches provide solid foundation for the development of next generation CNC system for hybrid micro-machines.There is a growing trend for hybrid micro-machines to integrate more functional modules. Machine developers tend to choose modules from different vendors to satisfy the performance and cost requirements. However, those modules often possess proprietary hardware and software interfaces and the lack of plug-and-play solutions lead to tremendous difficulty in system integration. This thesis proposes a novel three-layer control architecture with component-based approach for system integration. The interaction of hardware is encapsulated into software components, while the data flow among different components is standardised. This approach therefore can significantly enhance the system flexibility. It has been successfully verified through the integration of a six-axis hybrid micro-machine. Parametric curves have been proven to be the optimal toolpath representation method for machining 3D micro-products with freeform surfaces, as they can eliminate the high-frequency fluctuation of feedrate and acceleration caused by the discontinuity in the first derivatives along linear or circular segmented toolpath. The interpolation for parametric curves is essentially an optimization problem, which is extremely difficult to get the time-optimal solution. This thesis develops a novel real-time interpolator for parametric curves (RTIPC), which provides a near time-optimal solution. It limits the machine dynamics (axial velocities, axial accelerations and jerk) and contour error through feedrate lookahead and acceleration lookahead operations. Experiments show that the RTIPC can simplify the coding significantly, and achieve up to ten times productivity than the industry standard linear interpolator. Furthermore, it is as efficient as the state-of-the-art Position-Velocity-Time (PVT) interpolator, while achieving much smoother motion profiles.Despite the fact that parametric curves have huge advantage in toolpath continuity, linear segmented toolpath is still dominantly used on the factory floor due to its straightforward coding and excellent compatibility with various CNC systems. This thesis presents a new real-time global toolpath smoothing algorithm, which bridges the gap in toolpath representation for CNC systems. This approach uses a cubic B-spline to approximate a sequence of linear segments. The approximation deviation is controlled by inserting and moving new control points on the control polygon. Experiments show that the proposed approach can increase the productivity by more than three times than the standard toolpath traversing algorithm, and 40% than the state-of-the-art corner blending algorithm, while achieving excellent surface finish.Finally, some further improvements for CNC systems, such as adaptive cutting force control and on-line machining parameters adjustment with metrology, are discussed in the future work section.It is well-recognised that micro-machining is a key enabling technology for manufacturing high value-added 3D micro-products, such as optics, moulds/dies and biomedical implants etc. These products are usually made of a wide range of engineering materials and possess complex freeform surfaces with tight tolerance on form accuracy and surface finish.In recent years, hybrid micro-machining technology has been developed to integrate several machining processes on one platform to tackle the manufacturing challenges for the aforementioned micro-products. However, the complexity of system integration and ever increasing demand for further enhanced productivity impose great challenges on current CNC systems. This thesis develops, implements and evaluates three novel control approaches to overcome the identified three major challenges, i.e. system integration, parametric interpolation and toolpath smoothing. These new control approaches provide solid foundation for the development of next generation CNC system for hybrid micro-machines.There is a growing trend for hybrid micro-machines to integrate more functional modules. Machine developers tend to choose modules from different vendors to satisfy the performance and cost requirements. However, those modules often possess proprietary hardware and software interfaces and the lack of plug-and-play solutions lead to tremendous difficulty in system integration. This thesis proposes a novel three-layer control architecture with component-based approach for system integration. The interaction of hardware is encapsulated into software components, while the data flow among different components is standardised. This approach therefore can significantly enhance the system flexibility. It has been successfully verified through the integration of a six-axis hybrid micro-machine. Parametric curves have been proven to be the optimal toolpath representation method for machining 3D micro-products with freeform surfaces, as they can eliminate the high-frequency fluctuation of feedrate and acceleration caused by the discontinuity in the first derivatives along linear or circular segmented toolpath. The interpolation for parametric curves is essentially an optimization problem, which is extremely difficult to get the time-optimal solution. This thesis develops a novel real-time interpolator for parametric curves (RTIPC), which provides a near time-optimal solution. It limits the machine dynamics (axial velocities, axial accelerations and jerk) and contour error through feedrate lookahead and acceleration lookahead operations. Experiments show that the RTIPC can simplify the coding significantly, and achieve up to ten times productivity than the industry standard linear interpolator. Furthermore, it is as efficient as the state-of-the-art Position-Velocity-Time (PVT) interpolator, while achieving much smoother motion profiles.Despite the fact that parametric curves have huge advantage in toolpath continuity, linear segmented toolpath is still dominantly used on the factory floor due to its straightforward coding and excellent compatibility with various CNC systems. This thesis presents a new real-time global toolpath smoothing algorithm, which bridges the gap in toolpath representation for CNC systems. This approach uses a cubic B-spline to approximate a sequence of linear segments. The approximation deviation is controlled by inserting and moving new control points on the control polygon. Experiments show that the proposed approach can increase the productivity by more than three times than the standard toolpath traversing algorithm, and 40% than the state-of-the-art corner blending algorithm, while achieving excellent surface finish.Finally, some further improvements for CNC systems, such as adaptive cutting force control and on-line machining parameters adjustment with metrology, are discussed in the future work section

Status of research at the Institute for Computer Applications in Science and Engineering (ICASE)

Research conducted at the Institute for Computer Applications in Science and Engineering in applied mathematics, numerical analysis and computer science is summarized

Opportunity Trajectory Reconstruction Techniques for Evaluation of ATC Systems

This paper describes some key points of a new tool being currently developed by Eurocontrol for the assessment of air traffic control (ATC) multisensor trackers performance. It summarizes the algorithmic foundations of the high-accuracy trajectory reconstruction process used to obtain reference trajectories from recorded measures. These trajectories will serve as a reference for the evaluation of the accuracy of ATC data processing centers. The performance of the system is illustrated with some reconstruction experiments on synthetic and real data

A novel parallel algorithm for surface editing and its FPGA implementation

A thesis submitted to the University of Bedfordshire in partial fulfilment of the requirements for the degree of Doctor of PhilosophySurface modelling and editing is one of important subjects in computer graphics. Decades of research in computer graphics has been carried out on both low-level, hardware-related algorithms and high-level, abstract software. Success of computer graphics has been seen in many application areas, such as multimedia, visualisation, virtual reality and the Internet. However, the hardware realisation of OpenGL architecture based on FPGA (field programmable gate array) is beyond the scope of most of computer graphics researches. It is an uncultivated research area where the OpenGL pipeline, from hardware through the whole embedded system (ES) up to applications, is implemented in an FPGA chip. This research proposes a hybrid approach to investigating both software and hardware methods. It aims at bridging the gap between methods of software and hardware, and enhancing the overall performance for computer graphics. It consists of four parts, the construction of an FPGA-based ES, Mesa-OpenGL implementation for FPGA-based ESs, parallel processing, and a novel algorithm for surface modelling and editing. The FPGA-based ES is built up. In addition to the Nios II soft processor and DDR SDRAM memory, it consists of the LCD display device, frame buffers, video pipeline, and algorithm-specified module to support the graphics processing. Since there is no implementation of OpenGL ES available for FPGA-based ESs, a specific OpenGL implementation based on Mesa is carried out. Because of the limited FPGA resources, the implementation adopts the fixed-point arithmetic, which can offer faster computing and lower storage than the floating point arithmetic, and the accuracy satisfying the needs of 3D rendering. Moreover, the implementation includes Bézier-spline curve and surface algorithms to support surface modelling and editing. The pipelined parallelism and co-processors are used to accelerate graphics processing in this research. These two parallelism methods extend the traditional computation parallelism in fine-grained parallel tasks in the FPGA-base ESs. The novel algorithm for surface modelling and editing, called Progressive and Mixing Algorithm (PAMA), is proposed and implemented on FPGA-based ES’s. Compared with two main surface editing methods, subdivision and deformation, the PAMA can eliminate the large storage requirement and computing cost of intermediated processes. With four independent shape parameters, the PAMA can be used to model and edit freely the shape of an open or closed surface that keeps globally the zero-order geometric continuity. The PAMA can be applied independently not only FPGA-based ESs but also other platforms. With the parallel processing, small size, and low costs of computing, storage and power, the FPGA-based ES provides an effective hybrid solution to surface modelling and editing

Radial Basis Functions: Biomedical Applications and Parallelization

Radial basis function (RBF) is a real-valued function whose values depend only on the distances between an interpolation point and a set of user-specified points called centers. RBF interpolation is one of the primary methods to reconstruct functions from multi-dimensional scattered data. Its abilities to generalize arbitrary space dimensions and to provide spectral accuracy have made it particularly popular in different application areas, including but not limited to: finding numerical solutions of partial differential equations (PDEs), image processing, computer vision and graphics, deep learning and neural networks, etc. The present thesis discusses three applications of RBF interpolation in biomedical engineering areas: (1) Calcium dynamics modeling, in which we numerically solve a set of PDEs by using meshless numerical methods and RBF-based interpolation techniques; (2) Image restoration and transformation, where an image is restored from its triangular mesh representation or transformed under translation, rotation, and scaling, etc. from its original form; (3) Porous structure design, in which the RBF interpolation used to reconstruct a 3D volume containing porous structures from a set of regularly or randomly placed points inside a user-provided surface shape. All these three applications have been investigated and their effectiveness has been supported with numerous experimental results. In particular, we innovatively utilize anisotropic distance metrics to define the distance in RBF interpolation and apply them to the aforementioned second and third applications, which show significant improvement in preserving image features or capturing connected porous structures over the isotropic distance-based RBF method. Beside the algorithm designs and their applications in biomedical areas, we also explore several common parallelization techniques (including OpenMP and CUDA-based GPU programming) to accelerate the performance of the present algorithms. In particular, we analyze how parallel programming can help RBF interpolation to speed up the meshless PDE solver as well as image processing. While RBF has been widely used in various science and engineering fields, the current thesis is expected to trigger some more interest from computational scientists or students into this fast-growing area and specifically apply these techniques to biomedical problems such as the ones investigated in the present work

Event-based Vision: A Survey

Event cameras are bio-inspired sensors that differ from conventional frame cameras: Instead of capturing images at a fixed rate, they asynchronously measure per-pixel brightness changes, and output a stream of events that encode the time, location and sign of the brightness changes. Event cameras offer attractive properties compared to traditional cameras: high temporal resolution (in the order of microseconds), very high dynamic range (140 dB vs. 60 dB), low power consumption, and high pixel bandwidth (on the order of kHz) resulting in reduced motion blur. Hence, event cameras have a large potential for robotics and computer vision in challenging scenarios for traditional cameras, such as low-latency, high speed, and high dynamic range. However, novel methods are required to process the unconventional output of these sensors in order to unlock their potential. This paper provides a comprehensive overview of the emerging field of event-based vision, with a focus on the applications and the algorithms developed to unlock the outstanding properties of event cameras. We present event cameras from their working principle, the actual sensors that are available and the tasks that they have been used for, from low-level vision (feature detection and tracking, optic flow, etc.) to high-level vision (reconstruction, segmentation, recognition). We also discuss the techniques developed to process events, including learning-based techniques, as well as specialized processors for these novel sensors, such as spiking neural networks. Additionally, we highlight the challenges that remain to be tackled and the opportunities that lie ahead in the search for a more efficient, bio-inspired way for machines to perceive and interact with the world