Motion control and synchronisation of multi-axis drive systems

Motion control and synchronisation of multi-axis drive system

Accuracy Enhancement during Robotic Milling using Force Feedback Control and Adaptive Speed Modulation

Six degree-of-freedom (6-dof) industrial robots have the potential to perform a variety of manufacturing tasks like machining or welding. Currently they are limited in their ability to perform high precision tasks (e.g. milling) due to inaccuracies caused by kinematic errors and low stiffness compared to conventional machine tools. In this thesis, a force model-based control algorithm will be developed for the process of face milling with a 6-dof industrial robot. In addition, a control algorithm for the detection and reduction of chatter vibrations through spindle speed modulation will be implemented. The research focus is on the improvement of accuracy and surface finish. Experiments will be conducted to validate the improvement in quality through both methods.M.S

Dynamic Model Identification and Trajectory Correction for Virtual Process Planning in Multi-Axis Machine Tools

In today’s industry, the capability to effectively reduce production time and cost gives a manufacturer a vital advantage against its competitors. Specifically, in the machining industry, the ability to simulate the dynamic performance of machine tools, and the physics of cutting processes, is critical to taking corrective actions, achieving process and productivity improvements, thereby enhancing competitiveness. In this context, being able to estimate mathematical models which describe the dynamic response of machine tools to commanded tool trajectories and external disturbance forces plays a key role in establishing virtual and intelligent manufacturing capability. These models can also be used in virtual simulations for process improvement, such as compensating for dynamic positioning errors by making small corrections to the commanded trajectory. This, in turn, can facilitate further productivity improvement and part quality in multi-axis manufacturing operations, such as machining. This thesis presents new methods for identifying the positioning response and friction characteristics of machine tool servo drives in a nonintrusive manner, and an approach for enhancing dynamic positioning accuracy through commanded trajectory correction via Iterative Learning Control (ILC). As the first contribution, the linear transfer functions correlating the positioning response to the commanded trajectory and friction disturbance inputs are identified using a new pole search method in conjunction with least squares (LS) projection. It is validated that this approach can work with in-process collected data, and demonstrates superior convergence and numerical characteristics, and model prediction accuracy, compared to an earlier ‘rapid identification’ approach based on the application of classical Least Squares for the full model. Effectiveness of the new method is demonstrated in simulations, and in experimental case studies for planar motion on two different machine tools, a gear grinding machine and a 5-axis machining center. Compared to the earlier approach, which could predict servo errors with 10-68% closeness, the new method improves the prediction accuracy to 0.5-2%. In the simulation of feed drives used in multi-axis machines, high fidelity prediction of the nonlinear stick-slip friction plays an important role. Specifically, time-dependent (i.e., dynamic) friction models help to improve the accuracy of virtual predictions. While many elaborate models have been proposed for this purpose, such as the generalized Maxwell-slip (GMS) model, their parameters can be numerous and difficult to identify from limited field data. In this thesis, as the second contribution, a new and highly efficient method of parameterizing the pre-sliding (hysteretic) portion of the GMS friction model is presented. This approach drastically reduces the number of unknown variables to identify, by estimating only the affective breakaway force, breakaway displacement, and ‘shape factor’ describing the shape of the pre-sliding virgin curve. Reduction in the number of unknowns enables this ‘reduced parameter’ GMS model to be identified much more easily from in-process data, compared to the fully parameterized GMS model, and the time-dependent friction dynamics can still be simulated accurately. Having improved the positioning response transfer function estimation and friction modeling, as the third contribution of this thesis, these two elements are combined together in a 3-step process. First, the servo response is estimated considering simplified Coulomb friction dynamics. Then, the friction model is replaced and identified as a reduced parameter GMS model. In the third step, the transfer function poles and zeros, and the reduced parameter GMS model, are concurrently optimized to replicate the observed experimental response with even greater fidelity. This improvement has been quantified as 12-44% in RMS and 28-54% in MAX values. This approach is successful in servo systems with predominantly rigid body behavior. However, its extension to a servo system with vibratory dynamics did not produce an immediately observed improvement. This is attributed to the dominance of vibrations in response to the commanded trajectory, and further investigation is recommended for future research. Having an accurate model of a multi-axis machine’s feed drive response allows for the dynamic positioning errors, which can lead to workpiece inaccuracy or defects, to be predicted and corrected ahead of time. For this purpose, ILC has been investigated. It is shown that through ILC, 1-2 orders of magnitude reduction in the servo errors is possible. While ILC is already available in certain commercial CNC systems, its training cycle (which is performed during the operation of the machine tool) can lead to part defects and wasted productive machining time. The new idea proposed in this thesis is to perform ILC on a virtual model, which is continuously updated via real-time production data using the identification methods developed in this work. This would minimize the amount of trial and error correction needed on the actual machine. In the course of this thesis research, after validating the effectiveness of ILC in simulations, to reliably and safely migrate the virtual modeling and trajectory correction results into industry (such as on a gear grinding machine tool), the author initiated and led the design and fabrication of an industry-scale testing platform, comprising a Siemens 840D SolutionLine CNC with a multi-axis feed drive setup. Majority of this implementation has been completed, and in near future work, the dynamic accuracy and productivity improvements facilitated with ‘virtually’ tuned ILC are expected to be demonstrated experimentally and tested in industry

Advances of Italian Machine Design

This 2028 Special Issue presents recent developments and achievements in the field of Mechanism and Machine Science coming from the Italian community with international collaborations and ranging from theoretical contributions to experimental and practical applications. It contains selected contributions that were accepted for presentation at the Second International Conference of IFToMM Italy, IFIT2018, that has been held in Cassino on 29 and 30 November 2018. This IFIT conference is the second event of a series that was established in 2016 by IFToMM Italy in Vicenza. IFIT was established to bring together researchers, industry professionals and students, from the Italian and the international community in an intimate, collegial and stimulating environment

The contemporary visualization and modelling technologies and the techniques for the design of the green roofs

The contemporary design solutions are merging the boundaries between real and virtual world. The Landscape architecture like the other interdisciplinary field stepped in a contemporary technologies area focused on that, beside the good execution of works, designer solutions has to be more realistic and “touchable”. The opportunities provided by Virtual Reality are certainly not negligible, it is common knowledge that the designs in the world are already presented in this way so the Virtual Reality increasingly used. Following the example of the application of virtual reality in landscape architecture, this paper deals with proposals for the use of virtual reality in landscape architecture so that designers, clients and users would have a virtual sense of scope e.g. rooftop garden, urban areas, parks, roads, etc. It is a programming language that creates a series of images creating a whole, so certain parts can be controlled or even modified in VR. Virtual reality today requires a specific gadget, such as Occulus, HTC Vive, Samsung Gear VR and similar. The aim of this paper is to acquire new theoretical and practical knowledge in the interdisciplinary field of virtual reality, the ability to display using virtual reality methods, and to present through a brief overview the plant species used in the design and construction of an intensive roof garden in a Mediterranean climate, the basic characteristics of roofing gardens as well as the benefits they carry. Virtual and augmented reality as technology is a very powerful tool for landscape architects, when modeling roof gardens, parks, and urban areas. One of the most popular technologies used by landscape architects is Google Tilt Brush, which enables fast modeling. The Google Tilt Brush VR app allows modeling in three-dimensional virtual space using a palette to work with the use of a three dimensional brush. The terms of two "programmed" realities - virtual reality and augmented reality - are often confused. One thing they have in common, though, is VRML - Virtual Reality Modeling Language. In this paper are shown the ways on which this issue can be solved and by the way, get closer the term of Virtual Reality (VR), also all the opportunities which the Virtual reality offered us. As well, in this paper are shown the conditions of Mediterranean climate, the conceptual solution and the plant species which will be used by execution of intensive green roof on the motel “Marković”

The benefits of an additional practice in descriptive geomerty course: non obligatory workshop at the Faculty of Civil Engineering in Belgrade

At the Faculty of Civil Engineering in Belgrade, in the Descriptive geometry (DG) course, non-obligatory workshops named “facultative task” are held for the three generations of freshman students with the aim to give students the opportunity to get higher final grade on the exam. The content of this workshop was a creative task, performed by a group of three students, offering free choice of a topic, i.e. the geometric structure associated with some real or imagery architectural/art-work object. After the workshops a questionnaire (composed by the professors at the course) is given to the students, in order to get their response on teaching/learning materials for the DG course and the workshop. During the workshop students performed one of the common tests for testing spatial abilities, named “paper folding". Based on the results of the questionnairethe investigation of the linkages between:students’ final achievements and spatial abilities, as well as students’ expectations of their performance on the exam, and how the students’ capacity to correctly estimate their grades were associated with expected and final grades, is provided. The goal was to give an evidence that a creative work, performed by a small group of students and self-assessment of their performances are a good way of helping students to maintain motivation and to accomplish their achievement. The final conclusion is addressed to the benefits of additional workshops employment in the course, which confirmhigherfinal scores-grades, achievement of creative results (facultative tasks) and confirmation of DG knowledge adaption