Design of an instrumented smart cutting tool and its implementation and application perspectives

This paper presents an innovative design of a smart cutting tool, using two surface acoustic wave (SAW) strain sensors mounted onto the top and the side surface of the tool shank respectively, and its implementation and application perspectives. This surface acoustic wave-based smart cutting tool is capable of measuring the cutting force and the feed force in a real machining environment, after a calibration process under known cutting conditions. A hybrid dissimilar workpiece is then machined using the SAW-based smart cutting tool. The hybrid dissimilar material is made of two different materials, NiCu alloy (Monel) and steel, welded together to form a single bar; this can be used to simulate an abrupt change in material properties. The property transition zone is successfully detected by the tool; the sensor feedback can then be used to initiate a change in the machining parameters to compensate for the altered material properties.The UK Technology Strategy Board (TSB) for supporting this research (SEEM Project, contract No. BD266E

Design and Performance Analysis of a Non-Standard EPICS Fast Controller

The large scientific projects present new technological challenges, such as the distributed control over a communication network. In particular, the middleware EPICS is the most extended communication standard in particle accelerators. The integration of modern control architectures in these EPICS networks is becoming common, as for example for the PXI/PXIe and xTCA hardware alternatives. In this work, a different integration procedure for PXIe real time controllers from National Instruments is proposed, using LabVIEW as the design tool. This methodology is considered and its performance is analyzed by means of a set of laboratory experiments. This control architecture is proposed for achieving the implementation requirements of the fast controllers, which need an important amount of computational power and signal processing capability, with a tight real-time demand. The present work studies the advantages and drawbacks of this methodology and presents its comprehensive evaluation by means of a laboratory test bench, designed for the application of systematic tests. These tests compare the proposed fast controller performance with a similar system implemented using an standard EPICS IOC provided by the CODAC system.Comment: This is the extended version of the Conference Record presented in the IEEE Real-Time Conference 2014, Nara, Japan. This paper has been submitted to the IEEE Transactions on Nuclear Scienc

Improving the Dynamic Performance of Five-Axis CNC Machine Tool by using the Software-in-the-Loop (SIL) Platform

The paper presents the development and implementation of a Software-in-the-loop (SIL) platform allowing the real-time simulation of the hybrid model of five-axis CNC machine tool which is implemented in SIMULINK. The interfacing between dSPACE software and the feed drives models in SIMULINK is explined. The values for the simulated positioning errors between the position demand and simulated position of orthogonal trimming head for the gantry axis are in the order of microns so proposed SIL model is validated. The accurate SIL platform could be used to build and optimise the machining process models including CNC machine tools under cutting conditions and improve machines’ dynamic performance

Integrated Design Tools for Embedded Control Systems

Currently, computer-based control systems are still being implemented using the same techniques as 10 years ago. The purpose of this project is the development of a design framework, consisting of tools and libraries, which allows the designer to build high reliable heterogeneous real-time embedded systems in a very short time at a fraction of the present day costs. The ultimate focus of current research is on transformation control laws to efficient concurrent algorithms, with concerns about important non-functional real-time control systems demands, such as fault-tolerance, safety,\ud reliability, etc.\ud The approach is based on software implementation of CSP process algebra, in a modern way (pure objectoriented design in Java). Furthermore, it is intended that the tool will support the desirable system-engineering stepwise refinement design approach, relying on past research achievements ¿ the mechatronics design trajectory based on the building-blocks approach, covering all complex (mechatronics) engineering phases: physical system modeling, control law design, embedded control system implementation and real-life realization. Therefore, we expect that this project will result in an\ud adequate tool, with results applicable in a wide range of target hardware platforms, based on common (off-theshelf) distributed heterogeneous (cheap) processing units

Control design toolbox for large scale variable speed pitch regulated wind turbines

The trend towards large multi-MW wind turbineshas given new impetus to the development of wind turbine controllers.Additional objectives are being placed on the controllermaking the specification of the control system more complex. A new toolbox, which assists with most of the control design cycle,has been developed. Its purpose is to assist and guide the control system designer through the design cycle, thereby enabling faster design. With the choice of control strategy unrestricted,the toolbox is sufficiently flexible to support the design processfor the aforementioned more complex specifications