Design of a five-axis ultra-precision micro-milling machine—UltraMill. Part 2: Integrated dynamic modelling, design optimisation and analysis

Using computer models to predict the dynamic performance of ultra-precision machine tools can help manufacturers to substantially reduce the lead time and cost of developing new machines. However, the use of electronic drives on such machines is becoming widespread, the machine dynamic performance depending not only on the mechanical structure and components but also on the control system and electronic drives. Bench-top ultra-precision machine tools are highly desirable for the micro-manufacturing of high-accuracy micro-mechanical components. However, the development is still at the nascent stage and hence lacks standardised guidelines. Part 2 of this two-part paper proposes an integrated approach, which permits analysis and optimisation of the entire machine dynamic performance at the early design stage. Based on the proposed approach, the modelling and simulation process of a novel five-axis bench-top ultra-precision micro-milling machine tool—UltraMill—is presented. The modelling and simulation cover the dynamics of the machine structure, the moving components, the control system and the machining process and are used to predict the entire machine performance of two typical configurations

A holistic integrated dynamic design and modelling approach applied to the development of ultraprecision micro-milling machines

Ultraprecision machines with small footprints or micro-machines are highly desirable for micro-manufacturing high-precision micro-mechanical components. However, the development of the machines is still at the nascent stage by working on an individual machine basis and hence lacks generic scientific approach and design guidelines. Using computer models to predict the dynamic performance of ultraprecision machine tools can help manufacturers substantially reduce the lead time and cost of developing new machines. Furthermore, the machine dynamic performance depends not only upon the mechanical structure and components but also the control system and electronic drives. This paper proposed a holistic integrated dynamic design and modelling approach, which supports analysis and optimization of the overall machine dynamic performance at the early design stage. Based on the proposed approach the modelling and simulation process on a novel 5-axis bench-top ultraprecision micro-milling machine tool – UltraMill – is presented. The modelling and simulation cover the dynamics of the machine structure, moving components, control system and the machining process, and are used to predict the overall machine performance of two typical configurations. Preliminary machining trials have been carried out and provided the evidence of the approach being helpful to assure the machine performing right at the first setup

A dynamics-driven approach to precision machines design for micro-manufacturing and its implementation perspectives

Precision machines are essential elements in fabricating high quality micro products or micro features and directly affect the machining accuracy, repeatability and efficiency. There are a number of literatures on the design of industrial machine elements and a couple of precision machines commercially available. However, few researchers have systematically addressed the design of precision machines from the dynamics point of view. In this paper, the design issues of precision machines are presented with particular emphasis on the dynamics aspects as the major factors affecting the performance of the precision machines and machining processes. This paper begins with a brief review of the design principles of precision machines with emphasis on machining dynamics. Then design processes of precision machines are discussed, and followed by a practical modelling and simulation approaches. Two case studies are provided including the design and analysis of a fast tool servo system and a 5-axis bench-top micro-milling machine respectively. The design and analysis used in the two case studies are formulated based on the design methodology and guidelines

An Integrated Design and Simulation Environment for Rapid Prototyping of Laminate Robotic Mechanisms

Laminate mechanisms are a reliable concept in producing lowcost robots for educational and commercial purposes. These mechanisms are produced using low-cost manufacturing techniques which have improved significantly during recent years and are more accessible to novices and hobbyists. However, iterating through the design space to come up with the best design for a robot is still a time consuming and rather expensive task and therefore, there is still a need for model-based analysis before manufacturing. Until now, there has been no integrated design and analysis software for laminate robots. This paper addresses some of the issues surrounding laminate analysis by introducing a companion to an existing laminate design tool that automates the generation of dynamic equations and produces simulation results via rendered plots and videos. We have validated the accuracy of the software by comparing the position, velocity and acceleration of the simulated mechanisms with the measurements taken from physical laminate prototypes using a motion capture system

Modeling, Stability Analysis, and Testing of a Hybrid Docking Simulator

A hybrid docking simulator is a hardware-in-the-loop (HIL) simulator that includes a hardware element within a numerical simulation loop. One of the goals of performing a HIL simulation at the European Proximity Operation Simulator (EPOS) is the verification and validation of the docking phase in an on-orbit servicing mission.....Comment: 30 papge

MIT Space Engineering Research Center

The Space Engineering Research Center (SERC) at MIT, started in Jul. 1988, has completed two years of research. The Center is approaching the operational phase of its first testbed, is midway through the construction of a second testbed, and is in the design phase of a third. We presently have seven participating faculty, four participating staff members, ten graduate students, and numerous undergraduates. This report reviews the testbed programs, individual graduate research, other SERC activities not funded by the Center, interaction with non-MIT organizations, and SERC milestones. Published papers made possible by SERC funding are included at the end of the report

Small-Signal Modelling and Analysis of Doubly-Fed Induction Generators in Wind Power Applications

The worldwide demand for more diverse and greener energy supply has had a significant impact on the development of wind energy in the last decades. From 2 GW in 1990, the global installed capacity has now reached about 100 GW and is estimated to grow to 1000 GW by 2025. As wind power penetration increases, it is important to investigate its effect on the power system. Among the various technologies available for wind energy conversion, the doubly-fed induction generator (DFIG) is one of the preferred solutions because it offers the advantages of reduced mechanical stress and optimised power capture thanks to variable speed operation. This work presents the small-signal modelling and analysis of the DFIG for power system stability studies. This thesis starts by reviewing the mathematical models of wind turbines with DFIG convenient for power system studies. Different approaches proposed in the literature for the modelling of the turbine, drive-train, generator, rotor converter and external power system are discussed. It is shown that the flexibility of the drive train should be represented by a two-mass model in the presence of a gearbox. In the analysis part, the steady-state behaviour of the DFIG is examined. Comparison is made with the conventional synchronous generators (SG) and squirrel-cage induction generators to highlight the differences between the machines. The initialisation of the DFIG dynamic variables and other operating quantities is then discussed. Various methods are briefly reviewed and a step-by-step procedure is suggested to avoid the iterative computations in initial condition mentioned in the literature. The dynamical behaviour of the DFIG is studied with eigenvalue analysis. Modal analysis is performed for both open-loop and closed-loop situations. The effect of parameters and operating point variations on small signal stability is observed. For the open-loop DFIG, conditions on machine parameters are obtained to ensure stability of the system. For the closed-loop DFIG, it is shown that the generator electrical transients may be neglected once the converter controls are properly tuned. A tuning procedure is proposed and conditions on proportional gains are obtained for stable electrical dynamics. Finally, small-signal analysis of a multi-machine system with both SG and DFIG is performed. It is shown that there is no common mode to the two types of generators. The result confirms that the DFIG does not introduce negative damping to the system, however it is also shown that the overall effect of the DFIG on the power system stability depends on several structural factors and a general statement as to whether it improves or detriorates the oscillatory stability of a system can not be made

Flexible structure control laboratory development and technology demonstration

An experimental structure is described which was constructed to demonstrate and validate recent emerging technologies in the active control and identification of large flexible space structures. The configuration consists of a large, 20 foot diameter antenna-like flexible structure in the horizontal plane with a gimballed central hub, a flexible feed-boom assembly hanging from the hub, and 12 flexible ribs radiating outward. Fourteen electrodynamic force actuators mounted to the hub and to the individual ribs provide the means to excite the structure and exert control forces. Thirty permanently mounted sensors, including optical encoders and analog induction devices provide measurements of structural response at widely distributed points. An experimental remote optical sensor provides sixteen additional sensing channels. A computer samples the sensors, computes the control updates and sends commands to the actuators in real time, while simultaneously displaying selected outputs on a graphics terminal and saving them in memory. Several control experiments were conducted thus far and are documented. These include implementation of distributed parameter system control, model reference adaptive control, and static shape control. These experiments have demonstrated the successful implementation of state-of-the-art control approaches using actual hardware

Multi - objective sliding mode control of active magnetic bearing system

Active Magnetic Bearing (AMB) system is known to inherit many nonlinearity effects due to its rotor dynamic motion and the electromagnetic actuators which make the system highly nonlinear, coupled and open-loop unstable. The major nonlinearities that are associated with AMB system are gyroscopic effect, rotor mass imbalance and nonlinear electromagnetics in which the gyroscopics and imbalance are dependent to the rotational speed of the rotor. In order to provide satisfactory system performance for a wide range of system condition, active control is thus essential. The main concern of the thesis is the modeling of the nonlinear AMB system and synthesizing a robust control method based on Sliding Mode Control (SMC) technique such that the system can achieve robust performance under various system nonlinearities. The model of the AMB system is developed based on the integration of the rotor and electromagnetic dynamics which forms nonlinear time varying state equations that represent a reasonably close description of the actual system. Based on the known bound of the system parameters and state variables, the model is restructured to become a class of uncertain system by using a deterministic approach. In formulating the control algorithm to control the system, SMC theory is adapted which involves the formulation of the sliding surface and the control law such that the state trajectories are driven to the stable sliding manifold. The surface design involves the transformation of the system into a special canonical representation such that the sliding motion can be characterized by a convex representation of the desired system performances. Optimal Linear Quadratic (LQ) characteristics and regional pole-clustering of the closed-loop poles are designed to be the objectives to be fulfilled in the surface design where the formulation is represented as a set of Linear Matrix Inequality optimization problem. For the control law design, a new continuous SMC controller is proposed in which asymptotic convergence of the system’s state trajectories in finite time is guaranteed. This is achieved by adapting the equivalent control approach with the exponential decaying boundary layer technique. The newly designed sliding surface and control law form the complete Multi-objective SMC (MO-SMC) and the proposed algorithm is applied into the nonlinear AMB in which the results show that robust system performance is achieved for various system conditions. The findings also demonstrate that the MO-SMC gives better system response than the reported ideal SMC (I-SMC) and continuous SMC (C-SMC)