Adaptive Sliding Mode Contouring Control Design Based on Reference Adjustment and Uncertainty Compensation for Feed Drive Systems

Industrial feed drive systems, particularly, ball-screw and lead-screw feed drives are among the dominating motion components in production and manufacturing industries. They operate around the clock at high speeds for coping with the rising production demands. Adversely, high-speed motions cause mechanical vibrations, high-energy consumption, and insufficient accuracy. Although there are many control strategies in the literature, such as sliding mode and model predictive controls, further research is necessary for precision enhancement and energy saving. This study focused on design of an adaptive sliding mode contouring control based on reference adjustment and uncertainty compensation for feed drive systems. A combined reference adjustment and uncertainty compensator for precision motion of industrial feed drive systems were designed. For feasibility of the approach, simulation using matlab was conducted, and results are compared with those of an adaptive nonlinear sliding model contouring controller. The addition of uncertainty compensator showed a substantial improvement in performance by reducing the average contour error by 85.71% and the maximum contouring error by 78.64% under low speed compared to the adaptive sliding mode contouring controller with reference adjustment. Under high speed, the addition of uncertainty compensator reduced the average and absolute maximum contour errors by 4.48% and 10.13%, respectively. The experimental verification will be done in future. Keywords:    Machine tools, Feed drive systems, contouring control, Uncertainty dynamics, Sliding mode control

Model Referenced Condition Monitoring of High Performance CNC Machine Tools

Generally, machine tool monitoring is the prediction of the system’s health based on signal acquisition and processing and classification in order to identify the causes of the problem. The producers of machine tools need to pay more attention to their products life cycle because their customers increasingly focus on machine tool reliability and costs. The present study is concerned with the development of a condition monitoring system for high speed Computer Numerical Control (CNC) milling machine tools. A model is a simplification of a real machine to visualize the dynamics of a mechatronic system. This thesis applies recent modelling techniques to represent all parameters which affect the accuracy of a component produced automatically. The control can achieve an accuracy approaching the tolerance restrictions imposed by the machine tool axis repeatability and its operating environment. The motion control system of the CNC machine tool is described and the elements, which compose the axis drives including both the electrical components and the mechanical ones, are analysed and modelled. SIMULINK models have been developed to represent the majority of the dynamic behaviour of the feed drives from the actual CNC machine tool. Various values for the position controller and the load torque have been applied to the motor to show their behaviour. Development of a mechatronic hybrid model for five-axis CNC machine tool using Multi-Body-System (MBS) simulation approach is described. Analysis of CNC machine tool performance under non-cutting conditions is developed. ServoTrace data have been used to validate the Multi-body simulation of tool-to-workpiece position. This thesis aspects the application of state of art sensing methods in the field of condition monitoring of electromechanical systems. The ballscrew-with-nut is perhaps the most prevalent CNC machine subsystem and the condition of each element is crucial to the success of a machining operation. It’s essential to know of the health status of ballscrew, bearings and nut. Acoustic emission analysis of machines has been carried out to determine the deterioration of the ballscrew. Standard practices such as use of a Laser Interferometer have been used to determine the position of the machine tool. A novel machine feed drive condition monitoring system using acoustic emission (AE) signals has been proposed. The AE monitoring techniques investigated can be categorised into traditional AE parameters of energy, event duration and peak amplitude. These events are selected and normalised to estimate remaining life of the machine. This method is shown to be successfully applied for the ballscrew subsystem of an industrial high-speed milling machine. Finally, the successful outcome of the project will contribute to machine tool industry making possible manufacturing of more accurate products with lower costs in shorter time

ESSE 2017. Proceedings of the International Conference on Environmental Science and Sustainable Energy

Environmental science is an interdisciplinary academic field that integrates physical-, biological-, and information sciences to study and solve environmental problems. ESSE - The International Conference on Environmental Science and Sustainable Energy provides a platform for experts, professionals, and researchers to share updated information and stimulate the communication with each other. In 2017 it was held in Suzhou, China June 23-25, 2017

Development of the UMAC-based control system with application to 5-axis ultraprecision micromilling machines

This thesis was submitted for the degree of Doctor of Philosophy and awarded by Brunel University.Increasing demands from end users in the fields of optics, defence, automotive, medical, aerospace, etc. for high precision 3D miniaturized components and microstructures from a range of materials have driven the development in micro and nano machining and changed the manufacturing realm. Conventional manufacturing processes such as chemical etching and LIGA are found unfavourable or limited due to production time required and have led mechanical micro machining to grow further. Mechanical micro machining is an ideal method to produce high accuracy micro components and micro milling is the most flexible enabling process and is thus able to generate a wider variety of complex micro components and microstructures. Ultraprecision micromilling machine tools are required so as to meet the accuracy, surface finish and geometrical complexity of components and parts. Typical manufacturing requirements are high dimensional accuracy being better than 1 micron, flatness and roundness better than 50 nm and surface finish ranging between 10 and 50 nm. Manufacture of high precision components and parts require very intricate material removal procedure. There are five key components that include machine tools, cutting tools, material properties, operation variables and environmental conditions, which constitute in manufacturing high quality components and parts. End users assess the performance of a machine tool based on the dimensional accuracy and surface quality of machined parts including the machining time. In this thesis, the emphasis is on the design and development of a control system for a 5-axis bench-type ultraprecision micromilling machine- Ultra-Mill. On the one hand, the developed control system is able to offer high motion and positioning accuracy, dynamic stiffness and thermal stability for motion control, which are essential for achieving the machining accuracy and surface finish desired. On the other hand, the control system is able to undertake in-process inspection and condition monitoring of the machine tool and process. The control of multi-axis precision machines with high-speed and high-accuracy motions and positioning are desirable to manufacture components with high accuracy and complex features to increase productivity and maintain machine stability, etc. The development of the control system has focused on fast, accurate and robust positioning requirements at the machine system design stage. Apart from the mechanical design, the performance of the entire precision systems is greatly dependent on diverse electrical and electronics subsystems, controllers, drive instruments, feedback devices, inspection and monitoring system and software. There are some variables that dynamically alter the system behaviour and sensitivity to disturbance that are not ignorable in the micro and nano machining realm. In this research, a structured framework has been developed and integrated to aid the design and development of the control system. The framework includes critically reviewing the state of the art of ultraprecision machining tools, understanding the control system technologies involved, highlighting the advantages and disadvantages of various control system methods for ultraprecision machines, understanding what is required by end-users and formulating what actually makes a machine tool be an ultraprecision machine particularly from the control system perspective. In the design and development stage, the possession of mechatronic know-how is essential as the design and development of the Ultra-Mill is a multidisciplinary field. Simulation and modelling tool such as Matlab/Simulink is used to model the most suitable control system design. The developed control system was validated through machining trials to observe the achievable accuracy, experiments and testing of subsystems individually (slide system, tooling system, monitoring system, etc.). This thesis has successfully demonstrated the design and development of the control system for a 5-axis ultraprecision machine tool- Ultra-Mill, with high performance characteristics, fast, accurate, precise, etc. for motion and positioning, high dynamic stiffness, robustness and thermal stability, whereby was provided and maintained by the control system

Pneumatic motion control systems for modular robots

This thesis describes a research study in the design, implementation, evaluation and commercialisation of pneumatic motion control systems for modular robots. The research programme was conducted as part of a collaborative study, sponsored by the Science and Engineering Research Council, between Loughborough University and Martonair (UK) Limited. Microprocessor based motion control strategies have been used to produce low cost pneumatic servo-drives which can be used for 'point-to-point' positioning of payloads. Software based realtime control strategies have evolved which accomplish servo-controlled positioning while compensating for drive system non-linearities and time delays. The application of novel compensation techniques has resulted in a significant improvement in both the static and dynamic performance of the drive. A theoretical foundation is presented based on a linearised model of a pneumatic actuator, servo-valve, and load system. The thesis describes the design and evolution of microprocessor based hardware and software for motion control of pneumatic drives. A British Standards based test-facility has allowed control strategies to be evaluated with reference to standard performance criteria. It is demonstrated in this research study that the dynamic and static performance characteristics of a pneumatic motion control system can be dramatically improved by applying appropriate software based realtime control strategies. This makes the application of computer controlled pneumatic servos in manufacturing very attractive with cost performance ratios which match or better alternative drive technologies. The research study has led to commercial products (marketed by Martonair Ltd), in which realtime control algorithms implementing these control strategy designs are executed within a microprocessor based motion controller

Development of the UMAC-based control system with application to 5-axis ultraprecision micromilling machines

Increasing demands from end users in the fields of optics, defence, automotive, medical, aerospace, etc. for high precision 3D miniaturized components and microstructures from a range of materials have driven the development in micro and nano machining and changed the manufacturing realm. Conventional manufacturing processes such as chemical etching and LIGA are found unfavourable or limited due to production time required and have led mechanical micro machining to grow further. Mechanical micro machining is an ideal method to produce high accuracy micro components and micro milling is the most flexible enabling process and is thus able to generate a wider variety of complex micro components and microstructures. Ultraprecision micromilling machine tools are required so as to meet the accuracy, surface finish and geometrical complexity of components and parts. Typical manufacturing requirements are high dimensional accuracy being better than 1 micron, flatness and roundness better than 50 nm and surface finish ranging between 10 and 50 nm. Manufacture of high precision components and parts require very intricate material removal procedure. There are five key components that include machine tools, cutting tools, material properties, operation variables and environmental conditions, which constitute in manufacturing high quality components and parts. End users assess the performance of a machine tool based on the dimensional accuracy and surface quality of machined parts including the machining time. In this thesis, the emphasis is on the design and development of a control system for a 5-axis bench-type ultraprecision micromilling machine- Ultra-Mill. On the one hand, the developed control system is able to offer high motion and positioning accuracy, dynamic stiffness and thermal stability for motion control, which are essential for achieving the machining accuracy and surface finish desired. On the other hand, the control system is able to undertake in-process inspection and condition monitoring of the machine tool and process. The control of multi-axis precision machines with high-speed and high-accuracy motions and positioning are desirable to manufacture components with high accuracy and complex features to increase productivity and maintain machine stability, etc. The development of the control system has focused on fast, accurate and robust positioning requirements at the machine system design stage. Apart from the mechanical design, the performance of the entire precision systems is greatly dependent on diverse electrical and electronics subsystems, controllers, drive instruments, feedback devices, inspection and monitoring system and software. There are some variables that dynamically alter the system behaviour and sensitivity to disturbance that are not ignorable in the micro and nano machining realm. In this research, a structured framework has been developed and integrated to aid the design and development of the control system. The framework includes critically reviewing the state of the art of ultraprecision machining tools, understanding the control system technologies involved, highlighting the advantages and disadvantages of various control system methods for ultraprecision machines, understanding what is required by end-users and formulating what actually makes a machine tool be an ultraprecision machine particularly from the control system perspective. In the design and development stage, the possession of mechatronic know-how is essential as the design and development of the Ultra-Mill is a multidisciplinary field. Simulation and modelling tool such as Matlab/Simulink is used to model the most suitable control system design. The developed control system was validated through machining trials to observe the achievable accuracy, experiments and testing of subsystems individually (slide system, tooling system, monitoring system, etc.). This thesis has successfully demonstrated the design and development of the control system for a 5-axis ultraprecision machine tool- Ultra-Mill, with high performance characteristics, fast, accurate, precise, etc. for motion and positioning, high dynamic stiffness, robustness and thermal stability, whereby was provided and maintained by the control system.EThOS - Electronic Theses Online ServiceGBUnited Kingdo

NASA Tech Briefs Index, 1978

Approximately 601 announcements of new technology derived from the research and development activities of the National Aeronautics and Space Administration are presented. Emphasis is placed on information considered likely to be transferrable across industrial, regional, or disciplinary lines. Subject matter covered includes: electronic components and circuits; electron systems; physical sciences; materials; life sciences; mechanics; machinery; fabrication technology; and mathematics and information sciences

NASA Tech Briefs, Winter 1978

Topics covered include: NASA TU Services: Technology Utilization services that can assist you in learning about and applying NASA technology; New Product Ideas: A summary of selected innovations of value to manufacturers for the development of new products; Electronic Components and Circuits; Electronic Systems; Physical Sciences; Materials; Life Sciences; Mechanics; Machinery; Fabrication Technology; Mathematics and Information Sciences

NASA Tech Briefs Index 1978

Tech Briefs are short announcements of new technology derived from the research and development activities of the National Aeronautics and Space Administration. These briefs emphasize information considered likely to be transferrable across industrial, regional, or disciplinary lines and are issued to encourage commercial application. This Index to NASA Tech Briefs contains abstracts and four indexes -- subject, personal author, originating Center, and Tech Brief number -- for 1978 Tech Briefs