Five-Axis Machine Tool Condition Monitoring Using dSPACE Real-Time System

This paper presents the design, development and SIMULINK implementation of the lumped parameter model of C-axis drive from GEISS five-axis CNC machine tool. The simulated results compare well with the experimental data measured from the actual machine. Also the paper describes the steps for data acquisition using ControlDesk and hardware-in-the-loop implementation of the drive models in dSPACE real-time system. The main components of the HIL system are: the drive model simulation and input – output (I/O) modules for receiving the real controller outputs. The paper explains how the experimental data obtained from the data acquisition process using dSPACE real-time system can be used for the development of machine tool diagnosis and prognosis systems that facilitate the improvement of maintenance activities

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

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

Neural-Network Vector Controller for Permanent-Magnet Synchronous Motor Drives: Simulated and Hardware-Validated Results

This paper focuses on current control in a permanentmagnet synchronous motor (PMSM). The paper has two main objectives: The first objective is to develop a neural-network (NN) vector controller to overcome the decoupling inaccuracy problem associated with conventional PI-based vector-control methods. The NN is developed using the full dynamic equation of a PMSM, and trained to implement optimal control based on approximate dynamic programming. The second objective is to evaluate the robust and adaptive performance of the NN controller against that of the conventional standard vector controller under motor parameter variation and dynamic control conditions by (a) simulating the behavior of a PMSM typically used in realistic electric vehicle applications and (b) building an experimental system for hardware validation as well as combined hardware and simulation evaluation. The results demonstrate that the NN controller outperforms conventional vector controllers in both simulation and hardware implementation

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

Analysis and design of space vehicle flight control systems. Volume X - Man in the loop

Methods for use in design and analysis of space vehicle flight control systems - recommendations for placing man in control loop of booster

A Modified Positive Velocity and Position Feedback scheme with delay compensation for improved nanopositioning performance

Acknowledgments This paper was sponsored by the Spanish FPU12/00984 Program (Ministerio de Educacion, Cultura y Deporte). It was also sponsored by the Spanish Government Research Program with the Project DPI2012-37062-CO2-01 (Ministerio de Economia y Competitividad) and by the European Social Fund.Peer reviewedPostprin

Proportional-Integral-Plus Control Strategy of an Intelligent Excavator

This article considers the application of Proportional-Integral-Plus (PIP) control to the Lancaster University Computerised Intelligent Excavator (LUCIE), which is being developed to dig foundation trenches on a building site. Previous work using LUCIE was based on the ubiquitous PI/PID control algorithm, tuned on-line, and implemented in a rather ad hoc manner. By contrast, the present research utilizes new hardware and advanced model-based control system design methods to improve the joint control and so provide smoother, more accurate movement of the excavator arm. In this article, a novel nonlinear simulation model of the system is developed for MATLAB/SIMULINK, allowing for straightforward refinement of the control algorithm and initial evaluation. The PIP controller is compared with a conventionally tuned PID algorithm, with the final designs implemented on-line for the control of dipper angle. The simulated responses and preliminary implementation results demonstrate the feasibility of the approach