Novel control approaches for the next generation computer numerical control (CNC) system for hybrid micro-machines

It is well-recognised that micro-machining is a key enabling technology for manufacturing high value-added 3D micro-products, such as optics, moulds/dies and biomedical implants etc. These products are usually made of a wide range of engineering materials and possess complex freeform surfaces with tight tolerance on form accuracy and surface finish.In recent years, hybrid micro-machining technology has been developed to integrate several machining processes on one platform to tackle the manufacturing challenges for the aforementioned micro-products. However, the complexity of system integration and ever increasing demand for further enhanced productivity impose great challenges on current CNC systems. This thesis develops, implements and evaluates three novel control approaches to overcome the identified three major challenges, i.e. system integration, parametric interpolation and toolpath smoothing. These new control approaches provide solid foundation for the development of next generation CNC system for hybrid micro-machines.There is a growing trend for hybrid micro-machines to integrate more functional modules. Machine developers tend to choose modules from different vendors to satisfy the performance and cost requirements. However, those modules often possess proprietary hardware and software interfaces and the lack of plug-and-play solutions lead to tremendous difficulty in system integration. This thesis proposes a novel three-layer control architecture with component-based approach for system integration. The interaction of hardware is encapsulated into software components, while the data flow among different components is standardised. This approach therefore can significantly enhance the system flexibility. It has been successfully verified through the integration of a six-axis hybrid micro-machine. Parametric curves have been proven to be the optimal toolpath representation method for machining 3D micro-products with freeform surfaces, as they can eliminate the high-frequency fluctuation of feedrate and acceleration caused by the discontinuity in the first derivatives along linear or circular segmented toolpath. The interpolation for parametric curves is essentially an optimization problem, which is extremely difficult to get the time-optimal solution. This thesis develops a novel real-time interpolator for parametric curves (RTIPC), which provides a near time-optimal solution. It limits the machine dynamics (axial velocities, axial accelerations and jerk) and contour error through feedrate lookahead and acceleration lookahead operations. Experiments show that the RTIPC can simplify the coding significantly, and achieve up to ten times productivity than the industry standard linear interpolator. Furthermore, it is as efficient as the state-of-the-art Position-Velocity-Time (PVT) interpolator, while achieving much smoother motion profiles.Despite the fact that parametric curves have huge advantage in toolpath continuity, linear segmented toolpath is still dominantly used on the factory floor due to its straightforward coding and excellent compatibility with various CNC systems. This thesis presents a new real-time global toolpath smoothing algorithm, which bridges the gap in toolpath representation for CNC systems. This approach uses a cubic B-spline to approximate a sequence of linear segments. The approximation deviation is controlled by inserting and moving new control points on the control polygon. Experiments show that the proposed approach can increase the productivity by more than three times than the standard toolpath traversing algorithm, and 40% than the state-of-the-art corner blending algorithm, while achieving excellent surface finish.Finally, some further improvements for CNC systems, such as adaptive cutting force control and on-line machining parameters adjustment with metrology, are discussed in the future work section.It is well-recognised that micro-machining is a key enabling technology for manufacturing high value-added 3D micro-products, such as optics, moulds/dies and biomedical implants etc. These products are usually made of a wide range of engineering materials and possess complex freeform surfaces with tight tolerance on form accuracy and surface finish.In recent years, hybrid micro-machining technology has been developed to integrate several machining processes on one platform to tackle the manufacturing challenges for the aforementioned micro-products. However, the complexity of system integration and ever increasing demand for further enhanced productivity impose great challenges on current CNC systems. This thesis develops, implements and evaluates three novel control approaches to overcome the identified three major challenges, i.e. system integration, parametric interpolation and toolpath smoothing. These new control approaches provide solid foundation for the development of next generation CNC system for hybrid micro-machines.There is a growing trend for hybrid micro-machines to integrate more functional modules. Machine developers tend to choose modules from different vendors to satisfy the performance and cost requirements. However, those modules often possess proprietary hardware and software interfaces and the lack of plug-and-play solutions lead to tremendous difficulty in system integration. This thesis proposes a novel three-layer control architecture with component-based approach for system integration. The interaction of hardware is encapsulated into software components, while the data flow among different components is standardised. This approach therefore can significantly enhance the system flexibility. It has been successfully verified through the integration of a six-axis hybrid micro-machine. Parametric curves have been proven to be the optimal toolpath representation method for machining 3D micro-products with freeform surfaces, as they can eliminate the high-frequency fluctuation of feedrate and acceleration caused by the discontinuity in the first derivatives along linear or circular segmented toolpath. The interpolation for parametric curves is essentially an optimization problem, which is extremely difficult to get the time-optimal solution. This thesis develops a novel real-time interpolator for parametric curves (RTIPC), which provides a near time-optimal solution. It limits the machine dynamics (axial velocities, axial accelerations and jerk) and contour error through feedrate lookahead and acceleration lookahead operations. Experiments show that the RTIPC can simplify the coding significantly, and achieve up to ten times productivity than the industry standard linear interpolator. Furthermore, it is as efficient as the state-of-the-art Position-Velocity-Time (PVT) interpolator, while achieving much smoother motion profiles.Despite the fact that parametric curves have huge advantage in toolpath continuity, linear segmented toolpath is still dominantly used on the factory floor due to its straightforward coding and excellent compatibility with various CNC systems. This thesis presents a new real-time global toolpath smoothing algorithm, which bridges the gap in toolpath representation for CNC systems. This approach uses a cubic B-spline to approximate a sequence of linear segments. The approximation deviation is controlled by inserting and moving new control points on the control polygon. Experiments show that the proposed approach can increase the productivity by more than three times than the standard toolpath traversing algorithm, and 40% than the state-of-the-art corner blending algorithm, while achieving excellent surface finish.Finally, some further improvements for CNC systems, such as adaptive cutting force control and on-line machining parameters adjustment with metrology, are discussed in the future work section

Improving Lookahead search for grid-based pathfinding

Pathfinding is an essential part of navigation systems, often used in video games, route planning and robotic navigation. A* search has been one of the most well-known and frequently used algorithms for pathfinding. A* uses an open list and a closed list to keep track of all nodes generated and expanded. The size and performance of these data structures are major drawbacks of A*. Lookahead is used to investigate future outcomes and improve the quality of available choices. Lookaheads are done on a DFS manner from the frontier of A* search. This combination of A* and DFS lookahead has been shown to save space when working with puzzles. We leverage this concept with grid-based pathfinding in video games to save the amount of space consumed. However, because grids contain redundant paths, the DFS lookaheads end up being an overhead as they do not maintain a list of nodes visited or expanded. By using a domain-specific pruning technique, we significantly improve the time taken by the algorithm and further improve upon the space consumed. A combination of lookahead and A* search with this pruning technique is, therefore, able to achieve improvement in both space-consumed and time-taken over the standard A* search algorithm for grid-based pathfinding

Exact distributional analysis of online algorithms with lookahead

In online optimization, input data is revealed sequentially. Optimization problems in practice often exhibit this type of information disclosure as opposed to standard offline optimization where all information is known in advance. We analyze the performance of algorithms for online optimization with lookahead using a holistic distributional approach. To this end, we first introduce the performance measurement method of counting distribution functions. Then, we derive analytical expressions for the counting distribution functions of the objective value and the performance ratio in elementary cases of the online bin packing and the online traveling salesman problem. For bin packing, we also establish a relation between algorithm processing and the Catalan numbers. The paper shows that an exact analysis is strongly interconnected to the combinatorial structure of the problem and algorithm under consideration. Results further indicate that the value of lookahead heavily relies on the problem itself. The analysis also shows that exact distributional analysis could be used in order to discover key effects and identify related root causes in relatively simple problem settings. These insights can then be transferred to the analysis of more complex settings where the introduced performance measurement approach has to be used on an approximative basis (e.g., in a simulation-based optimization)

Identifying and Harnessing Concurrency for Parallel and Distributed Network Simulation

Although computer networks are inherently parallel systems, the parallel execution of network simulations on interconnected processors frequently yields only limited benefits. In this thesis, methods are proposed to estimate and understand the parallelization potential of network simulations. Further, mechanisms and architectures for exploiting the massively parallel processing resources of modern graphics cards to accelerate network simulations are proposed and evaluated

FREEDOM: Validated Method for the Rapid Assessment of Incipient Multimodal Faults of Complex Aerospace Systems

Model-based Fault Detection and Isolation (FDI) methods allow to infer the health status of complex aerospace systems through a large quantity of data acquired in-flight, and evaluations of numerical models of the equipment. This results in an intensive computational procedure that can be addressed only grounding the aircraft. We introduce an original methodology to sensitively accelerate FDI by reducing the computational demand to identify the health status of the aircraft. Our scheme FREEDOM – Fast REliability Estimate and incipient fault Detection Of Multiphysics aerospace systems – proposes an original combination of a novel two-step compression strategy to compute offline a synthesized representation of the dynamical response of the system, and uses an inverse Bayesian optimization approach to infer online the level of damage determined by multiple fault modes affecting the equipment. We demonstrate and validate FREEDOM against numerical and physical experiments for the case of an ElectroMechanical Actuator (EMA) employed for secondary flight controls. Particular attention is dedicated to simultaneous incipient mechanical and electrical faults considering different experimental settings. The outcomes validate our FDI strategy, which permits to achieve the accurate identification of complex damages outperforming the computational time of state of the art algorithms by two orders of magnitude