Real-time performance of mechatronic PZT module using active vibration feedback control

This paper proposes an innovative mechatronic piezo-actuated module to control vibrations in modern machine tools. Vibrations represent one of the main issues that seriously compromise the quality of the workpiece. The active vibration control (AVC) device is composed of a host part integrated with sensors and actuators synchronized by a regulator; it is able to make a self-assessment and adjust to alterations in the environment. In particular, an innovative smart actuator has been designed and developed to satisfy machining requirements during active vibration control. This study presents the mechatronic model based on the kinematic and dynamic analysis of the AVC device. To ensure a real time performance, a H2-LQG controller has been developed and validated by simulations involving a machine tool, PZT actuator and controller models. The Hardware in the Loop (HIL) architecture is adopted to control and attenuate the vibrations. A set of experimental tests has been performed to validate the AVC module on a commercial machine tool. The feasibility of the real time vibration damping is demonstrated and the simulation accuracy is evaluate

PKM mechatronic clamping adaptive device

This study proposes a novel adaptive fixturing device based on active clamping systems for smart micropositioning of thin-walled precision parts. The modular architecture and the structure flexibility make the system suitable for various industrial applications. The proposed device is realized as a Parallel Kinematic Machine (PKM), opportunely sensorized and controlled, able to perform automatic error-free workpiece clamping procedures, drastically reducing the overall fixturing set-up time. The paper describes the kinematics and dynamics of this mechatronic system. A first campaign of experimental trails has been carried out on the prototype, obtaining promising results

Wireless sensor networks for active vibration control in automobile structures

International audienceWireless Sensor Network (WSN) are nowadays widely used in monitoring and tracking applications. This paper presents the feasibility of using Wireless Sensor Networks in active vibration control strategy. The active control method used is an active-structural acoustic control using piezoelectric sensors distributed on the car structure. This system aims at being merged in wireless sensor network whose head node collects data and process control law so as to command piezoelectric actuators wisely placed on the structure. We will study the feasibility of implementing WSN in active vibration control and introduce a complete design methodology to optimize hardware/software and control law synergy in mechatronic systems. A design space exploration will be conducted so as to identify the best Wireless Sensor Network platform and the resulting impact on control

Evolutionary algorithms for active vibration control of flexible manipulator

Flexible manipulator systems offer numerous advantages over their rigid counterparts including light weight, faster system response, among others. However, unwanted vibration will occur when flexible manipulator is subjected to disturbances. If the advantages of flexible manipulator are not to be sacrificed, an accurate model and efficient control system must be developed. This thesis presents the development of a Proportional-Integral-Derivative (PID) controller tuning method using evolutionary algorithms (EA) for a single-link flexible manipulator system. Initially, a single link flexible manipulator rig, constrained to move in horizontal direction, was designed and fabricated. The input and output experimental data of the hub angle and endpoint acceleration of the flexible manipulator were acquired. The dynamics of the system was later modeled using a system identification (SI) method utilizing EA with linear auto regressive with exogenous (ARX) model structure. Two novel EAs, Genetic Algorithm with Parameter Exchanger (GAPE) and Particle Swarm Optimization with Explorer (PSOE) have been developed in this study by modifying the original Genetic Algorithm (GA) and Particle Swarm Optimization (PSO) algorithms. These novel algorithms were introduced for the identification of the flexible manipulator system. Their effectiveness was then evaluated in comparison to the original GA and PSO. Results indicated that the identification of the flexible manipulator system using PSOE is better compared to other methods. Next, PID controllers were tuned using EA for the input tracking and the endpoint vibration suppression of the flexible manipulator structure. For rigid motion control of hub angle, an auto-tuned PID controller was implemented. While for vibration suppression of the endpoint, several PID controllers were tuned using GA, GAPE, PSO and PSOE. The results have shown that the conventional auto-tuned PID was effective enough for the input tracking of the rigid motion. However, for end-point vibration suppression, the result showed the superiority of PID-PSOE in comparison to PID-GA, PID-GAPE and PID-PSO. The performance of the best simulated controller was validated experimentally later. Through experimental validation, it was found that the PID-PSOE was capable to suppress the vibration of the single-link flexible manipulator with highest attenuation of 31.3 dB at the first mode of the vibration. The outcomes of this research revealed the effectiveness of the PID controller tuned using PSOE for the endpoint vibration suppression of the flexible manipulator amongst other evolutionary methods

Sensorless Position Control of Piezoelectric Ultrasonic Motors:a Mechatronic Design Approach

This dissertation considers mechatronic systems driven by piezoelectric ultrasonic motors (PUM). The focus is set on optimal system design and sensorless position control. Mechatronic industry faces the challenge to deliver ever more efficient and reliable products while being confronted to increasingly short time to market demands and economic constraints driven by competition. Although optimal design strategies are applied to master this challenge, they do not entirely respond to the given circumstances, as often only local criteria are optimised. In order to obtain a globally optimal solution, the many subfunctions of a mechatronic system and their models must be interrelated and evaluated concurrently from the very beginning of the design process. In this context PUM have been used increasingly during the last decade for various positioning applications in the field of mechatronic systems, laboratory equipment, and consumer electronics where their performances are superior to conventional electromechanical drive systems based on DC or BLDC motors. The position of the mobile component must be controlled. In some cases open-loop control is a solution, but more often than not sensors are used as feedback device in closed-loop control. Sensors are expensive, large in size and add fragile hardware to the device that compromises its reliability. Thus, not only the superior performance is not fully exploited but also the economical feasibility of the PUM drive system is jeopardised. Replacing sensors by advanced control techniques is an approach to these problems that is well established in the field of BLDC motors. Those sensorless control strategies are not directly transferrable, because of the fundamentally different working principles of PUM. Hence, the research of sensorless closed-loop position control techniques applicable to PUM and their validation with digitally controlled functional models is the very topic of this thesis. We propose a dedicated design methodology to this statement of the problem. A core model of the mechatronic system is conceived as general and simple as possible. It then develops for the different interrelated views reflecting the mechanical, electromechanical, drive electronic, sensorial and digital control functions of the global system. Each one becoming more specific and detailed in this process, the different views still enable mutual constraint adjustments and the dynamic integration of results from the other views during the design process. Starting with the stator of the PUM, a view describes the mechanical displacement. An electric equivalent model is written such that power input from the drive electronics is related to the mechanical energy transmitted to the mechanics. The resulting differential equations are solved by the finite element method (FEM). Position feedback configurations in the mobile part of the PUM are modelled analytically in order to be implemented in digital control and their electrical implications are updated to the stator model. In this way, sensors do not necessarily materialise physically any more, but are distributed among the mechanical configuration, the drive electronics and the digital controller. With respect to the sensor data, the controller is not simply receiving finalised data on the measured system parameter, but rather implements the sensor itself in software. Finally, the position detection performance obtained with the aforementioned design methodology was evaluated with the example of mechatronic locking devices actuated by custom-made as well as OEM motors. Functional models of motors, electronics and digital controllers were used to identify the limits of the proposed methods, and suggestions for further research were deduced. These results contribute to the development of robust sensorless position controllers for PUM

Design, control and error analysis of a fast tool positioning system for ultra-precision machining of freeform surfaces

This thesis was previously held under moratorium from 03/12/19 to 03/12/21Freeform surfaces are widely found in advanced imaging and illumination systems, orthopaedic implants, high-power beam shaping applications, and other high-end scientific instruments. They give the designers greater ability to cope with the performance limitations commonly encountered in simple-shape designs. However, the stringent requirements for surface roughness and form accuracy of freeform components pose significant challenges for current machining techniques—especially in the optical and display market where large surfaces with tens of thousands of micro features are to be machined. Such highly wavy surfaces require the machine tool cutter to move rapidly while keeping following errors small. Manufacturing efficiency has been a bottleneck in these applications. The rapidly changing cutting forces and inertial forces also contribute a great deal to the machining errors. The difficulty in maintaining good surface quality under conditions of high operational frequency suggests the need for an error analysis approach that can predict the dynamic errors. The machining requirements also impose great challenges on machine tool design and the control process. There has been a knowledge gap on how the mechanical structural design affects the achievable positioning stability. The goal of this study was to develop a tool positioning system capable of delivering fast motion with the required positioning accuracy and stiffness for ultra-precision freeform manufacturing. This goal is achieved through deterministic structural design, detailed error analysis, and novel control algorithms. Firstly, a novel stiff-support design was proposed to eliminate the structural and bearing compliances in the structural loop. To implement the concept, a fast positioning device was developed based on a new-type flat voice coil motor. Flexure bearing, magnet track, and motor coil parameters were designed and calculated in detail. A high-performance digital controller and a power amplifier were also built to meet the servo rate requirement of the closed-loop system. A thorough understanding was established of how signals propagated within the control system, which is fundamentally important in determining the loop performance of high-speed control. A systematic error analysis approach based on a detailed model of the system was proposed and verified for the first time that could reveal how disturbances contribute to the tool positioning errors. Each source of disturbance was treated as a stochastic process, and these disturbances were synthesised in the frequency domain. The differences between following error and real positioning error were discussed and clarified. The predicted spectrum of following errors agreed with the measured spectrum across the frequency range. It is found that the following errors read from the control software underestimated the real positioning errors at low frequencies and overestimated them at high frequencies. The error analysis approach thus successfully revealed the real tool positioning errors that are mingled with sensor noise. Approaches to suppress disturbances were discussed from the perspectives of both system design and control. A deterministic controller design approach was developed to preclude the uncertainty associated with controller tuning, resulting in a control law that can minimize positioning errors. The influences of mechanical parameters such as mass, damping, and stiffness were investigated within the closed-loop framework. Under a given disturbance condition, the optimal bearing stiffness and optimal damping coefficients were found. Experimental positioning tests showed that a larger moving mass helped to combat all disturbances but sensor noise. Because of power limits, the inertia of the fast tool positioning system could not be high. A control algorithm with an additional acceleration-feedback loop was then studied to enhance the dynamic stiffness of the cutting system without any need for large inertia. An analytical model of the dynamic stiffness of the system with acceleration feedback was established. The dynamic stiffness was tested by frequency response tests as well as by intermittent diamond-turning experiments. The following errors and the form errors of the machined surfaces were compared with the estimates provided by the model. It is found that the dynamic stiffness within the acceleration sensor bandwidth was proportionally improved. The additional acceleration sensor brought a new error source into the loop, and its contribution of errors increased with a larger acceleration gain. At a certain point, the error caused by the increased acceleration gain surpassed other disturbances and started to dominate, representing the practical upper limit of the acceleration gain. Finally, the developed positioning system was used to cut some typical freeform surfaces. A surface roughness of 1.2 nm (Ra) was achieved on a NiP alloy substrate in flat cutting experiments. Freeform surfaces—including beam integrator surface, sinusoidal surface, and arbitrary freeform surface—were successfully machined with optical-grade quality. Ideas for future improvements were proposed in the end of this thesis.Freeform surfaces are widely found in advanced imaging and illumination systems, orthopaedic implants, high-power beam shaping applications, and other high-end scientific instruments. They give the designers greater ability to cope with the performance limitations commonly encountered in simple-shape designs. However, the stringent requirements for surface roughness and form accuracy of freeform components pose significant challenges for current machining techniques—especially in the optical and display market where large surfaces with tens of thousands of micro features are to be machined. Such highly wavy surfaces require the machine tool cutter to move rapidly while keeping following errors small. Manufacturing efficiency has been a bottleneck in these applications. The rapidly changing cutting forces and inertial forces also contribute a great deal to the machining errors. The difficulty in maintaining good surface quality under conditions of high operational frequency suggests the need for an error analysis approach that can predict the dynamic errors. The machining requirements also impose great challenges on machine tool design and the control process. There has been a knowledge gap on how the mechanical structural design affects the achievable positioning stability. The goal of this study was to develop a tool positioning system capable of delivering fast motion with the required positioning accuracy and stiffness for ultra-precision freeform manufacturing. This goal is achieved through deterministic structural design, detailed error analysis, and novel control algorithms. Firstly, a novel stiff-support design was proposed to eliminate the structural and bearing compliances in the structural loop. To implement the concept, a fast positioning device was developed based on a new-type flat voice coil motor. Flexure bearing, magnet track, and motor coil parameters were designed and calculated in detail. A high-performance digital controller and a power amplifier were also built to meet the servo rate requirement of the closed-loop system. A thorough understanding was established of how signals propagated within the control system, which is fundamentally important in determining the loop performance of high-speed control. A systematic error analysis approach based on a detailed model of the system was proposed and verified for the first time that could reveal how disturbances contribute to the tool positioning errors. Each source of disturbance was treated as a stochastic process, and these disturbances were synthesised in the frequency domain. The differences between following error and real positioning error were discussed and clarified. The predicted spectrum of following errors agreed with the measured spectrum across the frequency range. It is found that the following errors read from the control software underestimated the real positioning errors at low frequencies and overestimated them at high frequencies. The error analysis approach thus successfully revealed the real tool positioning errors that are mingled with sensor noise. Approaches to suppress disturbances were discussed from the perspectives of both system design and control. A deterministic controller design approach was developed to preclude the uncertainty associated with controller tuning, resulting in a control law that can minimize positioning errors. The influences of mechanical parameters such as mass, damping, and stiffness were investigated within the closed-loop framework. Under a given disturbance condition, the optimal bearing stiffness and optimal damping coefficients were found. Experimental positioning tests showed that a larger moving mass helped to combat all disturbances but sensor noise. Because of power limits, the inertia of the fast tool positioning system could not be high. A control algorithm with an additional acceleration-feedback loop was then studied to enhance the dynamic stiffness of the cutting system without any need for large inertia. An analytical model of the dynamic stiffness of the system with acceleration feedback was established. The dynamic stiffness was tested by frequency response tests as well as by intermittent diamond-turning experiments. The following errors and the form errors of the machined surfaces were compared with the estimates provided by the model. It is found that the dynamic stiffness within the acceleration sensor bandwidth was proportionally improved. The additional acceleration sensor brought a new error source into the loop, and its contribution of errors increased with a larger acceleration gain. At a certain point, the error caused by the increased acceleration gain surpassed other disturbances and started to dominate, representing the practical upper limit of the acceleration gain. Finally, the developed positioning system was used to cut some typical freeform surfaces. A surface roughness of 1.2 nm (Ra) was achieved on a NiP alloy substrate in flat cutting experiments. Freeform surfaces—including beam integrator surface, sinusoidal surface, and arbitrary freeform surface—were successfully machined with optical-grade quality. Ideas for future improvements were proposed in the end of this thesis

Full-field vibrometry by high-speed digital holography for middle-ear mechanics

Hearing loss affects approximately 1 in 10 people in the world and this percentage is increasing every year. Some of the most common causes of hearing loss are disorders of the middle-ear. Early detection and diagnosis of hearing loss as well as research to understand the hearing processes depend on medical and research tools for quantification of hearing capabilities and the function of the middle-ear in the complex acousto-mechanical transformation of environmental sounds into vibrations of the middle-ear, particular of the human tympanic membrane (TM or eardrum). Current ear exams assess the state of a patient’s hearing capabilities mainly based on qualitative evaluation of the healthiness of the TM. Existing quantitative clinical methods for description of the motion of the TM are limited to either average acoustic estimates (admittance or reflectance) or single-point displacement measurements. Such methods could leave examiners and researchers blind to the complex spatio-temporal response of the nanometer scale displacements of the entire TM. Current state-of-the-art medical research tools provide full-field nanometer displacement measurements of the surface of the human TM excited by steady state (tonal) stimuli. However, to fully understand the mechanics of hearing, and the complex acousto-mechanical characteristics of TM in particular, new tools are needed for full-field high-speed characterization of the nanometer scale displacements of the human TM subjected to impulse (wideband) acoustic excitation. This Dissertation reports the development of a new high-speed holographic system (HHS) for full-field nanometer transient (i.e., \u3e 10 kHz) displacement measurement of the human middle-ear and the tympanic membrane, in particular. The HHS allows spatial (i.e., \u3e500k data points) and temporal (i.e., \u3e 40 kHz) resolutions that enable the study of the acoustical and mechanical characteristics of the middle-ear at a level of detail that have never been reached before. The realization of the HHS includes the development and implementation of novel phase sampling and acquisition approaches that allow the use of state-of-the-art high-resolution (i.e., \u3e5 MP) and high-speed (\u3e 80,000 fps) cameras through modular and expandable control architectures. The development of novel acquisition approaches allows the use of conventional speed (i.e., \u3c20 fps) cameras to realize high-temporal resolutions (i.e., \u3c15 us) at equivalent sampling rates of \u3e 50,000 fps with minimum hardware cost and modifications. The design and implementation of novel spatio-temporal phase sampling methods utilize the high temporal resolution (i.e., \u3c 5 us exposure) and frame rate (i.e., \u3e80,000 fps) of high-speed cameras without imposing constraints on their spatial resolution (i.e., \u3e20 um pixel size). Additionally, the research and in-vivo applications capabilities of the HHS are extended through the development and implementation of a holographic otoscope head (OH) and a mechatronic otoscope positioner (MOP). The large (i.e., \u3e 1 GB with \u3e 8x10^9 parameters) spatio-temporal data sets of the HHS measurements are automatically processed by custom parallel data mining and interpretation (PDMI) methods, which allow automatic quantification of medically relevant motion parameters (MRMPs), such as modal frequencies, time constants, and acoustic delays. Such capabilities could allow inferring local material properties across the surface of the TM. The HHS is a new medical tool that enables otologists to improve the quality of diagnosis and treatments as well as provides researchers with spatio-temporal information of the hearing process at a level of detail never reached before

Mechatronic Design, Dynamics, Controls, and Metrology of a Long-Stroke Linear Nano-Positioner

Precision motion systems find a broad range of application in various fields such as micro/nano machining tools, lithography scanners, testing and metrology machines, micro-assembly, biotechnology, optics manufacturing, magnetic data-storage, and optical disk drives. In this thesis, an ultraprecision motion stage (nano-positioner) is designed and built based on the concept of a low-cost desktop precision micro machine tool. Linear positioning performance requirements of such a machine tool are used as design objectives. The nano-positioner’s mechatronic design is carried out in such a way to integrate different components towards high performance in terms of high dynamic range, high feedrate, servo accuracy, and geometric accuracy. A self-aligning air-bearing/bushing arrangement is employed for frictionless motion with infinite theoretical resolution, as well as reduced assembly costs and footprint. The air discharge from the air bearings/bushings are also utilized for assistance in the removal of heat dissipated from actuator coils. A voice coil actuator (VCA) is chosen for continuous, non-contact operation, and designed from scratch. A number of dimensional variables of the cylindrical VCA are set according to required forces, motion range, production/assembly tolerances, magnet availability, leakage flux, etc. The remainder of variables is determined according to two novel optimization objectives defined independent of the coil wire gauge, which separately aim for maximum stage acceleration capacity and minimum heat generation per generated force. The actuators are operated in a complementary double configuration for control simplicity which allows for a straightforward and robust design for controller stability. Controller design is carried out at current control and position control levels. Current frequency response of the voice coil actuators is obtained, and they are observed to possess additional high frequency dynamics on top of the expected first order lumped resistance and inductance model. These are attributed to the eddy currents in the stator structure. A closed loop bandwidth of better than 907 [Hz] is achieved using the integrator plus lead current controller. The position controller is designed using the identified overall plant which includes the moving body, current dynamics and the force response. The lead-lag position controller is tuned at 450 [Hz] cross-over frequency and 40 [deg] phase margin. The control error during the tracking of a step trajectory filtered at 40 [Hz] is found to vary between ±5 [nm], indicating a 4 million dynamic range over the 20 [mm] stroke length. Dynamic Error Budgeting (DEB) method has been used to resolve the components of the error, and the largest contributor is found to be the sensor noise. The actual positioning error, which is an ideal signal excluding sensor noise is estimated using the same methodology and disturbance models, and it is found to be 0.680 [nm] root-mean-square (RMS). For the trajectory following case, experiments are carried out with and without a compensation scheme for encoder quadrature detection errors. The compensation is observed to reduce the ±45 [nm] control error to ±15 [nm]. For the assessment of stage performance and the verification of design choices, modal testing and laser interferometric metrology have been applied to the linear nano-positioner. For modal testing, two independent methods are used and their predictions are compared. In the first method, a graphical approach, namely the peak-picking method, is employed to identify modal parameters (natural frequency and damping ratio) and mode shapes. In the second method, a modal testing software package is used to identify the same using automated algorithms. The first mode, which is the most critical one for controller design, is identified at 65 [Hz] as a roll mode, followed by horizontal, vertical, and pitch modes at 450, 484, and 960 [Hz], respectively. The geometric errors of the system are identified using laser interferometric measurements, using various optical setups for linear and angular components. An error budget is formed using these results, together with the estimated thermal errors and servo errors. The accuracy of the stage is determined to be ±5.0 [μm], which had a ±1.1 [μm] non-repeatable component. In the future, the controller structure can be enhanced with an additional pole beyond the crossover frequency, in order to suppress unnecessary oscillations of the control effort signal around the set point due to the encoder noise transmitted to the controller input. Using an estimation of air bearing pitch stiffness from the catalogue values for normal stiffness, the roll mode was predicted at 672 [Hz]. The much lower natural frequency for that mode identified in modal testing (65 [Hz]) can be attributed to the shortcomings of the estimation method, primarily the neglect of the distortion of the supporting air cushion at the bearing interface due to out of plane rotations. In the future, experimental data can be obtained to characterize the air bearing pitch stiffness more accurately. It was observed that the preferred compensation scheme for the encoder quadrature detection errors is unable to match third and fourth harmonics of the encoder measurement error sufficiently. In the future, better compensation methods can be investigated for an improved match. During laser interferometric measurements, measurement uncertainty due to laser beam misalignment and air turbulence were inferred to be high. In the future, better ways to align the laser with the optics, as well as methods for improved assessment and compensation of environmental effects can be investigated

Pjezorobotų trajektorijų valdymas nanopalydovų stabilizavimui

Rapid industrial advancement requires novel ideas, new scientific approaches and effective technologies that would ensure quality and precision. Application of piezoelectric actuators in robotics opens many possibilities to create systems with extreme precision and control. A very important step in the development of autonomous robots is the formation of motion trajectories. Classical interpolation methods used for formation of the trajectories are suitable only when robots have wheels, legs or other parts for motion transmission. Piezorobots that are analyzed in this dissertation have no additional components that create motion, only contact points with the static plane. Therefore, traditional motion formation methods are not suitable and a problem arises how to define motion trajectory of such device. The aim of this work is to create a trajectory control algorithm of multi-degrees-of-freedom piezorobot used for nanosatellite stabilization. In order to achieve the objective, the following tasks had to be solved: to analyze constructions of precise piezorobots, their operating principles and motion formation methods; to analyze stabilization problems of satellites and application of multi-degrees-of-freedom piezorobots for nanosatellite stabilization; to create piezorobots’ motion formation algorithms according to electrode excitation schemes, to perform an experimental research; to determine quantitative characteristics of the constructed piezorobots and their motion trajectories. The introduction describes the importance and novelty of this thesis, goals of this work, its practical value and defended statements. The first chapter analyses the principals of ultrasonic devices, gives a thorough review of constructions of ultrasonic devices with multi-degrees-of-freedom. The second chapter provides a review of satellite stabilization principles and how multi-degrees-of-freedom piezorobots can be applied for nanosatellite stabilization. Motion formation methods for ultrasonic devices with multi-degrees-of-freedom are presented. The third chapter presents the detailed analysis of different piezorobots. In the fourth chapter experimental results are provided. Trajectory planning of piezorobot is shown, results are compared to numerical calculations performed in the third chapter. The conclusions about applicability of piezorobots’ motion formation algorithms according to electrode excitation schemes are given. Seven articles focusing on the subject of the dissertation have been published, two presentations on the subject have been presented in conferences at international level. The research for the dissertation has been funded by the Lithuanian State Science and Studies Foundation: European Regional Development Fund, Project No. DOTSUT-234 and Research Council of Lithuania, Project No. MIP-084/2015.Dissertatio

Control and Automation

Control and automation systems are at the heart of our every day lives. This book is a collection of novel ideas and findings in these fields, published as part of the Special Issue on Control and Automation. The core focus of this issue was original ideas and potential contributions for both theory and practice. It received a total number of 21 submissions, out of which 7 were accepted. These published manuscripts tackle some novel approaches in control, including fractional order control systems, with applications in robotics, biomedical engineering, electrical engineering, vibratory systems, and wastewater treatment plants. This Special Issue has gathered a selection of novel research results regarding control systems in several distinct research areas. We hope that these papers will evoke new ideas, concepts, and further developments in the field