A Review of Modeling and Control of Piezoelectric Stick-Slip Actuators

Piezoelectric stick-slip actuators with high precision, large actuating force, and high displacement resolution are currently widely used in the field of high-precision micro-nano processing and manufacturing. However, the non-negligible, non-linear factors and complexity of their characteristics make its modeling and control quite difficult and affect the positioning accuracy and stability of the system. To obtain higher positioning accuracy and efficiency, modeling and control of piezoelectric stick-slip actuators are meaningful and necessary. Firstly, according to the working principle of stick-slip drive, this paper introduces the sub-models with different characteristics, such as hysteresis, dynamics, and friction, and presents the comprehensive modeling representative piezoelectric stick-slip actuators. Next, the control approaches suggested by different scholars are also summarized. Appropriate control strategies are adopted to reduce its tracking error and position error in response to the influence of various factors. Lastly, future research and application prospects in modeling and control are pointed out

Modeling and Control of Piezoelectric Actuators

Piezoelectric actuators (PEAs) utilize the inverse piezoelectric effect to generate fine displacement with a resolution down to sub-nanometers and as such, they have been widely used in various micro- and nanopositioning applications. However, the modeling and control of PEAs have proven to be challenging tasks. The main difficulties lie in the existence of various nonlinear or difficult-to-model effects in PEAs, such as hysteresis, creep, and distributive vibration dynamics. Such effects can seriously degrade the PEA tracking control performances or even lead to instability. This raises a great need to model and control PEAs for improved performance. This research is aimed at developing novel models for PEAs and on this basis, developing model-based control schemes for the PEA tracking control taking into account the aforementioned nonlinear effects. In the first part of this research, a model of a PEA for the effects of hysteresis, creep, and vibration dynamics was developed. Notably, the widely-used Preisach hysteresis model cannot represent the one-sided hysteresis of PEAs. To overcome this shortcoming, a rate-independent hysteresis model based on a novel hysteresis operator modified from the Preisach hysteresis operator was developed, which was then integrated with the models of creep and vibration dynamics to form a comprehensive model for PEAs. For its validation, experiments were carried out on a commercially-available PEA and the results obtained agreed with those from model simulations. By taking into account the linear dynamics and hysteretic behavior of the PEA as well as the presliding friction between the moveable platform and the end-effector, a model of the piezoelectric-driven stick-slip (PDSS) actuator was also developed in the first part of the research. The effectiveness of the developed model was illustrated by the experiments on the PDSS actuator prototyped in the author's lab. In the second part of the research, control schemes were developed based on the aforementioned PEA models for tracking control of PEAs. Firstly, a novel PID-based sliding mode (PIDSM) controller was developed. The rational behind the use of a sliding mode (SM) control is that the SM control can effectively suppress the effects of matched uncertainties, while the PEA hysteresis, creep, and external load can be represented by a lumped matched uncertainty based on the developed model. To solve the chattering and steady-state problems, associated with the ideal SM control and the SM control with boundary layer (SMCBL), the novel PIDSM control developed in the present study replaces the switching control term in the ideal SM control schemes with a PID regulator. Experiments were carried out on a commercially-available PEA and the results obtained illustrate the effectiveness of the PIDSM controller, and its superiorities over other schemes of PID control, ideal SM control, and the SMCBL in terms of steady state error elimination, chattering suppression, and tracking error suppression. Secondly, a PIDSM observer was also developed based on the model of PEAs to provide the PIDSM controller with state estimates of the PEA. And the PIDSM controller and the PIDSM observer were combined to form an integrated control scheme (PIDSM observer-controller or PIDSMOC) for PEAs. The effectiveness of the PIDSM observer and the PIDSMOC were also validated experimentally. The superiority of the PIDSMOC over the PIDSM controller with σ-β filter control scheme was also analyzed and demonstrated experimentally. The significance of this research lies in the development of novel models for PEAs and PDSS actuators, which can be of great help in the design and control of such actuators. Also, the development of the PIDSM controller, the PIDSM observer, and their integrated form, i.e., PIDSMOC, enables the improved performance of tracking control of PEAs with the presence of various nonlinear or difficult-to-model effects

Modeling and Control of Piezoactive Micro and Nano Systems

Piezoelectrically-driven (piezoactive) systems such as nanopositioning platforms, scanning probe microscopes, and nanomechanical cantilever probes are advantageous devices enabling molecular-level imaging, manipulation, and characterization in disciplines ranging from materials science to physics and biology. Such emerging applications require precise modeling, control and manipulation of objects, components and subsystems ranging in sizes from few nanometers to micrometers. This dissertation presents a comprehensive modeling and control framework for piezoactive micro and nano systems utilized in various applications. The development of a precise memory-based hysteresis model for feedforward tracking as well as a Lyapunov-based robust-adaptive controller for feedback tracking control of nanopositioning stages are presented first. Although hysteresis is the most degrading factor in feedforward control, it can be effectively compensated through a robust feedback control design. Moreover, an adaptive controller can enhance the performance of closed-loop system that suffers from parametric uncertainties at high-frequency operations. Comparisons with the widely-used PID controller demonstrate the effectiveness of the proposed controller in tracking of high-frequency trajectories. The proposed controller is then implemented in a laser-free Atomic Force Microscopy (AFM) setup for high-speed and low-cost imaging of surfaces with micrometer and nanometer scale variations. It is demonstrated that the developed AFM is able to produce high-quality images at scanning frequencies up to 30 Hz, where a PID controller is unable to present acceptable results. To improve the control performance of piezoactive nanopositioning stages in tracking of time-varying trajectories with frequent stepped discontinuities, which is a common problem in SPM systems, a supervisory switching controller is designed and integrated with the proposed robust adaptive controller. The controller switches between two control modes, one mode tuned for stepped trajectory tracking and the other one tuned for continuous trajectory tracking. Switching conditions and compatibility conditions of the control inputs in switching instances are derived and analyzed. Experimental implementation of the proposed switching controller indicates significant improvements of control performance in tracking of time-varying discontinuous trajectories for which single-mode controllers yield undesirable results. Distributed-parameters modeling and control of rod-type solid-state actuators are then studied to enable accurate tracking control of piezoactive positioning systems in a wide frequency range including several resonant frequencies of system. Using the extended Hamilton\u27s principle, system partial differential equation of motion and its boundary conditions are derived. Standard vibration analysis techniques are utilized to formulate the truncated finite-mode state-space representation of the system. A new state-space controller is then proposed for asymptotic output tracking control of system. Integration of an optimal state-observer and a Lyapunov-based robust controller are presented and discussed to improve the practicability of the proposed framework. Simulation results demonstrate that distributed-parameters modeling and control is inevitable if ultra-high bandwidth tracking is desired. The last part of the dissertation, discusses new developments in modeling and system identification of piezoelectrically-driven Active Probes as advantageous nanomechanical cantilevers in various applications including tapping mode AFM and biomass sensors. Due to the discontinuous cross-section of Active Probes, a general framework is developed and presented for multiple-mode vibration analysis of system. Application in the precise pico-gram scale mass detection is then presented using frequency-shift method. This approach can benefit the characterization of DNA solutions or other biological species for medical applications

MICROCANTILEVER-BASED FORCE SENSING, CONTROL AND IMAGING

This dissertation presents a distributed-parameters base modeling framework for microcantilever (MC)-based force sensing and control with applications to nanomanipulation and imaging. Due to the widespread applications of MCs in nanoscale force sensing or atomic force microscopy with nano-Newton to pico-Newton force measurement requirements, precise modeling of the involved MCs is essential. Along this line, a distributed-parameters modeling framework is proposed which is followed by a modified robust controller with perturbation estimation to target the problem of delay in nanoscale imaging and manipulation. It is shown that the proposed nonlinear model-based controller can stabilize such nanomanipulation process in a very short time compared to available conventional methods. Such modeling and control development could pave the pathway towards MC-based manipulation and positioning. The first application of the MC-based (a piezoresistive MC) force sensors in this dissertation includes MC-based mass sensing with applications to biological species detection. MC-based sensing has recently attracted extensive interest in many chemical and biological applications due to its sensitivity, extreme applicability and low cost. By measuring the stiffness of MCs experimentally, the effect of adsorption of target molecules can be quantified. To measure MC\u27s stiffness, an in-house nanoscale force sensing setup is designed and fabricated which utilizes a piezoresistive MC to measure the force acting on the MC\u27s tip with nano-Newton resolution. In the second application, the proposed MC-based force sensor is utilized to achieve a fast-scan laser-free Atomic Force Microscopy (AFM). Tracking control of piezoelectric actuators in various applications including scanning probe microscopes is limited by sudden step discontinuities within time-varying continuous trajectories. For this, a switching control strategy is proposed for effective tracking of such discontinuous trajectories. A new spiral path planning is also proposed here which improves scanning rate of the AFM. Implementation of the proposed modeling and controller in a laser-free AFM setup yields high quality image of surfaces with stepped topographies at frequencies up to 30 Hz. As the last application of the MC-based force sensors, a nanomanipulator named here MM3A® is utilized for nanomanipulation purposes. The area of control and manipulation at the nanoscale has recently received widespread attention in different technologies such as fabricating electronic chipsets, testing and assembly of MEMS and NEMS, micro-injection and manipulation of chromosomes and genes. To overcome the lack of position sensor on this particular manipulator, a fused vision force feedback robust controller is proposed. The effects of utilization of the image and force feedbacks are individually discussed and analyzed for use in the developed fused vision force feedback control framework in order to achieve ultra precise positioning and optimal performance

Modeling and experimental validation of a parallel microrobot for biomanipulation

The main purpose of this project is the development of a commercial micropositioner's (SmarPod 115.25, SmarAct GmbH) geometrical model. SmarPod is characterized by parallel kinematics and is employed for precise and accurate sample's positioning under SEM microscope, being vacuum-compatible, for various applications. Geometrical modeling represents the preliminar step to fully understand, and possibly improve, robot's closed loop behaviour in terms of task's quality precision, when enterprises does not provide sufficient documentation. The robotic system, in fact, represents in this case a "black box" from which it's possible to extract information. This step is essential in order to improve, consequently, the reliability of bio-microsystem manipulation and characterization. Disposing of a detailed microrobot's model becomes essential to deal with the typical lack of sensing at microscale, as it allows a 3D precise and adequate reconstruction, realized through proper softwares, of the manipulation set-up. The roles of Virtual Reality (VR) and of simulations, carried out, in this case, in Blender environment, are asserted as well as an essential helping tool in mycrosystem's task planning. Blender is a professional free and open-source 3D computer graphics software and it is proven to be a basic instrument to validate microrobot's model, even to simplify it in case of complex system's geometries

AFM-Based Mechanical Nanomanipulation

Advances in several research areas increase the need for more sophisticated fabrication techniques and better performing materials. Tackling this problem from a bottom-up perspective is currently an active field of research. The bottom-up fabrication procedure offers sub-nanometer accurate manipulation. At this time, candidates to achieve nanomanipulation include chemical (self-assembly), biotechnology methods (DNA-based), or using controllable physical forces (e.g. electrokinetic forces, mechanical forces). In this thesis, new methods and techniques for mechanical nanomanipulation using probe force interaction are developed. The considered probes are commonly used in Atomic Force Microscopes (AFMs) for high resolution imaging. AFM-based mechanical nanomanipulation will enable arranging nanoscale entities such as nanotubes and molecules in a precise and controlled manner to assemble and produce novel devices and systems at the nanoscale. The novelty of this research stems from the development of new modeling of the physics and mechanics of the tip interaction with nanoscale entities, coupled with the development of new smart cantilevers with multiple degrees of freedom. The gained knowledge from the conducted simulations and analysis is expected to enable true precision and repeatability of nanomanipulation tasks which is not feasible with existing methods and technologies

Optical scanning sensor system with submicron resolution

In this work, autofocus and optical scanning technologies are brought together in the design of a simplified scanning microscope. The developed system uses an autofocus sensor based on the Foucault knife-edge principle and piezo-based stages for scanning the samples in axial and lateral directions. It is built with a reduced number of components and designed to offer a simple set-up for the analysis of optical aberrations. The traditional way of addressing optical aberrations in scanning system is to improve the optical system such that it works as a paraxial lens. Breaking this paradigm and observing the optics as part of a complex system, it is possible to use simpler optics and correct the resultant errors computationally. These errors are systematic and, as long as they can be measured and modelled, they can be predicted and corrected. This way, the design of the system becomes more flexible and the task of error handling can be divided between optics optimization and computational correction, reducing overall size and weight, raising system dynamics and reducing costs.Laser-Scanning Mikroskopie ist eine im Bereich der Oberflächenmessung wichtige und vielversprechende Technologie für schnelle, genaue und wiederholbare Messungen. Es ist im Grunde eine Technik zur Erhöhung von Kontrast und Auflösung in optischen Abbildungssystemen. Ein Prüfling wird punktweise abgetastet und ein dreidimensionales Bild seiner Oberfläche mit Hilfe eines Rechners erfasst und rekonstruiert. In dieser Arbeit werden Autofokus- und optische Abtastverfahren in der Entwicklung und Konstruktion eines alternativen, vereinfachten Scanning Mikroskops für Oberflächenmessungen im Millimeterbereich mit Sub-Mikrometer Auflösung zusammengebracht. Das entwickelte System verwendet einen auf dem Foucault‘sches Schneidenverfahren basierenden Autofokussensor um die Fokuslage zu bestimmen und einen Piezo-Linearantrieb für die Verschiebung des Objektivs entlang der optischen Achse und das Abtasten des Prüflings in der axialen Richtung. Die laterale Abtastung des Prüflings wird durch den Einsatz eines Piezo-Spiegels realisiert, der um zwei Achsen schwenkbar ist. Das entwickelte Mikroskop hat eine reduzierte Anzahl von optischen Komponenten und bietet einen einfachen und vielseitigen Versuchsaufbau zur Messung und Analyse von Fehlern, die durch die bewusste Verwendung von unkompensierten Optiken auftreten. Die damit verbundenen Abbildungsfehler erzeugen Asymmetrien in den Autofokussensoren und beeinträchtigen die Gesamtleistung. Die herkömmliche Lösung dieser Problematik ist das System durch Addition zusätzlicher Komponenten zu verbessern, sodass es wie ein paraxiales System wirkt. Diese Verbesserung bringt aber die Nachteile von Baugröße, Gewicht und Kosten mit sich. Durch das Brechen des Paradigmas der Verbesserung der Optik bis zu einem paraxialen System und die Betrachtung der Optik als Teil eines komplexen Systems ist es möglich, simplere Optik zu verwenden, und die resultierenden Fehler rechnerisch zu korrigieren. Diese Fehler sind systematisch und können – solange sie modelliert und gemessen werden können – vorhergesagt und korrigiert werden. Damit wird das Design des optischen Systems flexibler und die Aufgabe der Fehlerbehandlung zwischen Optimierung der Optik und rechnerischer Korrektur aufgeteilt. Baugröße, Gewicht und Kosten können dann reduziert werden und die Systemdynamik erhöht sich, ohne Einschränkung der Präzision. Das Ziel ist nicht jeden Abbildungsfehler individuell zu untersuchen, sondern deren Zusammenwirken auf die Messungen zu beobachten und zu modellieren. Verschiedene Strategien für die Behandlung dieser Messfehler werden in dieser Arbeit vorgeschlagen, diskutiert und experimentell validiert.Laser Scanning Microscopy has been used for a long time in the field of surface measurement and is today one of the most promising technologies for fast, accurate and repeatable measurements. It is technique for increasing contrast and resolution in optical imaging systems through the rejection of out-of-focus light. Images are acquired point-by-point and reconstructed with a computer, allowing three-dimensional reconstructions of objects. In this work, autofocus and optical scanning technologies are brought together in the design of an alternative simplified scanning microscope for surface measuring in millimetre range with sub-micrometer resolution. The developed system uses an autofocus sensor based on the Foucault knife-edge principle to generate a defocus signal and a piezo positioning stage for translating the objective and scanning the samples in the axial direction. For the lateral scanning, a piezo driven tip-tilt mirror is used. The developed scanning microscope is built with a reduced number of optical components and designed to offer a simple and versatile set-up for the measurement and analysis of errors induced by optical aberrations due to the use of suboptimal optics. The use of uncompensated lenses has always been avoided in scanning microscopy as it generates asymmetries in the defocus signal and deteriorates its overall performance. The traditional way of solving this problem is to improve the optical system such that it works as a paraxial lens, but that comes with the price of heavy and costly optics. By breaking the paradigm of improving the optics to a paraxial lens and observing the optics as part of a complex system, it is possible to use simpler optics and correct the resultant errors computationally. These errors are systematic and, as long as they can be measured and modelled, they can be predicted and corrected. This way, the design of the optical system becomes much more flexible and the task of error handling can be divided between optics optimization and computational correction, reducing overall size and weight, raising system dynamics and reducing costs, without losing accuracy. The goal is not to study each optical aberration individually, but to measure and model their combined influence in the measurements. Different strategies for addressing these measurement errors caused by the use of uncompensated optics are proposed, discussed and experimentally validate

Affordable flexible hybrid manipulator for miniaturised product assembly

Miniaturised assembly systems are capable of assembling parts of a few millimetres in size with an accuracy of a few micrometres. Reducing the size and the cost of such a system while increasing its flexibility and accuracy is a challenging issue. The introduction of hybrid manipulation, also called coarse/fine manipulation, within an assembly system is the solution investigated in this thesis. A micro-motion stage (MMS) is designed to be used as the fine positioning mechanism of the hybrid assembly system. MMSs often integrate compliant micro-motion stages (CMMSs) to achieve higher performances than the conventional MMSs. CMMSs are mechanisms that transmit an output force and displacement through the deformation of their structure. Although widely studied, the design and modelling techniques of these mechanisms still need to be improved and simplified. Firstly, the linear modelling of CMMSs is evaluated and two polymer prototypes are fabricated and characterised. It is found that polymer based designs have a low fabrication cost but not suitable for construction of a micro-assembly system. A simplified nonlinear model is then derived and integrated within an analytical model, allowing for the full characterisation of the CMMS in terms of stiffness and range of motion. An aluminium CMMS is fabricated based on the optimisation results from the analytical model and is integrated within an MMS. The MMS is controlled using dual-range positioning to achieve a low-cost positioning accuracy better than 2µm within a workspace of 4.4×4.4mm2. Finally, a hybrid manipulator is designed to assemble mobile-phone cameras and sensors automatically. A conventional robot manipulator is used to pick and place the parts in coarse mode while the aluminium CMMS based MMS is used for fine alignment of the parts. A high-resolution vision system is used to locate the parts on the substrate and to measure the relative position of the manipulator above MMS using a calibration grid with square patterns. The overall placement accuracy of the assembly system is ±24µm at 3σ and can reach 2µm, for a total cost of less than £50k, thus demonstrating the suitability of hybrid manipulation for desktop-size miniaturised assembly systems. The precision of the existing system could be significantly improved by making the manipulator stiffer (i.e. preloaded bearings…) and adjustable to compensate for misalignment. Further improvement could also be made on the calibration of the vision system. The system could be either scaled up or down using the same architecture while adapting the controllers to the scale.Engineering and Physical Sciences Research Council (EPSRC

International Workshop on MicroFactories (IWMF 2012): 17th-20th June 2012 Tampere Hall Tampere, Finland

This Workshop provides a forum for researchers and practitioners in industry working on the diverse issues of micro and desktop factories, as well as technologies and processes applicable for micro and desktop factories. Micro and desktop factories decrease the need of factory floor space, and reduce energy consumption and improve material and resource utilization thus strongly supporting the new sustainable manufacturing paradigm. They can be seen also as a proper solution to point-of-need manufacturing of customized and personalized products near the point of need