Improved performance of hard disk drive servomechanism using digital multirate control

Ph.DDOCTOR OF PHILOSOPH

Mechatronics of systems with undetermined configurations

This work is submitted for the award of a PhD by published works. It deals with some of the efforts of the author over the last ten years in the field of Mechatronics. Mechatronics is a new area invented by the Japanese in the late 1970's, it consists of a synthesis of computers and electronics to improve mechanical systems. To control any mechanical event three fundamental features must be brought together: the sensors used to observe the process, the control software, including the control algorithm used and thirdly the actuator that provides the stimulus to achieve the end result. Simulation, which plays such an important part in the Mechatronics process, is used in both in continuous and discrete forms. The author has spent some considerable time developing skills in all these areas. The author was certainly the first at Middlesex to appreciate the new developments in Mechatronics and their significance for manufacturing. The author was one of the first mechanical engineers to recognise the significance of the new transputer chip. This was applied to the LQG optimal control of a cinefilm copying process. A 300% improvement in operating speed was achieved, together with tension control. To make more efficient use of robots they have to be made both faster and cheaper. The author found extremely low natural frequencies of vibration, ranging from 3 to 25 Hz. This limits the speed of response of existing robots. The vibration data was some of the earliest available in this field, certainly in the UK. Several schemes have been devised to control the flexible robot and maintain the required precision. Actuator technology is one area where mechatronic systems have been the subject of intense development. At Middlesex we have improved on the Aexator pneumatic muscle actuator, enabling it to be used with a precision of about 2 mm. New control challenges have been undertaken now in the field of machine tool chatter and the prevention of slip. A variety of novel and traditional control algorithms have been investigated in order to find out the best approach to solve this problem

Energy efficient control of electrostatically actuated MEMS

Plenty of Micro-electro-mechanical Systems (MEMS) devices are actuated using electrostatic forces, and specially, parallel-plate actuators are extensively used, due to the simplicity of their design. Nevertheless, parallel-plate actuators have some limitations due to the nonlinearity of the generated force. The dissertation analyzes the dynamics of the lumped electrostatically actuated nonlinear system, in order to obtain insight on its characteristics, define desired performance goals and implement a controller for energy efficient robustly stable actuation of MEMS resonators. In the first part of the dissertation, the modeling of the electromechanical lumped system is developed. From a complete distributed parameters model for MEMS devices which rely on electrostatic actuation, a concentrated parameters simplification is derived to be used for analysis and control design. Based on the model, energy analysis of the pull-in instability is performed. The classic approach is revisited to extend the results to models with a nonlinear springs. Analysis of the effect of dynamics is studied as an important factor for the stability of the system. From this study, the Resonant Pull-in Condition for parallel-plate electrostatically actuated MEMS resonators is defined and experimentally validated. Given the importance of the nonlinear dynamics and its richness in behaviors, Harmonic Balance is chosen as a tool to characterize the steady-state oscillation of the resonators. This characterization leads to the understanding of the key factors for large and stable oscillation of resonators. An important conclusion is reached, Harmonic Balance predicts that any oscillation amplitude is possible for any desired frequency if the appropriate voltage is applied to the resonator. And the energy consumption is dependent on this chosen oscillation frequency. Based on Harmonic Balance results, four main goals are defined for the control strategy: Stable oscillation with large amplitudes of motion; Robust oscillation independently of MEMS imperfections; Pure sinus-like oscillation for high-grade sensing; and Low energy consumption. The second part of the dissertation deals with the controller selection, design and verification. A survey of prior work on MEMS control confirms that existing control approaches cannot provide the desired performance. Consequently, a new three-stage controller is proposed to obtain the desired oscillation with the expected stability and energy efficiency. The controller has three different control loops. The first control loop includes a Robust controller designed using on µ-synthesis, to deal with MEMS resonators uncertainties. The second control loop includes an Internal-Model-Principle Resonant controller, to generate the desired control action to obtain the desired oscillation. And the third control loop handles the energy consumption minimization through an Extremum Seeking Controller, which selects the most efficient working frequency for the desired oscillation. The proposed controller is able to automatically generate the needed control voltage, as predicted by the Harmonic Balance analysis, to operate the parallel-plate electrostatically actuated MEMS resonator at the desired oscillation. Performance verification of stability, robustness, sinus-like oscillation and energy efficiency is carried out through simulation. Finally, the needed steps for a real implementation are analyzed. Independent two-sided actuation for full-range amplitude oscillation is introduced to overcome the limitations of one-sided actuation. And a modification of standard Electromechanical Amplitude Modulation is analyzed and validated for position feedback implementation. With these improvements, a MEMS resonator with the desired specifications for testing the proposed control is designed for fabrication. Based on this design, testing procedure is discussed as future work.Molts microsistemes (MEMS) són actuats amb forces electrostàtiques, i especialment, els actuadors electrostàtics de plaques paral.leles són molt usats, degut a la simplicitat del seu disseny. Tot i això, aquests actuadors tenen limitacions degut a la no-linealitat de les forces generades. La tesi analitza el sistema mecànic no-lineal actuat electrostàticament que forma el MEMS, per tal d'entendre'n les característiques, definir objectius de control de l'oscil.lació, i implementar un controlador robust, estable i eficient energèticament. A la primera part de la tesi es desenvolupa el modelat del sistema electromecànic complert. A partir de la formulació de paràmetres distribuïts aplicada a dispositius MEMS amb actuació electrostàtica, es deriva una formulació de paràmetres concentrats per a l'anàlisi i el disseny del control. Basat en aquest model, s'analitza energèticament la inestabilitat anomenada Pull-in, ampliant els resultats de l'enfocament clàssic al model amb motlles no-lineals. Dins de l'anàlisi, l'evolució dinàmica s'estudia per ser un factor important per a l'estabilitat. D'aquest estudi, la Resonant Pull-in Condition per a actuadors electrostàtics de plaques paral.leles es defineix i es valida experimentalment. Donada la importància de la dinàmica no-lineal del sistema i la seva riquesa de comportaments, s'utilitza Balanç d'Harmònics per tal de caracteritzar les oscil.lacions en estacionari. Aquesta caracterització permet entendre els factors claus per a obtenir oscil.lacions estables i d'amplitud elevada. El Balanç d'Harmònics dóna una conclusió important: qualsevol amplitud d'oscil.lació és possible per a qualsevol freqüència desitjada si s'aplica el voltatge adequat al ressonador. I el consum energètic associat a aquesta oscil.lació depèn de la freqüència triada. Llavors, basat en aquests resultats, quatre objectius es plantegen per a l'estratègia de control: oscil.lació estable amb amplituds elevades; robustesa de l'oscil.lació independentment de les imperfeccions dels MEMS; oscil.lació sinusoïdal sense harmònics per a aplicacions d'alta precisió; i baix consum energètic. La segona part de la tesi tracta la selecció, disseny i verificació dun controlador adequat per a aquests objectius. La revisió dels treballs existents en control de MEMS confirma que cap dels enfocaments actuals permet obtenir els objectius desitjats. En conseqüència, es proposa el disseny d'un nou controlador amb tres etapes per tal d'obtenir l'oscil.lació desitjada amb estabilitat i eficiència energètica. El controlador té tres llaços de control. Al primer llaç, un controlador robust dissenyat amb µ-síntesis gestiona les incertes es dels MEMS. El segon llaç inclou un controlador Ressonant, basat en el Principi del Model Intern, per a generar l'acció de control necessària per a obtenir l'oscil.lació desitjada. I el tercer llaç de control gestiona la minimització de l'energia consumida mitjançant un controlador basat en Extremum Seeking, el qual selecciona la freqüència de treball més eficient energèticament per a l'oscil.lació triada. El controlador proposat és capaç de generar automàticament el voltatge necessari, igual al previst pel Balanç d'Harmònics, per tal d'operar electrostàticament amb plaques paral.leles els ressonadors MEMS. Mitjançant simulació se'n verifica l'estabilitat, robustesa, inexistència d'harmònics i eficiència energètica de l'oscil.lació. Finalment, la implementació real és analitzada. En primer lloc, un nou esquema d'actuació per dos costats amb voltatges independents es proposa per aconseguir l'oscil.lació del ressonador en tot el rang d'amplituds. I en segon lloc, una modificació del sensat amb Modulació d'Amplitud Electromecànica s'utilitza per tancar el llaç de control de posició. Amb aquestes millores, un ressonador MEMS es dissenya per a ser fabricat i validar el control. Basat en aquest disseny, es proposa un procediment de test plantejat com a treball futur.Postprint (published version

Semi-Passive Control Strategy using Piezoceramic Patches in Non Linear Commutation Architecture for Structural-Acoustic Smart Systems

The demands for novel smart damping materials can be summarized in: external power source not required for operation; device not needing to be tuned to a specific frequency; device operation not affected by changes in modal frequency; device suppressing vibration over a number of modes, weight and size minimized; self-contained unit device. This thesis focuses on these points and it shows that the dilemma between active and passive vibration control may be solved with a new approach, implementing a semipassive technique without penalties in terms of robustness and performance. Connecting a shunt circuit to a piezoelectric transducer leads to a simple and low cost vibration controller that is able to efficiently suppress unwanted structural vibrations: this is a way to fulfil the abovementioned demands. The objective of this work is to develop and validate by an experimental campaign a computational tool integrated with finite element Nastran software. An original 4-channel switched shunt control system has been realized using a tachometer device. The control system has been tested first of all on a simple cantilevered beam attaining a max vibrations reduction of 16.2 dB for the first bending mode. Further reference test article consisted of a 10 ply fibreglass laminate plate. A multimodal control has applied within a band range of 700Hz including the first seven modes. A maximum reduction of 16 dB has been found. Further numerical and experimental tests have been planned to extend the ability of the SSC to produce structural-borne sound reduction in acoustic rigid cavities for fluid-structure interaction problems. Numerical sound power radiation of an aluminium plate, controlled by synchronized switch system, compared with the experimental acoustic energy detected in acoustic room, has been planned in the ongoing activities

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

Dynamics and Controls of Fluidic Pressure-Fed Mechanism (FPFM) of Nanopositioning System

Flexure or compliant mechanisms are employed in many precisions engineered devices due to their compactness, linearity, resolution, etc. Yet, critical issues remain in motion errors, thermal instability, limited bandwidth, and vibration of dynamic systems. Those issues cannot be negligible to maintain high precision and accuracy for precision engineering applications. In this thesis, a novel fluidic pressure-fed mechanism (FPFM) is proposed and investigated. The proposed method is designing internal fluidic channels inside the spring structure of the flexure mechanism using the additive manufacturing (AM) process to overcome addressed challenges. By applying pneumatic/hydraulic pressure and filling media into fluidic channels, dynamic characteristics of each spring structure of the flexure mechanism can be altered or adjusted to correct motion errors, increase operating speed, and suppress vibration. Additionally, FPFM can enhance thermal stability by flowing fluids without affecting the motion quality of the dynamic system. Lastly, the motion of the nanopositioning system driven by FPFM can provide sub-nanometer resolution motion, and this enables the nanopositioning system to have two linear motion in a monolithic structure. The main objective of this thesis is to propose and validate the feasibility of FPFM that can ultimately be used for a monolithic FPFM dual-mode stage for providing high positioning performance without motion errors while reducing vibration and increasing thermal stability and bandwidth

Actuator Feasibility Study for Active Control of Ducted Axial Fan Noise

A feasibility study was performed to investigate actuator technology which is relevant for a particular application of active noise control for gas turbine stator vanes. This study investigated many different classes of actuators and ranked them on the order of applicability. The most difficult requirements the actuators had to meet were high frequency response, large amplitude deflections, and a thin profile. Based on this assessment, piezoelectric type actuators were selected as the most appropriate actuator class. Specifically, Rainbows (a new class of high performance piezoelectric actuators), and unimorphs (a ceramic/metal composite) appeared best suited to the requirements. A benchtop experimental study was conducted. The performance of a variety of different actuators was examined, including high polymer films, flextensional actuators, miniature speakers, unimorphs, and Rainbows. The displacement/frequency response and phase characteristics of the actuators were measured. Physical limitations of actuator operation were also examined. This report includes the first known, high displacement, dynamic data obtained for Rainbow actuators. A new "hard" ceramic Rainbow actuator which does not appear to be limited in operation by self heating as "soft" ceramic Rainbows was designed, constructed and tested. The study concludes that a suitable actuator for active noise control in gas turbine engines can be achieved with state of the art materials and processing

Active vibration control for a free piston stirling engine with linear alternator FPSE/LA

New regulations introduced by the European Network of Transmission System Operators for Electricity (ENTSO) have brought further requirements for grid connected generators into action in 2013. The β-type Stirling engine (FPSE/LA) used for micro combined heat and power systems (MCHP) is a synchronous machine that is designed and tuned to operate at 50Hz ± 0.5Hz. This type of technology has to comply with the new regulations that imposes a wider operating envelop (47Hz-53Hz). This engine suffers from continuous self-induced vibrations caused by the reciprocating motion of a permanent magnet attached to its piston inside a linear alternator. Currently, the damping of the vibrations in the FPSA/LA is achieved by employing a passive tuned mass damper (TMD) tuned to damp vibrations at 50Hz. While passive devices provide a simple and a reliable way to tackle many vibration problems, there exists distinct performance limitations associated with the use of only passive devices. As for this particular application, the main limitation of the TMD in its passive form is its narrow bandwidth of operation that cannot cope with the new bandwidth. Consequently, this could expose the engine to physical damage and failure. Therefore modifications to the existing TMD have to be introduced. This research involved the design and development of an active tuned mass damper (ATMD) and the suitable control strategies using an electromagnetic actuator, namely a linear voice coil motor (VCM). Starting with a validated vibration model of the engine based on two degrees of freedom system (2-DOF), two control techniques, Feedforward/Zero-Placement control with relative/absolute position and Linear Quadratic (LQ) optimal control, were investigated with numerical simulation in the frequency and time domains. For the purpose of testing and implementation, a test rig featuring an electromagnetic shaker, a VCM, and a TMD besides an embedded system was assembled. An electromechanical model of the test rig was also developed and simulated with the integration of the control strategies. A set of experimental tests were carried out and the concept of active vibration control was successfully illustrated. In addition to that, an in depth investigation of the effect of time delays on the control methodology was conducted. The study resulted in the identification of a time delay margin where below, stability is guaranteed. Furthermore, a set of comprehensive equations of the power and actuator force requirements to perform active damping with a VCM based on any general 2-DOF system are obtained for both the feedforward and the LQ control strategies

Effects Of Pulsation Frequency On Trailing Edge Plasma Actuators For Flight Control

This thesis details the aerodynamic testing of a dielectric barrier discharge (DBD) plasma actuator operating over a separation step created at the trailing edge of a modified NACA 0012 aerofoil. The work focuses specifically on the use of pulsed or interrupted plasma actuation as opposed to continuously driven actuation, to increase the change in the lift produced by activating the system. The behaviour of the actuation system is characterised in a lamina flow regime at a Reynolds number of 1.33 x 105 using force balance measurements. At zero incidence the actuator produced a peak change in CL of approximately 0.015. However, this result is sensitive to changes in the interruption frequency of the plasma, by changing the plasma drive waveform the system was able to produce both positive and negative changes in lift. A relationship was identified between the change in CL produced and the ratio of the plasma interruption frequency to the natural vortex shedding frequency. This effect was investigated using both time averaged particle image velocimetry (PIV) and instantaneous phase locked PIV images captured in sequence throughout the plasma interruption cycle. The phase locked images showed how variation in the pulsation frequency was able to produce bi-directional actuation by either constructively or destructively interfering with the vortex formation from the back of the separation step. This interference in turn altered the level of separation which was occurring, altering the degree of upwash in the wake and therefore the lift generated by the aerofoil. PIV images were also gathered for device operation at a Reynolds number of 2.3 x 104; this produced a much higher ratio of DBD jet energy to that of the freestream. These conditions showed modified actuator behaviour due to the increased authority over the flow. However, the data still showed a strong interdependence on the reinforcement or destruction of the vortex street by the actuator interruption. Furthermore, work was undertaken to develop an actuator topology based on thin metallised films along with a dielectric which was hardened against the chemical and electrical stresses present in a functioning DBD device. The failure mechanisms of metallised film actuators were investigated, and actuators with lifetimes exceeding 8 hours were demonstrated. A manufacture method for a silicon polymer (PDMS) – Kapton® laminate is detailed; this is shown to be highly resistant to both electrical breakdown and chemical attack by the oxygen plasma

Performance of Active Vibration Isolation in the Advanced LIGO Detectors

The second generation of LIGO detectors has finished construction and the commissioning effort is pushing the instruments towards their designed sensitivity. Around the world similar undertakings are underway, and soon a global network capable of astrophysical observation will be operational. The first sentences are being written in an important chapter of terrestrial gravitational wave detection, an entire century after the theoretical foundations of general relativity were laid, and after decades of calculation, design, proposals, plans, and laboratory work. In order to make sensitive measurements, the detector must be well isolated from the vibrations of the ground, and much of this thesis describes the effectiveness of active control platforms used to mitigate the transmission of seismic motions to the test masses. This work was performed both during the last science run of the first generation LIGO detector and as part of the commissioning of the second generation instrument