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

Top quark physics in hadron collisions

The top quark is the heaviest elementary particle observed to date. Its large mass makes the top quark an ideal laboratory to test predictions of perturbation theory concerning heavy quark production at hadron colliders. The top quark is also a powerful probe for new phenomena beyond the Standard Model of particle physics. In addition, the top quark mass is a crucial parameter for scrutinizing the Standard Model in electroweak precision tests and for predicting the mass of the yet unobserved Higgs boson. Ten years after the discovery of the top quark at the Fermilab Tevatron top quark physics has entered an era where detailed measurements of top quark properties are undertaken. In this review article an introduction to the phenomenology of top quark production in hadron collisions is given, the lessons learned in Tevatron Run I are summarized, and first Run II results are discussed. A brief outlook to the possibilities of top quark research a the Large Hadron Collider, currently under construction at CERN, is included.Comment: 84 pages, 32 figures, accepted for publication by Reports on Progress in Physic

Stability Analysis and Decentralized Control of Coupled Oscillators with Feedback Delays

Most dynamic systems do not react instantaneously to actuation signals. The temporal evolution of some others is based on retarded communications or depends on information from the past. In such cases, the mathematical models used to describe these systems must include information about the past dynamics of the states. These models are often referred to as delay or retarded systems. Delays could channel energy in and out of a system at incorrect time intervals producing instabilities and rendering controllers\u27 performance ineffective. The purpose of this research is two folds. The first investigates the effect of inherent system delays on the stability of coupled oscillators subjected to decentralized control and the second studies the prospectus of augmenting the delay into a larger delay period that could actually stabilize the coupled system and enhance its damping characteristics. Towards these ends, a system of two linearly-coupled oscillators with decentralized delayed-proportional feedback is considered. A comprehensive linear stability analysis is utilized to generate maps that divide the controllers\u27 gain and delay domain into regions of stability for different coupling values. These maps are then used to draw definite conclusions about the effect of coupling on the stability of the closed-loop in the presence of delay. Once the stability maps are generated, the Lambert-W function approach is utilized to find the stability exponents of the coupled system which, in turn, is used to generate damping contours within the pockets of stability. These contours are used to choose gain-delay combinations that could augment the inherent feedback delays into a larger delay period which can enhance the damping characteristics and reduce the system settling time significantly. An experimental plant comprised of two mass-spring-damper trios coupled with a spring is installed to validate the theoretical results and the proposed control hypothesis. Different scenarios consisting of different gains and delays are considered and compared with theoretical findings demonstrating very good agreement. Furthermore, the proposed delayed-proportional feedback decentralized controller is tested and its ability to dampen external oscillations is verified through different experiments. Such a research endeavor could prove very beneficial to many vital areas in our life. A good example is that of the coupled system of the natural and artificial cardiac pacemakers where the natural pacemaker represents a rhythmic oscillating system and the coupled artificial pacemaker provides a stabilizing signal through a feedback mechanism that senses the loss in rhythm. In this system, even the minute amount of delay in the sensing-actuating could prove very detrimental. The result of this research contributes to the solution of this and similar problems

The Physics of Hadronic Tau Decays

Hadronic tau decays represent a clean laboratory for the precise study of quantum chromodynamics (QCD). Observables (sum rules) based on the spectral functions of hadronic tau decays can be related to QCD quark-level calculations to determine fundamental quantities like the strong coupling constant, parameters of the chiral Lagrangian, |V_us|, the mass of the strange quark, and to simultaneously test the concept of quark-hadron duality. Using the best available measurements and a revisited analysis of the theoretical framework, the value alpha_s(m_tau) = 0.345 +- 0.004[exp] +- 0.009[theo] is obtained. Taken together with the determination of alpha_s(m_Z) from the global electroweak fit, this result leads to the most accurate test of asymptotic freedom: the value of the logarithmic slope of 1/alpha_s(s) is found to agree with QCD at a precision of 4%. In another approach, the tau spectral functions can be used to determine hadronic quantities that, due to the nonperturbative nature of long-distance QCD, cannot be computed from first principles. An example for this is the contribution from hadronic vacuum polarization to loop-dominated processes like the anomalous magnetic moment of the muon. This article reviews the measurements of nonstrange and strange tau spectral functions and their phenomenological applications.Comment: 89 pages, 32 figures; final version accepted for publication by Reviews of Modern Physic

susy23 v2.0: an Event Generator for Supersymmetric Processes at e+e−e^+e^- Colliders

\susy23 is a Monte-Carlo package for generating supersymmetric (SUSY) processes at $e^+e^-$ colliders. Twenty-three types of SUSY processes with 2 or 3 final state particles at tree level are included in version 2.0. {\susy23} addresses event simulation requirements at $e^+e^-$ colliders such as LEP. Matrix elements are generated by GRACE with the helicity amplitude method for processes involving massive fermions. The phase space integration of the matrix element gives the total and differential cross sections, then unweighted events are generated. Sparticle widths and decay branching ratios are calculated. Each final state particle may then decay according to these probabilities. Spin correlations are taken into account in the decays of sparticles. Corrections of initial state radiation (ISR) are implemented in two ways, one is based on the electron structure function formalism and the second uses the parton shower algorithm called QEDPS. Parton shower and hadronization of the final quarks are performed through an interface to JETSET.Comment: 36 pages, LaTe