Development of the UMAC-based control system with application to 5-axis ultraprecision micromilling machines

This thesis was submitted for the degree of Doctor of Philosophy and awarded by Brunel University.Increasing demands from end users in the fields of optics, defence, automotive, medical, aerospace, etc. for high precision 3D miniaturized components and microstructures from a range of materials have driven the development in micro and nano machining and changed the manufacturing realm. Conventional manufacturing processes such as chemical etching and LIGA are found unfavourable or limited due to production time required and have led mechanical micro machining to grow further. Mechanical micro machining is an ideal method to produce high accuracy micro components and micro milling is the most flexible enabling process and is thus able to generate a wider variety of complex micro components and microstructures. Ultraprecision micromilling machine tools are required so as to meet the accuracy, surface finish and geometrical complexity of components and parts. Typical manufacturing requirements are high dimensional accuracy being better than 1 micron, flatness and roundness better than 50 nm and surface finish ranging between 10 and 50 nm. Manufacture of high precision components and parts require very intricate material removal procedure. There are five key components that include machine tools, cutting tools, material properties, operation variables and environmental conditions, which constitute in manufacturing high quality components and parts. End users assess the performance of a machine tool based on the dimensional accuracy and surface quality of machined parts including the machining time. In this thesis, the emphasis is on the design and development of a control system for a 5-axis bench-type ultraprecision micromilling machine- Ultra-Mill. On the one hand, the developed control system is able to offer high motion and positioning accuracy, dynamic stiffness and thermal stability for motion control, which are essential for achieving the machining accuracy and surface finish desired. On the other hand, the control system is able to undertake in-process inspection and condition monitoring of the machine tool and process. The control of multi-axis precision machines with high-speed and high-accuracy motions and positioning are desirable to manufacture components with high accuracy and complex features to increase productivity and maintain machine stability, etc. The development of the control system has focused on fast, accurate and robust positioning requirements at the machine system design stage. Apart from the mechanical design, the performance of the entire precision systems is greatly dependent on diverse electrical and electronics subsystems, controllers, drive instruments, feedback devices, inspection and monitoring system and software. There are some variables that dynamically alter the system behaviour and sensitivity to disturbance that are not ignorable in the micro and nano machining realm. In this research, a structured framework has been developed and integrated to aid the design and development of the control system. The framework includes critically reviewing the state of the art of ultraprecision machining tools, understanding the control system technologies involved, highlighting the advantages and disadvantages of various control system methods for ultraprecision machines, understanding what is required by end-users and formulating what actually makes a machine tool be an ultraprecision machine particularly from the control system perspective. In the design and development stage, the possession of mechatronic know-how is essential as the design and development of the Ultra-Mill is a multidisciplinary field. Simulation and modelling tool such as Matlab/Simulink is used to model the most suitable control system design. The developed control system was validated through machining trials to observe the achievable accuracy, experiments and testing of subsystems individually (slide system, tooling system, monitoring system, etc.). This thesis has successfully demonstrated the design and development of the control system for a 5-axis ultraprecision machine tool- Ultra-Mill, with high performance characteristics, fast, accurate, precise, etc. for motion and positioning, high dynamic stiffness, robustness and thermal stability, whereby was provided and maintained by the control system

Containing the Nanometer “Pandora-Box”: Cross-Layer Design Techniques for Variation Aware Low Power Systems

The demand for richer multimedia services, multifunctional portable devices and high data rates can only been visioned due to the improvement in semiconductor technology. Unfortunately, sub-90 nm process nodes uncover the nanometer Pandora-box exposing the barriers of technology scaling—parameter variations, that threaten the correct operation of circuits, and increased energy consumption, that limits the operational lifetime of today’s systems. The contradictory design requirements for low-power and system robustness, is one of the most challenging design problems of today. The design efforts are further complicated due to the heterogeneous types of designs (logic, memory, mixed-signal) that are included in today’s complex systems and are characterized by different design requirements. This paper presents an overview of techniques at various levels of design abstraction that lead to low power and variation aware logic, memory and mixed-signal circuits and can potentially assist in meeting the strict power budgets and yield/quality requirements of future systems

Solutions pour l'auto-adaptation des systèmes sans fil

The current demand on ubiquitous connectivity imposes stringent requirements on the fabrication of Radio-Frequency (RF) circuits. Designs are consequently transferred to the most advanced CMOS technologies that were initially introduced to improve digital performance. In addition, as technology scales down, RF circuits are more and more susceptible to a lot of variations during their lifetime, as manufacturing process variability, temperature, environmental conditions, aging… As a result, the usual worst-case circuit design is leading to sub-optimal conditions, in terms of power and/or performance most of the time for the circuit. In order to counteract these variations, increasing the performances and also reduce power consumption, adaptation strategies must be put in place.More importantly, the fabrication process introduces more and more performance variability, which can have a dramatic impact on the fabrication yield. That is why RF designs are not easily fabricated in the most advanced CMOS technologies, as 32nm or 22nm nodes for instance. In this context, the performances of RF circuits need to be calibrated after fabrication so as to take these variations into account and recover yield loss.This thesis work is presenting on a post-fabrication calibration technique for RF circuits. This technique is performed during production testing with minimum extra cost, which is critical since the cost of test can be comparable to the cost of fabrication concerning RF circuits and cannot be further raised. Calibration is enabled by equipping the circuit with tuning knobs and sensors. Optimal tuning knob identification is achieved in one-shot based on a single test step that involves measuring the sensor outputs once. For this purpose, we rely on variation-aware sensors which provide measurements that remain invariant under tuning knob changes. As an auxiliary benefit, the variation-aware sensors are non-intrusive and totally transparent to the circuit.Our proposed methodology has first been demonstrated with simulation data with an RF power amplifier as a case study. Afterwards, a silicon demonstrator has then been fabricated in a 65nm technology in order to fully demonstrate the methodology. The fabricated dataset of circuits is extracted from typical and corner wafers. This feature is very important since corner circuits are the worst design cases and therefore the most difficult to calibrate. In our case, corner circuits represent more than the two third of the overall dataset and the calibration can still be proven. In details, fabrication yield based on 3 sigma performance specifications is increased from 21% to 93%. This is a major performance of the technique, knowing that worst case circuits are very rare in industrial fabrication.La demande courante de connectivité instantanée impose un cahier des charges très strict sur la fabrication des circuits Radio-Fréquences (RF). Les circuits doivent donc être transférées vers les technologies les plus avancées, initialement introduites pour augmenter les performances des circuits purement numériques. De plus, les circuits RF sont soumis à de plus en plus de variations et cette sensibilité s’accroît avec l’avancées des technologies. Ces variations sont par exemple les variations du procédé de fabrication, la température, l’environnement, le vieillissement… Par conséquent, la méthode classique de conception de circuits “pire-cas” conduit à une utilisation non-optimale du circuit dans la vaste majorité des conditions, en termes de performances et/ou de consommation. Ces variations doivent donc être compensées, en utilisant des techniques d’adaptation.De manière plus importante encore, le procédé de fabrication des circuits introduit de plus en plus de variabilité dans les performances des circuits, ce qui a un impact important sur le rendement de fabrication des circuits. Pour cette raison, les circuits RF sont difficilement fabriqués dans les technologies CMOS les plus avancées comme les nœuds 32nm ou 22nm. Dans ce contexte, les performances des circuits RF doivent êtres calibrées après fabrication pour prendre en compte ces variations et retrouver un haut rendement de fabrication.Ce travail de these présente une méthode de calibration post-fabrication pour les circuits RF. Cette méthodologie est appliquée pendant le test de production en ajoutant un minimum de coût, ce qui est un point essentiel car le coût du test est aujourd’hui déjà comparable au coût de fabrication d’un circuit RF et ne peut être augmenté d’avantage. Par ailleurs, la puissance consommée est aussi prise en compte pour que l’impact de la calibration sur la consommation soit minimisé. La calibration est rendue possible en équipant le circuit avec des nœuds de réglages et des capteurs. L’identification de la valeur de réglage optimale du circuit est obtenue en un seul coup, en testant les performances RF une seule et unique fois. Cela est possible grâce à l’utilisation de capteurs de variations du procédé de fabrication qui sont invariants par rapport aux changements des nœuds de réglage. Un autre benefice de l’utilisation de ces capteurs de variation sont non-intrusifs et donc totalement transparents pour le circuit sous test. La technique de calibration a été démontrée sur un amplificateur de puissance RF utilisé comme cas d’étude. Une première preuve de concept est développée en utilisant des résultats de simulation.Un démonstrateur en silicium a ensuite été fabriqué en technologie 65nm pour entièrement démontrer le concept de calibration. L’ensemble des puces fabriquées a été extrait de trois types de wafer différents, avec des transistors aux performances lentes, typiques et rapides. Cette caractéristique est très importante car elle nous permet de considérer des cas de procédé de fabrication extrêmes qui sont les plus difficiles à calibrer. Dans notre cas, ces circuits représentent plus des deux tiers des puces à disposition et nous pouvons quand même prouver notre concept de calibration. Dans le détails, le rendement de fabrication passe de 21% avant calibration à plus de 93% après avoir appliqué notre méthodologie. Cela constitue une performance majeure de notre méthodologie car les circuits extrêmes sont très rares dans une fabrication industrielle

Service robotics and machine learning for close-range remote sensing

L'abstract è presente nell'allegato / the abstract is in the attachmen

Development of the UMAC-based control system with application to 5-axis ultraprecision micromilling machines

Increasing demands from end users in the fields of optics, defence, automotive, medical, aerospace, etc. for high precision 3D miniaturized components and microstructures from a range of materials have driven the development in micro and nano machining and changed the manufacturing realm. Conventional manufacturing processes such as chemical etching and LIGA are found unfavourable or limited due to production time required and have led mechanical micro machining to grow further. Mechanical micro machining is an ideal method to produce high accuracy micro components and micro milling is the most flexible enabling process and is thus able to generate a wider variety of complex micro components and microstructures. Ultraprecision micromilling machine tools are required so as to meet the accuracy, surface finish and geometrical complexity of components and parts. Typical manufacturing requirements are high dimensional accuracy being better than 1 micron, flatness and roundness better than 50 nm and surface finish ranging between 10 and 50 nm. Manufacture of high precision components and parts require very intricate material removal procedure. There are five key components that include machine tools, cutting tools, material properties, operation variables and environmental conditions, which constitute in manufacturing high quality components and parts. End users assess the performance of a machine tool based on the dimensional accuracy and surface quality of machined parts including the machining time. In this thesis, the emphasis is on the design and development of a control system for a 5-axis bench-type ultraprecision micromilling machine- Ultra-Mill. On the one hand, the developed control system is able to offer high motion and positioning accuracy, dynamic stiffness and thermal stability for motion control, which are essential for achieving the machining accuracy and surface finish desired. On the other hand, the control system is able to undertake in-process inspection and condition monitoring of the machine tool and process. The control of multi-axis precision machines with high-speed and high-accuracy motions and positioning are desirable to manufacture components with high accuracy and complex features to increase productivity and maintain machine stability, etc. The development of the control system has focused on fast, accurate and robust positioning requirements at the machine system design stage. Apart from the mechanical design, the performance of the entire precision systems is greatly dependent on diverse electrical and electronics subsystems, controllers, drive instruments, feedback devices, inspection and monitoring system and software. There are some variables that dynamically alter the system behaviour and sensitivity to disturbance that are not ignorable in the micro and nano machining realm. In this research, a structured framework has been developed and integrated to aid the design and development of the control system. The framework includes critically reviewing the state of the art of ultraprecision machining tools, understanding the control system technologies involved, highlighting the advantages and disadvantages of various control system methods for ultraprecision machines, understanding what is required by end-users and formulating what actually makes a machine tool be an ultraprecision machine particularly from the control system perspective. In the design and development stage, the possession of mechatronic know-how is essential as the design and development of the Ultra-Mill is a multidisciplinary field. Simulation and modelling tool such as Matlab/Simulink is used to model the most suitable control system design. The developed control system was validated through machining trials to observe the achievable accuracy, experiments and testing of subsystems individually (slide system, tooling system, monitoring system, etc.). This thesis has successfully demonstrated the design and development of the control system for a 5-axis ultraprecision machine tool- Ultra-Mill, with high performance characteristics, fast, accurate, precise, etc. for motion and positioning, high dynamic stiffness, robustness and thermal stability, whereby was provided and maintained by the control system.EThOS - Electronic Theses Online ServiceGBUnited Kingdo

AI-based intrusion detection systems for in-vehicle networks: a survey.

The Controller Area Network (CAN) is the most widely used in-vehicle communication protocol, which still lacks the implementation of suitable security mechanisms such as message authentication and encryption. This makes the CAN bus vulnerable to numerous cyber attacks. Various Intrusion Detection Systems (IDSs) have been developed to detect these attacks. However, the high generalization capabilities of Artificial Intelligence (AI) make AI-based IDS an excellent countermeasure against automotive cyber attacks. This article surveys AI-based in-vehicle IDS from 2016 to 2022 (August) with a novel taxonomy. It reviews the detection techniques, attack types, features, and benchmark datasets. Furthermore, the article discusses the security of AI models, necessary steps to develop AI-based IDSs in the CAN bus, identifies the limitations of existing proposals, and gives recommendations for future research directions

Analysis and Life Cycle Assessment of Printed Antennas for Sustainable Wireless Systems

Siirretty Doriast

Applications of Antenna Technology in Sensors

During the past few decades, information technologies have been evolving at a tremendous rate, causing profound changes to our world and to our ways of living. Emerging applications have opened u[ new routes and set new trends for antenna sensors. With the advent of the Internet of Things (IoT), the adaptation of antenna technologies for sensor and sensing applications has become more important. Now, the antennas must be reconfigurable, flexible, low profile, and low-cost, for applications from airborne and vehicles, to machine-to-machine, IoT, 5G, etc. This reprint aims to introduce and treat a series of advanced and emerging topics in the field of antenna sensors

3D printing of Aluminium alloys: Additive Manufacturing of Aluminium alloys using selective laser melting

© 2019 The Authors Metal Additive Manufacturing (AM) processes, such as selective laser melting (SLM), enable the fabrication of arbitrary 3D-structures with unprecedented degrees of freedom. Research is rapidly progressing in this field, with promising results opening up a range of possible applications across both scientific and industrial sectors. Many sectors are now benefiting from fabricating complex structures using AM technologies to achieve the objectives of light-weighting, increased functionality, and part number reduction, among others. AM also lends potential in fulfilling demands for reducing the cost and design-to-manufacture time. Aluminium alloys are of the main material systems receiving attention in SLM research, being favoured in many high-value applications. However, processing them is challenging due to the difficulties associated with laser-melting aluminium where parts suffer various defects. A number of studies in recent years have developed approaches to remedy them and reported successful SLM of various Al-alloys and have gone on to explore its potential application in advanced componentry. This paper reports on recent advancements in this area and highlights some key topics requiring attention for further progression. It aims to develop a comprehensive understanding of the interrelation between the various aspects of the subject, as this is essential to demonstrate credibility for industrial needs

Synthesis of One-Dimensional And Two-Dimensional Carbon Based Nanomaterials

Particular physical and chemical properties of carbon based nanomaterials (CBNs) have promised and exhibited great applications in manufacturing various nanodevices such as electron field emitters, sensors, one-dimensional conductors, supercapacitors, reinforcing fibres, hydrogen storage devices, and catalyst support for fuel cells electrodes. Despite these amazing technical progresses, many challenges still remain in the development of synthesis methods suitable for commercial applications and fabricating novel functional nanostructures with complex architecture. In this Ph.D. thesis, one-dimensional (1D), two-dimensional (2D) carbon nanostructures, and 1D/2D hybrid of carbon nanostructures have been synthesized using various chemical vapour deposition (CVD) methods. The objective of this work is to explore the potential of various CVD methods, including specially-designed CVD techniques, such as modified spray pyrolysis, plasma enhanced CVD, and magnetron sputtering deposition. By making use of these innovative methods, high density regular and nitrogen-doped nanotubes, graphite nanosheets and assemblies have been successfully obtained on conducting and semiconducting substrates. For the modified spray pyrolysis method, systematic investigation of regular carbon nanotubes (CNTs) was conducted in terms of optimizing various experimental parameters such as hydrocarbon source, temperature, and catalyst in order to control the quality and structure of CBNs. Doping of nitrogen into carbon nanotubes was also systematically studied to enhance their electrical and mechanical properties. Interestingly, a novel structure of multi-branched nitrogen doped CNTs has been achieved by this modified spray pyrolysis method. By employing the plasma assisted CVD/sputtering hybrid system, selective growth of single and few walled CNTs have been realized. The device has also been able to produce 2D carbon nanostructures of nanosheets and a hybrid of nanosheets suspended on vertical aligned CNTs. Based on the magnetron sputtering deposition method, carbon nanowalls have been synthesized without any catalyst addition. Morphology, microstructure, and vibration properties of the CBNs were characterized by scanning electron microscopy, transmission electron microscopy, Raman spectroscopy, and X-ray photoelectron spectroscopy. Carbon nanomaterials, grown in high densities on conducting and semiconducting substrates, promise great potential in building various nanodevices with different electron conducting requirements. In addition, CBNs provide a very high surface area for the support of platinum particles for use in hydrogen fuel cell electrodes