Motion control and synchronisation of multi-axis drive systems

Motion control and synchronisation of multi-axis drive system

Design of the Annular Suspension and Pointing System (ASPS) (including design addendum)

The Annular Suspension and Pointing System is an experiment pointing mount designed for extremely precise 3 axis orientation of shuttle experiments. It utilizes actively controlled magnetic bearing to provide noncontacting vernier pointing and translational isolation of the experiment. The design of the system is presented and analyzed

A novel low-cost autonomous 3D LIDAR system

Thesis (M.S.) University of Alaska Fairbanks, 2018To aid in humanity's efforts to colonize alien worlds, NASA's Robotic Mining Competition pits universities against one another to design autonomous mining robots that can extract the materials necessary for producing oxygen, water, fuel, and infrastructure. To mine autonomously on the uneven terrain, the robot must be able to produce a 3D map of its surroundings and navigate around obstacles. However, sensors that can be used for 3D mapping are typically expensive, have high computational requirements, and/or are designed primarily for indoor use. This thesis describes the creation of a novel low-cost 3D mapping system utilizing a pair of rotating LIDAR sensors, attached to a mobile testing platform. Also, the use of this system for 3D obstacle detection and navigation is shown. Finally, the use of deep learning to improve the scanning efficiency of the sensors is investigated.Chapter 1. Introduction -- 1.1. Purpose -- 1.2. 3D sensors -- 1.2.1. Cameras -- 1.2.2. RGB-D Cameras -- 1.2.3. LIDAR -- 1.3. Overview of Work and Contributions -- 1.4. Multi-LIDAR and Rotating LIDAR Systems -- 1.5. Thesis Organization. Chapter 2. Hardware -- 2.1. Overview -- 2.2. Components -- 2.2.1. Revo Laser Distance Sensor -- 2.2.2. Dynamixel AX-12A Smart Serial Servo -- 2.2.3. Bosch BNO055 Inertial Measurement Unit -- 2.2.4. STM32F767ZI Microcontroller and LIDAR Interface Boards -- 2.2.5. Create 2 Programmable Mobile Robotic Platform -- 2.2.6. Acer C720 Chromebook and Genius Webcam -- 2.3. System Assembly -- 2.3.1. 3D LIDAR Module -- 2.3.2. Full Assembly. Chapter 3. Software -- 3.1. Robot Operating System -- 3.2. Frames of Reference -- 3.3. System Overview -- 3.4. Microcontroller Firmware -- 3.5. PC-Side Point Cloud Fusion -- 3.6. Localization System -- 3.6.1. Fusion of Wheel Odometry and IMU Data -- 3.6.2. ArUco Marker Localization -- 3.6.3. ROS Navigation Stack: Overview & Configuration -- 3.6.3.1. Costmaps -- 3.6.3.2. Path Planners. Chapter 4. System Performance -- 4.1. VS-LIDAR Characteristics -- 4.2. Odometry Tests -- 4.3. Stochastic Scan Dithering -- 4.4. Obstacle Detection Test -- 4.5. Navigation Tests -- 4.6. Detection of Black Obstacles -- 4.7. Performance in Sunlit Environments -- 4.8. Distance Measurement Comparison. Chapter 5. Case Study: Adaptive Scan Dithering -- 5.1. Introduction -- 5.2. Adaptive Scan Dithering Process Overview -- 5.3. Coverage Metrics -- 5.4. Reward Function -- 5.5. Network Configuration -- 5.6. Performance and Remarks. Chapter 6. Conclusions and Future Work -- 6.1. Conclusions -- 6.2. Future Work -- 6.3. Lessons Learned -- References

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

Linear Regression and Unsupervised Learning For Tracking and Embodied Robot Control.

Computer vision problems, such as tracking and robot navigation, tend to be solved using models of the objects of interest to the problem. These models are often either hard-coded, or learned in a supervised manner. In either case, an engineer is required to identify the visual information that is important to the task, which is both time consuming and problematic. Issues with these engineered systems relate to the ungrounded nature of the knowledge imparted by the engineer, where the systems have no meaning attached to the representations. This leads to systems that are brittle and are prone to failure when expected to act in environments not envisaged by the engineer. The work presented in this thesis removes the need for hard-coded or engineered models of either visual information representations or behaviour. This is achieved by developing novel approaches for learning from example, in both input (percept) and output (action) spaces. This approach leads to the development of novel feature tracking algorithms, and methods for robot control. Applying this approach to feature tracking, unsupervised learning is employed, in real time, to build appearance models of the target that represent the input space structure, and this structure is exploited to partition banks of computationally efficient, linear regression based target displacement estimators. This thesis presents the first application of regression based methods to the problem of simultaneously modeling and tracking a target object. The computationally efficient Linear Predictor (LP) tracker is investigated, along with methods for combining and weighting flocks of LP’s. The tracking algorithms developed operate with accuracy comparable to other state of the art online approaches and with a significant gain in computational efficiency. This is achieved as a result of two specific contributions. First, novel online approaches for the unsupervised learning of modes of target appearance that identify aspects of the target are introduced. Second, a general tracking framework is developed within which the identified aspects of the target are adaptively associated to subsets of a bank of LP trackers. This results in the partitioning of LP’s and the online creation of aspect specific LP flocks that facilitate tracking through significant appearance changes. Applying the approach to the percept action domain, unsupervised learning is employed to discover the structure of the action space, and this structure is used in the formation of meaningful perceptual categories, and to facilitate the use of localised input-output (percept-action) mappings. This approach provides a realisation of an embodied and embedded agent that organises its perceptual space and hence its cognitive process based on interactions with its environment. Central to the proposed approach is the technique of clustering an input-output exemplar set, based on output similarity, and using the resultant input exemplar groupings to characterise a perceptual category. All input exemplars that are coupled to a certain class of outputs form a category - the category of a given affordance, action or function. In this sense the formed perceptual categories have meaning and are grounded in the embodiment of the agent. The approach is shown to identify the relative importance of perceptual features and is able to solve percept-action tasks, defined only by demonstration, in previously unseen situations. Within this percept-action learning framework, two alternative approaches are developed. The first approach employs hierarchical output space clustering of point-to-point mappings, to achieve search efficiency and input and output space generalisation as well as a mechanism for identifying the important variance and invariance in the input space. The exemplar hierarchy provides, in a single structure, a mechanism for classifying previously unseen inputs and generating appropriate outputs. The second approach to a percept-action learning framework integrates the regression mappings used in the feature tracking domain, with the action space clustering and imitation learning techniques developed in the percept-action domain. These components are utilised within a novel percept-action data mining methodology, that is able to discover the visual entities that are important to a specific problem, and to map from these entities onto the action space. Applied to the robot control task, this approach allows for real-time generation of continuous action signals, without the use of any supervision or definition of representations or rules of behaviour

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

Gemini multi-conjugate adaptive optics system review II: Commissioning, operation and overall performance

The Gemini Multi-conjugate Adaptive Optics System - GeMS, a facility instrument mounted on the Gemini South telescope, delivers a uniform, near diffraction limited images at near infrared wavelengths (0.95 microns- 2.5 microns) over a field of view of 120 arc seconds. GeMS is the first sodium layer based multi laser guide star adaptive optics system used in astronomy. It uses five laser guide stars distributed on a 60 arc seconds square constellation to measure for atmospheric distortions and two deformable mirrors to compensate for it. In this paper, the second devoted to describe the GeMS project, we present the commissioning, overall performance and operational scheme of GeMS. Performance of each sub-system is derived from the commissioning results. The typical image quality, expressed in full with half maximum, Strehl ratios and variations over the field delivered by the system are then described. A discussion of the main contributor to performance limitation is carried-out. Finally, overheads and future system upgrades are described.Comment: 20 pages, 11 figures, accepted for publication in MNRA

Virtual prototyping of vehicular electric steering assistance system using co-simulations

Virtual prototyping is a practical necessity in vehicle system development. From desktop simulation to track testing, several simulation approaches, such as co-simulation and hardware-in-loop (HIL) simulation, are used. However, due to interfacing problems, the consistency of testing results may not be ensured. Correspondingly, inherent inaccuracies result from numerical coupling error and non-transparent HIL interface, which involves control tracking error, delay error, and attached hardware and noise effects. This work aims to resolve these problems and provide seamless virtual prototypes for vehicle and electric power-assisted steering (EPAS) system development.The accuracy and stability of explicit parallel co-simulation and HIL simulation are investigated. The imperfect factors propagate in the simulation tools like perturbations, yield inaccuracy, and even instability according to system dynamics. Hence, reducing perturbations (coupling problem) and improving system robustness (architecture problem) are considered.In the coupling problem, a delay compensation method relying on adaptive filters is developed for real-time simulation. A novel co-simulation coupling method on H-infinity synthesis is developed to improve accuracy for a wide frequency range and achieve low computational cost. In the architecture problem, a force(torque)-velocity coupling approach is employed. The application of a force (torque) variable to a component with considerable impedance, e.g., the steering rack (EPAS motor), yields a small loop gain as well as robust co-simulation and HIL simulation. On a given EPAS HIL system, an interface algorithm is developed for virtually shifting the impedance, thus enhancing system robustness.The theoretical findings and formulated methods are tested on generic benchmarks and implemented on a vehicle-EPAS engineering case. In addition to the acceleration of simulation speed, accuracy and robustness are also improved. Consequently, consistent testing results and extended validated ranges of virtual prototypes are obtained

Design and control of components-based integrated servo pneumatic drives

On-off traditional pneumatic drives are most widely used in industry offering low-cost, simple but flexible mechanical operation and relatively high power to weight ratio. For a period of decade from mid 1980's to 1990's, some initiatives were made to develop servo pneumatic drives for most sophisticated applications, employing purpose-designed control valves for pneumatic drives and low friction cylinders. However, it is found that the high cost and complex installation have discouraged the manufacturer from applying servo pneumatic drives to industrial usage, making them less favourable in comparison to their electric counterpart. This research aims to develop low-cost servo pneumatic drives which are capable of point-to-point positioning tasks, suitable for applications requiring intermediate performance characteristics. In achieving this objective, a strategy that involves the use of traditional on-off valve, simple control algorithm and distributed field-bus control networks has been adopted, namely, the design and control of Components-based Integrated Pneumatic Drives (CIPDs). Firstly, a new pneumatic actuator servo motion control strategy has been developed. With the new motion control strategy, the processes of positioning a payload can be achieved by opening the control valve only once. Hence, lowspeed on-off pneumatic control valves can be employed in keeping the cost low, a key attraction for employing pneumatic drives. The new servo motion control strategy also provides a way of controlling the load motion speed mechanically. Meanwhile, a new PD-based three-state closed-loop control algorithm also has been developed for the new control scheme. This control algorithm provides a way of adapting traditional PID (Proportional Integral Derivative) control theories for regulating pneumatic drives. Moreover, a deceleration control strategy has been developed so that both high-speed and accurate positioning control can be realised with low cost pneumatic drives. Secondly, the effects of system parameters on the transient response are studied. In assisting the analysis, a second order model is developed to encapsulate the velocity response characteristics of pneumatic drives to a step input signal. Stability analyses for both open loop and closed-loop control have also been carried out for the CIPDs with the newly developed motion control strategy. Thirdly, a distributed control strategy employing Lon Works has been devised and implemented, offering desirable attributes, high re-configurability, low cost and easy in installation and maintenance, etc to keep with the traditional strength for using pneumatic drives. By applying this technology, the CIPDs become standard components in "real" and "virtual" design environments. A remote service strategy for CIPDs using TCP/IP communication protocol has also been developed. Subsequently a range of experimental verifications has been carried out in the research. The experimental study of high-speed motion control indicates that the deceleration control strategy developed in the research can be an effective method in improving the behaviour of high speed CIPDs. The verification of open loop system behaviour of CIPDs shows that the model derived is largely indicative of the likely behaviour for the system considered, and the steady state velocity can be estimated using the Velocity Gain Kv. The evaluation made on a pneumatically driven pick-and-place machine has also confirmed that the system setup, including wiring, tuning, and system reconfiguration can be achieved in relative ease. This pilot study reveals the potential for employing CIPDs in building highly flexible cost effective manufacturing machines. It can thus be concluded that this research has developed successfully a new dimension and knowledge in both theoretical and practical terms in building low-cost servo pneumatic drives, which are capable of point-to-point positioning through employing traditional on-off pneumatic valves and actuators and through their integration with distributed control technology (LonWorks) by adopting a component-based design paradigm