Control and Design of Fast Tool Servos for Precision Machining

该赠款为开发高带宽快速致动器和加工应用控制提供资金。 快速刀具伺服系统将用于加工软件编程的确定性表面，并补偿过程中发生的动态误差。 该研究将首先开发一种创新的快速致动器，该致动器将双级固态致动器与流体动力传输相结合，以在紧凑的封装中实现高带宽致动。 多变量线性鲁棒性能控制设计方法，它结合了重复控制，预览前馈控制，并在一个统一的反馈控制公式的切削力的影响，将开发的致动器，以精确地产生动态轨迹。 为了实现尽可能快的致动器响应，以便可以加工精细的特征，还将研究用于脉冲宽度调制的开关控制。 加工实验将进行测试的驱动器和控制能力。 特别是，快速工具伺服系统将用于生成非圆形发动机气缸孔形状，用于补偿圆柱误差和表面纹理，以提供改善的气缸-活塞配合和摩擦学条件，从而减少排放，提高燃油经济性，并简化制造工艺。如果成功，这项研究的结果将导致速度，精度，以及加工不规则形状零件如发动机活塞轮廓、活塞销孔和气缸孔的一致性。 潜在的拟议的工作也可以适用于加工确定性的摩擦学表面的零件，如轴颈轴承，直线导轨，和液压阀/缸。 本文的研究工作对一般的运动控制领域也有一定的借鉴意义。 所提出的驱动器和控制设计方法可能有助于扩展运动控制性能，并找到新的应用程序以外的加工。

This grant provides funding for the development of high bandwidth fast actuators and control for machining applications. The fast tool servos will be used to machine software programmed deterministic surfaces and compensate for dynamic errors occurred in the process. The research will first develop an innovative fast actuator, which combines dual-stage solid state actuators with fluid power transmission for high bandwidth actuation in a compact package. Multivariable linear robust performance control design method, which incorporates repetitive control, previewed feedforward control, and the effect of the cutting force in a unified feedback control formulation, will be developed for the actuator to precisely generate dynamic trajectories. To realize the fastest possible actuator response so that a fine feature may be machined, switching control for pulse width modulation will also be investigated. Machining experiment will be conducted to test the actuator and control capabilities. In particular, the fast tool servos will be used to generate non-circular engine cylinder bore shapes for compensating cylindrical errors and surface texture to provide improved cylinder-piston fit and tribology conditions, thereby reducing emission, increasing fuel economy, and simplifying manufacturing processes.If successful, the results of this research will lead to improvements in the speed, accuracy, and consistency of machining such irregularly shaped parts as engine piston profiles, piston pin holes, and cylinder bores. Potentially the proposed work could also be applied to machining deterministic tribology surface in parts like journal bearings, linear guide ways, and hydraulic valves/cylinders. The proposed work also contribute in the general motion control field. The proposed actuator and control design methods may contribute to extend the motion control performance and find new applications besides machining.