Low-Cost and Energy-Efficient Vibration Reduction in Ultra-Precision Manufacturing Machines using Mode Coupling

该奖项的目的是研究被动隔离系统中的模式耦合，为实现超精密制造机器中低成本和节能的有害振动减少提供理论基础，这些机器在先进制造工艺中发挥着核心作用。研究方法包括三个主要任务：（1）将模态耦合引起的所谓“临界构形”作为关键隔振系统设计参数的函数进行数学描述：（2）确定重调平控制器稳定性、重力稳定性和模态耦合之间的数学关系;以及（3）研究和实施优化方案，有效利用从任务1和任务2中获得的知识，系统地选择系统参数，确保最佳减振效果，而不损害如果成功，这项研究所创造的知识将使尖端的超精密制造机器能够使用被动隔离器代替主动系统进行设计，这可能比被动系统高出90%以上，并且移动机器所消耗的能量增加一倍。的轴。这项研究的更广泛的影响是针对工业，教育和推广。与领先的美国-的超精密机床制造商将使这项研究的成果转移到工业。这项研究的知识将被纳入一个经过修改的研究生课程，旨在为下一代机床设计师提供基于机电一体化的方法来设计制造机器。最后，一个有前途的，但非常规的推广方法，旨在鼓励代表性不足的初中/高中学生追求科学/工程职业，介绍科学/工程职业在他们的社会文化背景下将追求。

The objective of this award is to investigate mode coupling in passively isolated systems to provide the theoretical basis for achieving low-cost and energy-efficient reduction of unwanted vibrations in ultra-precision manufacturing machines, which play a central role in advanced manufacturing processes. The research approach involves three main tasks: (1) mathematical characterization of the so-called "critical configurations" induced by mode coupling, as a function of key isolation system design parameters; (2) determination of the mathematical connections among re-leveling controller stability, gravitational stability and mode coupling; and (3) investigation and implementation of optimization schemes that effectively utilize the knowledge gained from Tasks 1 and 2 to methodically select system parameters that ensure optimal vibration reduction without compromising the stability of the isolated system.If successful, the knowledge created by this research will enable cutting-edge ultra-precision manufacturing machines to be designed using passive isolators in place of active systems, which can cost up to 90 percent more than passive systems and double the energy consumed to move the machine?s axes. The broader impacts of this research are directed to industry, education and outreach. Collaborations with leading U.S.-based ultra-precision machine manufacturers will enable the results of this research to be transferred to industry. Knowledge from this research will be incorporated into a revamped graduate-level course that aims to equip the next generation of machine tool designers with a mechatronics-based approach to designing manufacturing machines. Finally, a promising but unconventional outreach approach aimed at inspiring underrepresented middle/high school students towards pursuing science/engineering careers by presenting science/engineering careers in their socio-cultural context will be pursued.