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，为实现低成本和节能减少超精密制造机器中的不必要振动提供理论基础，这在先进制造过程中起着核心作用。研究方法包括三个主要任务：(1)由模式耦合引起的所谓“关键配置”的数学表征，作为关键隔离系统设计参数的函数；(2)确定再调平控制器稳定性、重力稳定性和模态耦合之间的数学联系；(3)研究和实施优化方案，有效地利用从任务1和任务2中获得的知识，有条不紊地选择系统参数，以确保在不损害孤立系统稳定性的情况下实现最佳减振。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来代替主动系统，被动隔离器的成本可能比被动系统高出90%，并且移动机器所需的能量是被动系统的两倍。年代轴。这项研究的更广泛的影响是针对工业，教育和推广。与美国领先的超精密机械制造商合作，将使这项研究成果转化为工业成果。本研究的知识将被纳入改进后的研究生课程，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，通过在社会文化背景下展示科学/工程职业，旨在激励未被充分代表的初高中学生追求科学/工程职业，这是一种有希望但非常规的推广方法。

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.