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，为实现在先进制造工艺中发挥核心作用的超精密制造机器中的不必要振动的低成本和高能效减少提供理论基础。该研究方法包括三个主要任务：(1)作为关键隔震系统设计参数的函数的由模式耦合引起的所谓“关键构型”的数学表征：(2)确定调平控制器稳定性、重力稳定性和模式耦合之间的数学关系；以及(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，在不损害隔振系统稳定性的情况下确保最佳减振。如果成功，这项研究创造的知识将使尖端超精密制造机器能够使用被动隔振器来设计，而不是主动系统，这可能比被动系统成本高出90%，并使机器移动的能量消耗增加一倍？S轴。这项研究的更广泛影响针对工业、教育和外展。与美国领先的超精密机械制造商的合作将使这项研究的结果能够转化为工业。这项研究的知识将被纳入一门经过修改的研究生课程，旨在让下一代机床设计师掌握基于机电一体化的制造机器设计方法。最后，将采取一种前景看好但非传统的外展方式，通过在社会文化背景下介绍科学/工程职业，鼓励未被充分代表的初中生/高中生从事科学/工程职业。

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.