Technical Brief

Development of a Cross-Coupled Robust Controller for a Multi-Axis Micro-Machining System

[+] Author and Article Information
Mumtazcan Karagoz

Graduate Student, Department of Mechanical Engineering, Bilkent University, Ankara, Turkey, 06800

Melih Cakmakci

Assistant Professor, Member of ASME, Department of Mechanical Engineering, Bilkent University, Ankara, Turkey, 06800

1Corresponding author.

ASME doi:10.1115/1.4040443 History: Received September 04, 2017; Revised May 24, 2018


In the current era of miniaturization for complex, ubiquitous and energy efficient systems, micro-manufacturing had become one of the most popular fields for engineering development. This paper introduces a modular robust cross-coupled controller design structure for a three axis micro-machining system that can be extended to more axis systems and configurations. In order to develop a robust controller that can withstand the disturbances due to tool-workpiece interactions a dynamic model of the whole system is needed. Developing control oriented models for micro-machining systems can be challenging. Using the Sum of Sines identification input essential non-linearities including the effects of assembly and slider orientation is included. Verification data shows these transfer function models represent the physical system satisfactorily while avoiding an over-fit. Using the transfer functions from the identified model, a controller structure with robust axis controllers with cross-coupled control are developed and fine-tuned with simulations. Machining experiments are also done in order to compare the performance of the PID control design, an adaptive robust controller (both from earlier work in literature) and the new H_{\infty} robust controller. According to results of experiments, the new robust controller showed the best tracking and contouring performance with improved surface quality due to reduced oscillations.

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