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Precision tracking control of a dual-stage measuring machine

Präzise Folgeregelung einer Dual-Stage-Messmaschine
  • Michael Ringkowski

    Michael Ringkowski received the M. Sc. degree in Engineering Cybernetics from the University of Stuttgart, Stuttgart, Germany, in 2017 and the Ph. D. degree from the same university in 2021. From 2017 until 2021 he has been a Research Assistant at the Institute for System Dynamics, University of Stuttgart, Germany. His research interests include estimation and control of measuring machines, with a focus on increasing dynamics while maintaining precision.

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    , Eckhard Arnold

    Eckhard Arnold received the Dipl.-Ing. degree in technical cybernetics and automatic control from the Technische Hochschule Ilmenau, Ilmenau, Germany, in 1985 and the Ph. D. degree from the same university in 1988. Since 2005, he is a research associate with the Institute for System Dynamics, University of Stuttgart, Germany. His main research interests include optimization and optimal control applications in control engineering.

    , Simon Hartlieb

    Simon Hartlieb received the M. Sc. degree in Mechanical Engineering from the University of Stuttgart, Germany, in 2017. Since 2018 he has been a Research Assistant at the Institute of Applied Optics in the field of 3D Metrology. His research interests include optical position measurement, image processing and 3D measurement.

    , Tobias Haist

    Tobias Haist studied physics and received the Ph. D. degree in engineering from the University of Stuttgart. He is currently leading the group 3D Surface Metrology at the Institute of Applied Optics, where he is working on new applications for spatial light modulators and 3-D measurement systems. His main research interests include optical and digital image processing, computer generated holography, and optical measurement systems.

    , Wolfgang Osten

    Wolfgang Osten received the Diploma in physics from the Friedrich-Schiller-University Jena, Jena, Germany, the Ph. D. degree from the Martin Luther University Halle-Wittenberg, in 1979 and 1983, respectively. Since September 2002, he has been a Full Professor with the University of Stuttgart and director of the Institute for Applied Optics. His main fields of work include new concepts for industrial inspection and metrology.

    and Oliver Sawodny

    Oliver Sawodny received the Dipl.-Ing. degree in electrical engineering from the University of Karlsruhe, Karlsruhe, Germany, in 1991, and the Ph. D. degree from the Ulm University, Ulm, Germany, in 1996. In 2002, he became a Full Professor with the Technical University of Ilmenau, Ilmenau, Germany. Since 2005, he has been the Director of the Institute for System Dynamics, University of Stuttgart, Stuttgart, Germany. His current research interests include methods of differential geometry, trajectory generation, and applications to mechatronic systems.

Abstract

Modern production requires shorter measuring cycles of measuring machines, which can be achieved with highly dynamic references causing dynamic deviations of the actual tool-center-point (TCP) position. To minimize the TCP tracking error, the considered measuring machine is extended with a redundant axis and a modular control concept is proposed. For this dual-stage actuation setting, a higher-level reference allocation module exploits the resulting redundancy and yields suitable position references for the lower-level controlled subsystems. On the higher-level, two dual-stage control concepts are presented, yielding both significantly reduced tracking errors in experiments compared to using only the main axis. Furthermore, to deal with strongly spatially varying friction of the main axis of the considered measuring machine, its lower-level control system is improved.

Zusammenfassung

Moderne Produktionsanlagen erfordern kürzere Messzyklen von Messmaschinen, die mittels hochdynamischer Referenzen erreicht werden können. Allerdings führen diese zu dynamischen Abweichungen der tatsächlichen Position des Werkzeugmittelpunktes (TCP). Um TCP-Folgefehler zu minimieren, wird die Hauptachse der betrachteten Messmaschine um eine redundante Zusatzachse erweitert und ein modulares Regelungskonzept vorgeschlagen. Für diese sogenannte Dual-Stage-Ansteuerung nutzt ein übergeordnetes Sollwertzuordnungsmodul die resultierende Redundanz aus und liefert geeignete Positionssollwerte für die untergeordnet geregelten Teilsysteme. Auf der übergeordneten Ebene werden zwei Dual-Stage-Regelungskonzepte vorgestellt, die in Experimenten deutlich reduzierte Folgefehler im Vergleich zur alleinigen Verwendung der Hauptachse erzielen. Außerdem wird die unterlagerte Regelung der Hauptachse aufgrund örtlich stark variierender Reibung verbessert.

Funding statement: This work was supported by the DFG (Deutsche Forschungsgemeinschaft/German Research Foundation) under grants SA 847/16-2 and OS 111/42-2.

About the authors

Michael Ringkowski

Michael Ringkowski received the M. Sc. degree in Engineering Cybernetics from the University of Stuttgart, Stuttgart, Germany, in 2017 and the Ph. D. degree from the same university in 2021. From 2017 until 2021 he has been a Research Assistant at the Institute for System Dynamics, University of Stuttgart, Germany. His research interests include estimation and control of measuring machines, with a focus on increasing dynamics while maintaining precision.

Eckhard Arnold

Eckhard Arnold received the Dipl.-Ing. degree in technical cybernetics and automatic control from the Technische Hochschule Ilmenau, Ilmenau, Germany, in 1985 and the Ph. D. degree from the same university in 1988. Since 2005, he is a research associate with the Institute for System Dynamics, University of Stuttgart, Germany. His main research interests include optimization and optimal control applications in control engineering.

Simon Hartlieb

Simon Hartlieb received the M. Sc. degree in Mechanical Engineering from the University of Stuttgart, Germany, in 2017. Since 2018 he has been a Research Assistant at the Institute of Applied Optics in the field of 3D Metrology. His research interests include optical position measurement, image processing and 3D measurement.

Tobias Haist

Tobias Haist studied physics and received the Ph. D. degree in engineering from the University of Stuttgart. He is currently leading the group 3D Surface Metrology at the Institute of Applied Optics, where he is working on new applications for spatial light modulators and 3-D measurement systems. His main research interests include optical and digital image processing, computer generated holography, and optical measurement systems.

Wolfgang Osten

Wolfgang Osten received the Diploma in physics from the Friedrich-Schiller-University Jena, Jena, Germany, the Ph. D. degree from the Martin Luther University Halle-Wittenberg, in 1979 and 1983, respectively. Since September 2002, he has been a Full Professor with the University of Stuttgart and director of the Institute for Applied Optics. His main fields of work include new concepts for industrial inspection and metrology.

Oliver Sawodny

Oliver Sawodny received the Dipl.-Ing. degree in electrical engineering from the University of Karlsruhe, Karlsruhe, Germany, in 1991, and the Ph. D. degree from the Ulm University, Ulm, Germany, in 1996. In 2002, he became a Full Professor with the Technical University of Ilmenau, Ilmenau, Germany. Since 2005, he has been the Director of the Institute for System Dynamics, University of Stuttgart, Stuttgart, Germany. His current research interests include methods of differential geometry, trajectory generation, and applications to mechatronic systems.

Abbreviations

DOB

disturbance observer;

DSA

dual-stage actuation;

KF

Kalman filter;

MA

main axis;

MME

maximum-modulus-error;

MPC

model predictive control;

MPRA

model predictive reference allocation;

MRC

modified repetitive controller;

QP

quadratic programm;

RA

redundant axis;

RC

repetitive controller;

RMSE

root-mean-square-error;

TCP

tool-center-point

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Received: 2021-11-20
Accepted: 2022-02-15
Published Online: 2022-07-02
Published in Print: 2022-07-26

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