Title: Smart Adaptronic Elements for Active Vibration Control (Slimme adaptronische elementen voor actieve trillingscontrole)
Other Titles: Smart Adaptronic Elements for Active Vibration Control
Authors: El-said, Mohamed; S0176137
Issue Date: 18-Jun-2013
Abstract: “Smart adaptronic Elements for Active Vibration Control”The induced vibrations of the high-precision machine limit the achievable required accuracy, such that constrain the performance improvement of the machine specifications. The main goal in the design of high precision machines is to enhance the accuracy while increasing productivity. These two design parameters are negatively coupled, as increasing the machine dynamics leads to more induced vibrations, especially with light structure machines. The induced vibrations will limit both the productivity and the accuracy of the machine. Within the scope of this thesis the main motivated question was “Could we improve the performance parameters like: precision, accuracy, productivity, and process stability; by design and produce smart adaptronic modules that will be integrated in a modular way within the high precision machines?”, This main question has been split to three main tasks (motivated questions to be answered) during the different research activities:1. When to use active vibration compensation adaptronic modules? 2. How to design the active vibration compensation adaptronic modules? And, 3. How to use the active adaptronic modules? The development of such adaptronic elements is not an easy task, as it requires an extensive knowledge for a number of different scientific fields, which will be discussed at the beginning, followed by a suggested design methodology to develop the adaptronic element. This design methodology is a series of integrated mechatronic concurrent design processes, which will be applied through the different chapters of this thesis. This design approach consists of three main concurrent design phases:· Identification of the adaptronic design problem.· Integrated design of the adaptronic elements within the mechatronic system.· Adaptronic concept validation.As a real practical applications for the different research activities in this thesis, two prototypes of developed adaptronic modules for active vibration compensation will be presented, namely the active 3DOF stiffness element A3DSE (patent no. WO 2011/041858 A2), and the adaptronic smart platform (European project HARCO (FP7-2010-NMP-ICT-FoF). The first prototype A3DSE module is ideally suited for implementing active vibration compensation in the mechanical structure of machine elements, especially struts, that are subjected to axial or/and bending disturbances. According to the used controller strategy, the A3DSE is an adaptronic device for active disturbance-rejection and active vibration-damping applications. The design idea of the A3DSE is based on the incorporation of three piezoelectric displacement actuators, each equipped with a collocated piezoelectric force sensor, which are assembled in an axisymmetrical configuration within a mechanical holding structure, using suitable mechanical and electronic interfaces. The second module is the adaptronic platform, which has been designed as an adaptronic modular interface between the spindle housing and the machine frame of high-precision milling machine FIDIA DL 155, to compensate the vibrations of the cutting tool, to improve the workpiece final surface quality and to reduce the lead time. The working principle is similar to the A3DSE, and is based on the incorporation of three powerful high voltage piezoelectric displacement actuators, each equipped with a collocated, piezoelectric force sensor in preloaded units, which are distributed in axisymmetrical configuration to connect the movable and the fixed flanges of milling machine’s spindle. The two developed prototypes will be experimentally tested, using suitable developed test benches, besides testing the first prototype of the adaptronic smart platform on the real high precision milling machine FIDIA DL 155. Active feedback control technique will be implemented in simple straightforward way to present it as an industrial product in the future work. For the A3DSE; the results proved the capability of compensating the axial and bending vibration of the active struts where the A3DSE module is integrated in. The dimension and maximum stroke of the used piezoelectric actuators represent the most important factors which determine the range of the compensated vibrations. The adaptronic smart platform module has been tested within developed test bench; the used control strategy depends on two different types of possible feedback measured signal. Firstly, using the collocated force feedback signals from the piezoelectric force sensors integrated in the actuating unit with the three piezoelectric actuators. Secondly, using the acceleration feedback signals from three accelerometers collocated with the three actuating units. The experimental results revealed that the two tilting modes could be successfully damped, and the stiffness at the low frequency range has been improved. The first prototype of the adaptronic smart platform has been mounted on the real FIDIA DL 155 high precision milling machine at the workshop of FIDIA s.p.a., San Mauro Torinese, Italy. The preliminary test results succeeded to compensate the tool-tip vibrations over a wide range of rotating speeds, up to 60% tool tip vibration suppression.For future work, this research is considered to be a road map covers the full path from identification to controller synthesis and validation, where provided an integrated mechatronic design approach for adaptronic modules. This integrated approach includes: the identification of the adaptronic design problem, the integration of the adaptronic modules within the mechatronic system, and the adaptronic concept validation. It is general methodology which is suitable to apply for different adaptronic modules depend on the case study.
Publication status: published
KU Leuven publication type: TH
Appears in Collections:Production Engineering, Machine Design and Automation (PMA) Section

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