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Performance optimization of a fast tool servo for single-point diamond turning machines

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3 Author(s)
Cuttino, J.F. ; Metrol. & Precision Eng. Lab., Alabama Univ., Tuscaloosa, AL, USA ; Miller, A.C., Jr. ; Schinstock, D.E.

This paper describes a new, fast tool servo system designed for fabrication of nonrotationally symmetric components using single-point diamond turning machines. A prototype device, designed for flexible interfacing to typical machine tool controllers, is described, along with performance testing data of tilted flat and off-axis conic sections. Techniques for controlling the piezoelectric actuator to less than 1% error are discussed. The performance of a standard integral controller shows a significant error due to hysteresis in the actuator. The effects of the hysteresis were reduced by implementing two control schemes, an optimized PID controller and a technique that utilizes a dynamic compensator module in conjunction with the linear controller. The compensator samples the hysteretic voltage/displacement relationship in real time and modifies the effective gain accordingly. Experimental implementation results in an 80% reduction in the motion error caused by hysteresis, but peak-to-valley errors are limited by side effects from the compensation

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Mechatronics, IEEE/ASME Transactions on  (Volume:4 ,  Issue: 2 )