Optimization Design of Electromagnetic Actuator Applied as Fast Tool Servo

Fast tool servos (FTS) for single point diamond turning are widely employed for machine optical free-form surfaces. A FTS with a large stroke and a high bandwidth can increase the efficiency of a machine and complexity of a work-piece. In this paper, a FTS driven by a Maxwell electromagnetic actuator is developed to obtain a relatively large stroke and high bandwidth. In this study, a multi-objective optimization model is proposed based on the whole system by considering electromagnetic driving principles, kinematic model, and mechanical model. The proposed optimization model can be applied to solve the parameters of electromagnetic actuators with diverse application requirements. A sequential quadratic programming (SQP) algorithm is implemented to solve the problem. The optimization results are verified through both finite element analysis and experiments. The optimized FTS can produce 49.55 μm of full stroke with a frequency response of 3.2 kHz.

[1]  Dan Wu,et al.  Design of a Normal Stress Electromagnetic Fast Linear Actuator , 2010, IEEE Transactions on Magnetics.

[2]  Dong Min Kim,et al.  Optimal design of high precision XY-scanner with nanometer-level resolution and millimeter-level working range , 2009 .

[3]  Francisco Facchinei,et al.  On the Accurate Identification of Active Constraints , 1998, SIAM J. Optim..

[4]  W. Lee.  Prediction of microcutting force variation in ultra-precision machining , 1990 .

[5]  Gavin Chapman.  Ultra-precision Machining Systems ; an Enabling Technology for Perfect Surfaces , 2001 .

[6]  D. Trumper,et al.  Electromagnetically Driven UltraFast Tool Servo * , 2004 .

[7]  Jie Tian,et al.  Development of a fast tool servo in noncircular turning and its control , 2013 .

[8]  Qiang Liu,et al.  Multi-objective optimum design of fast tool servo based on improved differential evolution algorithm , 2011 .

[9]  Fengzhou Fang,et al.  System design of Maxwell force driving fast tool servos based on model analysis , 2014 .

[10]  Paul I. Ro,et al.  Magnetic servo levitation by sliding-mode control of nonaffine systems with algebraic input invertibility , 2005, IEEE Transactions on Industrial Electronics.

[11]  Lei Zhu,et al.  Development of a piezoelectrically actuated two-degree-of-freedom fast tool servo with decoupled motions for micro-/nanomachining , 2014 .

[12]  David L. Trumper,et al.  Ultrafast Tool Servos for Diamond Turning , 2005 .

[13]  Kai Cheng,et al.  Performance analysis and optimal design of fast tool servo used for machining microstructured surfaces , 2008 .

[14]  Sven Leyffer,et al.  Local Convergence of SQP Methods for Mathematical Programs with Equilibrium Constraints , 2006, SIAM J. Optim..

[15]  Xiaoqin Zhou,et al.  An improved adaptive feedforward cancellation for tool trajectory tracking in diamond turning of freeform optics , 2010, 2010 International Conference on Mechanic Automation and Control Engineering.

[16]  Zhenhua Xiong,et al.  Multi-objective topology optimization of compliant mechanism for fast tool servo , 2013, 2013 IEEE/ASME International Conference on Advanced Intelligent Mechatronics.

[17]  James F. Cuttino,et al.  Design and testing of a long-range, precision fast tool servo system for diamond turning , 2009 .

[18]  K. Schittkowski,et al.  Numerical comparison of nonlinear programming algorithms for structural optimization , 1994 .

[19]  Zhang Xiao-dong.  Design of Fast Tool Servo System Based on Magnetic Field Analysis , 2011 .

[20]  A. C. W. Grace.  Computer-aided control system design using optimization methods , 1989 .

[21]  Stuart T. Smith,et al.  Flexures: Elements of Elastic Mechanisms , 2000 .