Micro-lens fabrication by a long-stroke precision stage with switching control based on model response prediction

This paper develops an automatic control switching mechanism for a long-stroke precision stage intended to improve micro-lens fabrication. The stage consists of a piezoelectric transducer (PZT) stage and a motor stage that achieves centimeter-length travel distances with nanometer precision. We obtained the PZT stage model by experiments and then applied robust loop-shaping techniques to design two controllers: one gave fast responses and the other gave smooth responses. The two controllers were further simplified as robust proportional-integral-derivative (PID) controllers for hardware implementation. We then developed a control switching mechanism, based on model response prediction, to combine the merits of these two controllers. For the motor stage, we derived the stage model by experiments and designed a gain-scheduling controller that regulated the stage to move at the fastest speed for long travel distances until it was within the stroke of the PZT stage. The two stages were then combined with a double-loop control structure to provide a travel range of 10 cm with a precision of 1.23 nm. We implemented the designed control mechanisms and structures for experimental verification. The combined stage was also integrated with a two-photon polymerization (TPP) system to fabricate micro-lenses. The optical properties of the micro-lenses were evaluated to demonstrate the effectiveness of the proposed control in precision positioning for long travel distances.