복합시스템설계및제어연구실 HySDC LABhysdc.hanyang.ac.kr/HySDC.pdf · 2016-05-28 · 복합시스템설계및제어연구실 (Hybrid System Design & Control Laboratory

복합시스템 설계 및 제어 연구실(Hybrid System Design & Control Laboratory HySDC Lab )

HySDC LAB복합시스템 설계및제어 연구실

지도교수 : 정 성 종 (Sung-Chong Chung)1979, 한양대학교 공과대학 기계공학과 (B.S.)

(Hybrid System Design & Control Laboratory, HySDC Lab. )

교육 및 연구 목표

1981, KAIST 기계공학과 (M.S.)1987, KAIST 기계공학과 (Ph. D.)

교육 및 연구 목표

첨단기계장비, 로봇, 자동차 등 기계 전자기 비전 기술 등이 복합된 기계시스템의 고속화, 정밀화자동화 기술 개발을 위해 CAD/CAM, 정밀공학, MECHATRONICS 분야의 기술을 선도한다.

연락처연락처

전 화: 02-2220-0444, 02-2296-2750이메일: [email protected], 홈페이지 : http://hysdc.hanyang.ac.kr실험실: M-102 M-103 (공업센터 1층) A-217(공업센터별관 2층)실험실: M 102, M 103 (공업센터 1층), A 217(공업센터별관 2층)

수상 경력

International Journal of Machine Tools and Manufacture (Editorial Board Member)미국생산공학회 (SME/NAMRI) 우수논문상 (2000년 5월)대한기계학회 효석학술상 (2003년 11월)한국CAD/CAM학회 CAD소프트웨어개발 은상 (2004년 2월)한국CAD/CAM학회 CAD소프트웨어개발 대상 [정보통신부장관상] (2005년 1월)

Hybrid System Design and Control Lab.

한국 학회 웨어개발 대상 [정 통신부장관상] ( 월)Who’s Who in the World; Who’s Who in Science and Engineering; Who’s Who in Finance and Industry, etc.

첨단기계장비, 로봇, 자동차 등 복합시스템의 고속화, 정밀화, 자동화 기술개발을 위해CAD/CAM, 정밀공학, MECHATRONICS 분야의 Integrated Design 기술을 연구한다.


Integrated Design for High Performance Servos (1/2)서보 시스템 기계요소 규명법 서보서보 시스템시스템 기계요소기계요소 규명규명 결과결과서보 시스템 기계요소 규명법 서보서보 시스템시스템 기계요소기계요소 규명규명 결과결과

90

100

110

de (d

B)

F .R .F .

Estim ated T F

70

80

90

Mag

nitu

-90

0

g) F .R .F .

Estim ated T.F .

101 102 103 104-450

-360

-270

-180

90

Pha

se (d

eg

E stim ated T.F .

Frequency (rad/sec)서보 시스템 정적오차(pitch error) 보상

0.020 0.020보상전위치오차 보상후위치오차

0 005

0.010

0.015

h er

ror (

mm

)

0 005

0.010

0.015

h er

ror (

mm

)

0 50 100 150 200 250-0.005

0

0.005

Pitc

0 50 100 150 200 250-0.005

0

0.005

Pitc

h


Position (mm)0 50 100 150 200 250

Position (mm)

서보 시스템 실시간 제어블록 구성도

Integrated Design for High Performance Servos (2/2)

서보 시스템 실시간 제어블록 구성도

-K-

FFCGain

Positinon Command Torque

cFrictionX.c

danipcie.ccYoiCounterNew.c

X-axis Plant

Torref

Terminator

Saturation

PosErr

PID Controller

Mode

Interpolator

Friction compensator

-K-

FBCgainTorque input

Velocity Torque

command

1

X-AxisTorque

Position

VelocityPID ControllerXc

Yc

Circualr Motion Generator

cCircleCommand.c

cPID SI XP cSwitch

Disturbance observer

feedbackcPID_SI_XP.c

서보 시스템 통합설계 결과

0

0.02 (mm)90

120 0

0.02 (mm)90

120

서보 시스템 통합설계 결과

PID only0.04

0.06일반서보시스템 통합설계된서보시스템

-0.04

-0.02 30150

180 0

-0.04

-0.02 30150

180 0

-0 02

0

0.02

PID+DOB

PID+Friction comp.Integrated design

210

240270

300

330 210

240270

300

330

-0.06

-0.04

-0.02

Ti ( )9 9.5 10 10.5 11 11.5 12

PID DOB


270 270Time (sec)

Fuzzy Logic Control of Shaft Straightening Machines (1/2)

QQ S l

servovalve & cylinder

controller

sAp

33점점 굽힘굽힘 공정공정 모델모델

Permanent Deflection

Punch Stroke Control SystemShaft Straightening Machine

QinQout Servovalve

LoadMotor

D Fi xv QL -+

controller

P 3-Point-Bending

Cal. ofCal. of

+

-)(sGc 1s

Ksvsv qK sVK

A

et

c

p

4P M S

M MS

F Fk k

Springback

LoadCell Encoder

ServoAmplifier

PLC

OUT IN

Cal. ofCal. of

Permanent Deflection Observer

0k0kFP 0 0k k

LVDT

Anvil

AMP & A/D DIO D/AAMP & A/D

Observer

DIO D/A

Controller

MICRO COMPUTERDatabase

F

x xL


Multi step Straightening Process

Fuzzy Logic Control of Shaft Straightening Machines (2/2)

Supporting condition - symmetric

DeflectionLimits

MaximumDeflection Value

ChangeRatios

D i d P t

DATABASEMODULE

CES

S

LE

영구변형량 결정방법

Straightening point - maximum deflection point

Multi-step Straightening Process

sy et c Straightening direction 2nd

Deflection ValueMaximum

Deflection Point

Deflection Value

DeflectionPattern

StraighteningPoint

Desired PermanentDeflection

SupportingCondition

St i ht i ND

ING

PR

OC

RIN

G M

OD

UL

2

2 1 21

12

1 22 2 12

11 22 21 12D

y yy y y y

p Desired permanent deflection

F1 F2

1 2

y21D.y11D

.

12

2nd Direction StraighteningDirection

CompensationFUZZY SELF-

MULTI-STEP STRAIGHTENING MODULE

3-PO

INT-

BE

MEA

SUR

MaximumDirection

Anvil A Anvil BLVDT1 LVDT2

d2 y12.d d2y22

.d

3

CompensationValue

FUZZY SELFLEARING MODULE

(k)Fuzzy Self-learning Control Algorithm

Number ofstraightening cycle 1 2 3 4 5 6 7 Average

PerformanceIndex

Rule TableFuzzifierError

e(k)

c(k)

y(k)

e(k)^

c(k)

+

+Rule Modifier v(k-d)^ r(k)

u(k-d)^

Straightening Results of Rack Bars

straightening cycle

Number of items 13 15 25 16 7 2 1 3.0 cycles

Average time requiredfor straightening

7 13 20 27 33 38 45 19.9sec

DF

3-Point-BendingProcess desired permanent

Multi-StepStraightening

yd(k)

yd(k+1)y(k)

+-

change ratios

Database

u(k+1)^

u(k+1)FuzzyInference

yd(k) + +


for straightening pdefletion

yd(k+1)change ratios

e 기반 사출금형 설계/제조 자동화 시스템

Pre-&PostProcessor

Web-based Collaborative System for Design and Manufacture

e-기반 사출금형 설계/제조 자동화 시스템

금형업체와 사출업체가 대부분 지역적으로 분산된 환경에 놓여 있기때문에 설계 및 제작상의 문제점 수정을 위해 많은 비용과 시간이 소모되며 설계 변경에 대한 빠른 대응이어렵다.

이를 해결하기 위해 네트워크 기술

DesignerGroup

InternetCMM

Inspector

Integrated Server

DMIS

Client

이를 해결하기 위해 네트워크 기술을 이용한 협동과 여기에서 발생하는문제점을 해결하기 위한 네트워크 기반의 협동 설계에 대한 연구를 진행한다

Native File TranslatorInternet ComputingEnvironment

...

...

한다. DMIS TranslatorApplication Server

Any CAD SystemInternet

Web Server

Native

Geometry, Topology, Material, Dimensions

Data Viewer

Designer

InspectorGroup

ManufacturerGroup

NativeFile

Real-time Multi-viewing Design & Dimension VerificationWeb based Intelligent CMM

3D Modeling Kernel Handling Real-time Collaboration Dimension & Draft Verification

Tolerances, Assembled structure Designer


Web-based Intelligent CMM CAD Data Interface

Dimension & Draft Verification Markup & Annotation

웹기반 치수 검증 시스템

e-based Collaborative CAD/CAM System웹기반 3D 형상 표현 시스템 웹기반 치수 검증 시스템

A

B

웹기반 3D 형상 표현 시스템

웹기반웹기반 협업검증협업검증 시스템시스템 구성구성

C

D

E

F

90-90

0

3

1

2

90

웹기반 구배 해석 검증 시스템협동 설계를 위한 마크업 기능 협업시스템협업시스템 구조구조


웹기반 구배 해석 검증 시스템협동 설계를 위한 마크업 기능 협업시스템협업시스템 구조구조

Precision 3D Measurement RobotLayout 머신 자동제어기 구성 Layout 머신 사용자 인터페이스Layout 머신 자동제어기 구성

Position, Velocity commmand

PC - MMIJoy-stick

I l

Layout 머신 사용자 인터페이스

Controller

monitoring

InterpolatorGenerate path

- Linear- Circular- Spline

Digital controllerF db k t l

InterfaceCurrent

controller

current

position, velocity feedback

VoltageFeedback control- Position control- Velocity control

Acc&Dec control- Trapezoid profile- S-curve profile

A/D D/ADI/O

Counter

Motor

Layout 머신의 자동/수동 측정 실험

자동 측정x

yLeqK L

eqK

Layout 머신 모드해석

수동 측정자동 측정

(NC)Beam elementeqK

eqK z

0.5Mode shape : x20 / f 7

-120

-100 33.43 169.28242.65

394.14

RECEPTANCE

수동 측정

(Joystick)

1

-0.5

0

Y

1st Mode shape2nd Mode shape3th Mode shape

240

-220

-200

-180

-160

-140

Mag

nitu

de(m

/N) [

dB]


0 0.5 1 1.5 2-1

Arm Coordinate[m]101 102 103

-240

Frequency[Hz]

Reverse Design / Engineering for CAD/CAM Reverse Engineering

Reverse Engineering• 점 데이터 측정• 기하학적 곡면 모델링• NC가공 코드 생성

계

• 상업용 CAD와 연계

Acquisition Measured data

CAD Interface

Surface Inspection Fitting, Fairing

Mean Value : 17.9mStandard Deviation : 12 1 mError distribution for inspection region ‘A’ : Eave = 7 2 m

Interface with a commercial CAD/CAM system


Standard Deviation : 12.1 mError distribution for inspection region A Eave 7.2 mError distribution for inspection region ‘B’ : Eave = 7.2 m

Mona-Lisa (painting) Venus (sculpture)

3D Reconstruction for CAD Interface Mona-Lisa (painting) Venus (sculpture)

Golden-Gate-Bridge (photograph)

Reconstructed 3D CAD File


3D Reconstruction for CAD/CAM

Original image Result of 3D

Visualized 3D CAD model onOriginal image

(photograph)

Result of 3D reconstruction

model on Power-Mill


Generation of tool-path (Power-Mill) Result of high-speed-machining (Mold) Injection molded part

Automatic Boundary Recognition for 2.5D CAD/CAM

Case Studies Generation of NURBS curves

NURBS curve equation

Case Studies

(1)NURBS curve equation

Original Image Recognized Boundary Curves

( )


Fitted NURBSFitted NURBS Curves

(2)



Crack-free Glass Micro-Engraving linked with 2.5D CAD/CAM

IGES translation

CAD Model on CATIAMachining Simulation on PowerMill

translation

CAD Model on CATIA

2.5D Embossed Result


CAD Model on PowerMill Machining on the Glass on the Glass

Machine Vision for 2D & 3D Measurement and RecognitionActive Stereo Vision의 응용분야Active Stereo Vision Active Stereo Vision의 응용분야Active Stereo Vision

Sojourner - the Pathfinder flight roverLeft Image Right Image

Rocky 7- a next generation prototype for the 2003 mission with stereo vision

3D plot of computed disparity map

Multilevel Thresholding Algorithm for Inspection of Ball Grid Array

20.00

25.00

30.00

35.00

40.00

epth

(mm

)

Proposed

NCC

ProposedBGA Source Otsu Kapur

0.00

5.00

10.00

15.00

Measured points

De NCC

SSD

Reference


Comparison of depth profile in area AComparison of depth profile in area A Binocular parallel axis stereoBinocular parallel axis stereo

Machine Vision for 3D Micro-MeasurementMachine Vision System Shape form Focus System 가공된 구멍의 위치 및 확대 오차

CCDcamera

Machine Vision System Shape form Focus System...1 2 10 11

가공된 구멍의 위치 및 확대 오차

Zoom lens

CCD camera

Coaxial

LED light

Stepnumber

Zoomlens

4

SeatN=3

N=n

Raw and edge detected images

Linear scale

Coaxialhalogen light

N=3

Focusedobject plane

45 oN=n

z

N=0N=1N=2

Servo motor

Lightsource

N=0N=1N=2

Movingresolution

Referenceplane

d미소드릴링시 버의 3차원 형상 측정

Hole No. 1 2 3 4 5 6

Diametral error [um] 7.42 7.51 7.59 10.01 8.02 7.88

Location error [um] 22.58 30.33 28.28 40.63 13.76 33.03

Burr Height

[um]

Max Height Circle Square Triangle

195.09 185.12~195.09 138.37~148.63 88.29~103.68

Burr Width

[ ]

Burr Width A Burr Width B Burr Width C Burr Width D

Location degree [° ] 226 292 271 184 296 121

Hole No. 7 8 9 10 11 Mean

Diametral error [um] 9.92 8.01 10.50 9.68 7.75 8.57

Location error [um] 15.29 11.77 13.97 15.54 24.24 22.67

Location degree [° ] 69 70 103 91 97


[um] 292.25 144.23 133.65 162.02Location degree [ ] 69 70 103 91 97 -

Circumferential dir

Active Machine Vision for 3D Topography

밸밸브브마마

Circumferential dir.Radial dir.

6

Measuring surface

Z dir. Isometric Plot of the worn valveIsometric Plot of the worn valve

Determine

마멸 분석 시스템의 흐름도

멸멸1041.6

rect

ion

(㎛)

600

800

6

92

Image Acquisition

DetermineMeasurement

Conditions

n=0

1388.80Radial direction (㎛)

Circ

umfe

rent

ial d

ir

200 400 600 800 1000 1200

400

200

dSFFn=n+1

시시트트

2527.5

Z dir.

Circumferential dir. n = nf

Compute FMIs at (i j)

Yes

NoIsometric Plot of the worn seatIsometric Plot of the worn seat

마마멸멸

1041.6

on (㎛

) 800

20 Measuring surfaceRadial dir.

Compute FMIs at (i,j)

Estimate d*Compute 3DTopography

1388.80Radial direction (㎛)

Circ

umfe

rent

ial d

irect

i

200 400 600 800 1000 1200

600

400

200

Wear Analysis


( )

Realtime 6-DOF Laser Measurement System for Precision Servos

다자유도 초정밀측정시스템

모든 이송체의 운동오차= 3개의 병진운동 오차+ 3개의 회전운동 오차

길이측정오차 : 10nm/10m각도측정오차 : 0.2arcsec/10m

y x

Laser HeadBB

Optical System of 6DOF Error Measurement

PD2

z

BS

BS

BB

QPD3BS

ExpansionLens set

BB

L2

BS

L1

Arithmetic Position Sensing Unit

Error Generating Mechanism

PBS

PBS

BS

PD1

PD4

Reference RR

BS

QPD1QPD2

BS

Polarizer

BB

L+ L /4 Plate

g

PD3 /2 Plate

S l i d e

RR1MirrorRR2

D

RR3

Direction of travel

PBS


D

Active Magnetic Bearing Systems

Data Acquisition SystemCurrentSSensor

Power Amp.Sensor Amp. Oscilloscope

AMB System

+Digital/Analog

+

DSP(TMS320C)

g gPID Controller

S h ti Di f A ti M ti B i S t

PC


Schematic Diagram of Active Magnetic Bearing Systems

Realtime Thermal Error Compensator for Highspeed Machining Centers

열변형 오차 모델링 열변형 오차 자동제어기 의 구성도열변형 오차 모델링

Spindlemotor

열변형 오차 자동제어기 의 구성도

Spindle baseSpindle

Slant column

mode1

d 2

mode3

mode5

mode429

28

6

30

19

Colume base

mode2

17

Bending mode : 2, 4 Expansion mode : 1, 3, 5

50

odel

( m

)

열변형 오차 보상제어 실험 결과

0 50 100 150 200 250 300-50

0

Con

stru

ct m

o

expsimerr

100

보상전가공표면 보상후가공표면

0 100 200 300 400 500 600 700 800 900-50

0

50

Ver

ify m

odel

( m

) expsimerr


time(min)

Cutting Condition Monitoring and Adaptive Control SystemCutting Condition Monitoring and Adaptive Control System

PMC InterfaceControlSignal

Expert SystemData Processing Decision Rules

CNC

� Fuzzy Logic

� Adaptive Rules

� Knowledge Base

� Time Domain

� Filtering

� Frequency Domain

� Learning

� Diagnosis

� Forecasting

Force RegulationNeural Network Adaptive

ControllerIsIwIvIu

CurrentObserver

Torque

DataAcquisition

Tool WearChatter

Over LoadChi F ti

…

…

…

Update Cutting Conditions

or

FxFyF Chip Formation

Tool Breakage…

Sensor Fusion

or Stop/Alarm

Fz


SensorlessSensorless Monitoring Monitoring and Adaptive Control Systemand Adaptive Control System

Dynamometer(1) Estimation of Depth of Cuts

(3) Rapid Calibration(2) Cutting Force Estimaiton

Depth of CutsDepth of Cuts

M

easu

rmen

t

RrR

aRrR

Cutting Mechanism

CuttingProcess

FORCEyx FF

CuttingProcess

Force Estimation

M

Tool

orkp

iece

s

aR

21 rrKS Processtz FF Servo

System

atio

n

Wo

Cur

rent

s

szyx IIII

FeedrateSpindle Speed Feedrate

Spindle Speed App

lica

Robust Control

Robust ControlMonitoring ...

(4) Intelligent Mechatronic System


( ) g y

Documents

복합시스템설계및제어연구실 HySDC LABhysdc.hanyang.ac.kr/HySDC.pdf · 2016-05-28 · 복합시스템설계및제어연구실 (Hybrid System Design & Control Laboratory