Abstract
A digital twin-based optimization procedure is presented for an ultraprecision motion system with a flexible shaft connecting the motor to the (elastic) load, which is subject to both backlash and friction. The main contributions of the study are the design of the digital twin and its implementation, assuming a two-mass drive system. The procedure includes the virtual representation of mechanical and electrical components, non-linearities (backlash and friction), and the corresponding control system. A procedure for digital twin-based optimization is also presented, in which the maximum absolute position error is minimized while maintaining accuracy with no significant increase in the control effort. The optimal settings for the controller parameters and for the backlash peak amplitude, the backlash peak time, and the hysteresis amplitude are then determined, in order to guarantee an appropriate dynamic response in the presence of backlash and friction. The surface quality of certain manufactured components, such as hip and knee implants, depends on the smoothness and the accuracy of the real trajectory produced in the cutting process that is strongly influenced by the maximum position error. The simulations and experimental studies are presented using a real platform and two references for trajectory control, and a comparison of four digital twin-based optimization methods. The simulation study and the real-time experiments demonstrate the suitability of the digital twin-based optimization procedure and lay the foundations for the implementation of the proposed method at an industrial level.
Highlights
Nowadays, Industrial Cyber-Physical Systems (ICPS) lead to new production concepts that call for seamlessly integrated simulation models and different abstraction levels for increasing competitiveness [1]
The Digital Twin (DT) approach has emerged as a key concept for modeling, simulation, and optimization of ICPS
Recent studies have focused on ways to produce and to use big data in ICPS throughout the product lifecycle on the basis of a method for product design and manufacturing, service driven by the DT procedure [7]
Summary
Industrial Cyber-Physical Systems (ICPS) lead to new production concepts that call for seamlessly integrated simulation models and different abstraction levels for increasing competitiveness [1] In this context, the Digital Twin (DT) approach has emerged as a key concept for modeling, simulation, and optimization of ICPS. To the best of the authors’ knowledge, the key point is the design and implementation of the DT for the whole system, including the virtual representation of all mechanical and electrical components including the load, the main nonlinearities (backlash and friction), and the corresponding control system. Novel aspects of this work include simulation and experimental studies on a real platform using different trajectories for tracking control and the comparison of four methods in DT-based optimization in real experiments. The communication between Windows-based applications and real-time data, as well as the main parameters and variables can be accessed through the open CNC.
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