9313222 Ulsoy The award is for the design and development of an experimental, modular, open-architecture machining system controller for prismatic and rotational parts that enhances part quality by an order of magnitude while sustaining high machining rates. The approach would enable integration of underutilized results of the prior work of various researchers as well as generating new results. The hypothesis of the research is that information embedded in the control-loop error signals can be effectively used to improve part quality and machining system performance. A hierarchical controller structure is proposed consisting of compensators at the machine tool servo, process, and part inspection levels. Intelligent integration of hardware and software components of the controller is proposed here by combining expertise in machine tools, machining processes, sensors, control theory, software architecture, and real-time computing. The hierarchical, open-architecture controller is expected to have a major impact on manufacturing practice and research. Potential benefits for industrial users include reduction of part manufacturing cycle times, reduction of indirect inspection costs, controller improvement costs, and the cost of using sensors. Implementation of future machining research results would also be facilitated by the availability of such a controller.
