The utilization of micro-scale technologies is limited by the speed of their manufacture. Micro-milling is one particular technology used to manufacture micro-scale parts which could benefit extensively from an increase in throughput. Micro-milling involves a rotating cutter slightly thicker than a human hair removing material while spinning at speeds often over one hundred thousand revolutions per minute. An obvious solution to the throughput bottleneck is to move current micro-mills faster using existing technology; however, simply increasing the operational speed of existing micro-mills will lead to vibration and trajectory following problems. If a micro-mill cannot be positioned precisely, then part tolerances cannot be maintained. Thus any increase in throughput would be counterproductive in terms of overall performance. This dissertation presents techniques to improve the performance of micro-mills, as well as other flexible machines. Theses improvements are possible through the utilization of the vibration suppression scheme of input shaping. By thoughtfully altering the commands sent to flexible systems, their vibration can be significantly reduced. Input shaping was effectively applied to an existing micro-mill, which improved part tolerances and increased operational speed. However, at extremely high speeds, traditional input shaping is not effective at following complicated trajectories. Therefore, new input shaping techniques were developed specifically for trajectory tracking of extremely fast motions on micro-mills and other flexible systems. Often machines cannot achieve these high speeds while maintaining their accuracy because of the mechanical design of the machines themselves. If the mechanical design of micro-mills and other machines consider flexible and lightweight design alternatives that utilize input shaping for vibration suppression instead of stiff and heavy designs, then faster machine motion will be possible. By considering input shaped flexible systems as part of traditional mechanical design processes, these flexible solutions allow vast performance improvement. Specifically, embodiment design can be improved through consideration of input shaping performance requirements. Through these advancements, this dissertation improves the design, control, and performance of micro-mills and other flexible machines.

The Hopping Rotochute is a promising micro vehicle with the capability of exploring rough and complex terrains with minimum energy consumption. While it is able to fly over obstacles via thrust produced by its coaxial rotor, its physical architecture, inspired from a "Weebles Wooble," provides re-orientation wherever it hits the ground. Therefore, this aerial and ground vehicle represents a potential hybrid vehicle capable of reconnaissance and surveillance missions in complex environments. The most recent version of the Hopping Rotochute is manually controlled to follow a trajectory. The control commands, listed in a file prior to the particular mission, are executed exactly as defined, like a "batch job," regardless of the uncertain external events. This control scheme is likely to cause great deviations from the route. Consequently, the vehicle may finish the mission very far away from the desired end point. However, if a vehicle is capable of receiving the control commands during a mission, "interactive processing" can be realized and efficient path tracking would be achieved. Hence, the development of the Hopping Rotochute that follows a trajectory autonomously reveals the foundation of this thesis. Two control approaches inspired the proposed methodology for developing an autonomous trajectory-following algorithm. The first approach is rule-based control that enables decision making through conditional statements. In this thesis, rule-based control is used to select a target point for a particular hop based on the existence of an obstacle and/or wind in the environment. The second approach is model predictive control employed to predict future outputs from hop performance models. In other words, this technique approaches the problem by providing intelligence pertaining to how a particular hop will end up before being attempted. Hence, the optimum control commands are selected based on the predicted performance of a particular hop. This research demonstrates that the autonomous Hopping Rotochute can be realized by rule-based control embedded with some performance models. In the assumption of known boundaries such as wall and ceiling information, this study has two aims: (1) to avoid obstacles by creating a smaller operational volume inside the real boundaries so that the vehicle is restricted from exiting the operational volume and no violation occurs within the real boundaries; (2) to estimate the wind by previous hops to select the next hopping point with respect to the estimated wind information. Based on the developed methodology, simulations are conducted for four different scenarios in the existence of obstacles and/or wind, and the results of the simulations are analyzed. Finally, based on the statistics of simulation results, the effectiveness of the proposed methodology is discussed.

An Over-Actuated (OA) vehicle is a system that presents more control variables than degrees of freedom. Therefore, more than one configuration of the control input can drive the system to a desired state in the state space, and this redundancy can be exploited to fulfill other tasks or solve further problems. In particular, nowadays, challenges concerning electric vehicles regarding their autonomy and solutions to reduce energy consumption are becoming more and more attractive. OA vehicles, on this problem, offer the possibility of using the redundancy to choose the control input, among possible ones, so as to minimize energy consumption. In this regard, the research objective is to investigate different techniques to control in real-time an over-actuated autonomous driving vehicle to guarantee trajectory following and stability with the aim of minimizing energy consumption. The research project focuses on a vehicle able to drive and steer the four wheels (4WD, 4WS) independently. This work extends the contribution of previous theoretical energy-based research developed and provides a control algorithm that must work in real-time on a prototype vehicle (RCV-E) developed at the Integrated Transport Research Lab (ITRL) within KTH with the over-actuation investigated. To this end, the control algorithm has to balance the complexity of a multi-input system, the optimal allocation objectives, and the agility to run in real-time on the MicroAutoBox II - dSPACE system mounted on the vehicle. The solution proposed is a two-level controller which handles separately high and low-rate dynamics with an adequate level of complexity. The upper level is responsible for trajectory following and energy minimization. The allocation problem is solved in two steps. A Linear Time-Varying Model Predictive Controller (LTV-MPC) solves the trajectory-following problem and allocates the forces at the wheels considering the wheel energy losses due to longitudinal and lateral sliding. The second step re-allocates the longitudinal forces between the front and rear axles by considering each side of the vehicle independently to minimize energy loss in the motors. The lower level is responsible for transforming the forces at the wheels into torques and steering angles; it runs at a faster rate than the upper level to account for the high-frequency dynamics of the wheels. Last, the overall control strategy is tested in simulation concerning the trajectory-following and energy minimization performance. The real-time performance are assessed on MircoAutoBox II, the control interface used on the RCV-E. / Ett fordon med olika grad av över-aktuering är ett system som har fler kontrollvariabler än frihetsgrader. Därför kan mer än en konfiguration av styrinmatningen driva systemet till ett önskat tillstånd i tillståndsrummet, och denna redundans kan utnyttjas för att utföra andra uppgifter eller lösa andra problem. I synnerhet blir det i dag allt mer attraktivt med utmaningar som rör elfordon när det gäller deras självklörande drift och lösningar för att minska energiförbrukningen. Överaktuerat fordon ger möjlighet att använda redundansen för att välja en av de möjliga styrinmatningarna för att minimera energiförbrukningen. Forskningsmålet är att undersöka olika tekniker för att i realtid styra ett självkörande fordon som är överaktuerat för att garantera banföljning och stabilitet i syfte att minimera energiförbrukningen. Forskningsprojektet är inriktat på ett fordon som kan köra och styra de fyra hjulen (4WD, 4WS) självständigt. Detta arbete utökar bidraget från den tidigare teoretisk energi-baserade forskning som utvecklats genom att tillhandahålla en regleralgoritm som måste fungera i realtid på ett prototypfordon (RCV-E) som utvecklats vid ITRL inom KTH med den undersökta överaktueringen. I detta syfte måste regleralgoritmen balansera komplexiteten hos ett system med flera ingångar, målen för optimal tilldelning och smidigheten samt att fungera i realtid på MicroAutoBox II - dSPACE-systemet som är monterat på fordonet. Den föreslagna lösningen är en tvåstegsstyrning som hanterar dynamiken med hög och låg hastighet separat med en lämplig komplexitetsnivå. Den övre nivån ansvarar för banföljning och energiminimering. Tilldelningsproblemet löses i två steg. En LTV-MPC löser banföljningsproblemet och fördelar krafterna på hjulen med hänsyn till energiförlusterna på hjulen på grund av longitudinell och lateral glidning. I det andra steget omfördelas de längsgående krafterna mellan fram- och bakaxlarna genom att varje fordonssida beaktas oberoende av varandra för att minimera energiförlusterna i motorerna. Den lägre nivån ansvarar för att omvandla krafterna vid hjulen till vridmoment och styrvinklar; den körs i snabbare takt än den övre nivån för att ta hänsyn till hjulens högfrekventa dynamik. Slutligen testas den övergripande reglerstrategin i simulering med avseende på banföljning och energiminimering, och därefter på MircoAutoBox II monterad på RCV-E för att bedöma realtidsprestanda. / Un veicolo sovra-attuato è un sistema che presenta più variabili di controllo che gradi di libertà. Pertanto, più di una configurazione dell’ingresso di controllo può portare il sistema a uno stato desiderato nello spazio degli stati e questa ridondanza può essere sfruttata per svolgere altri compiti o risolvere ulteriori problemi. In particolare, al giorno d’oggi le sfide relative ai veicoli elettrici per quanto riguarda la loro autonomia e le soluzioni per ridurre il consumo energetico stanno diventando sempre più interessanti. I veicoli sovra-attuati, riguardo a questo problema, offrono la possibilità di utilizzare la ridondanza per scegliere l’ingresso di controllo, tra quelli possibili, che minimizza i consumi energetici. A questo proposito, l’obiettivo della ricerca è studiare diverse tecniche per controllare, in tempo reale, un veicolo a guida autonoma sovra-attuato per garantire l’inseguimento della traiettoria e la stabilità con l’obiettivo di minimizzare il consumo energetico. Questo studio si concentra su un veicolo in grado di guidare e sterzare le quattro ruote (4WD, 4WS) in modo indipendente, ed estende il contributo delle precedenti ricerche teoriche fornendo un algoritmo di controllo che deve funzionare in tempo reale su un prototipo di veicolo (RCV-E) sviluppato presso l’ITRL all’interno del KTH, che presenta la sovra-attuazione studiata. A tal fine, l’algoritmo di controllo deve bilanciare la complessità di un sistema a più ingressi, gli obiettivi di allocazione dell’azione di controllo ottimale e l’agilità di funzionamento in tempo reale sul sistema MicroAutoBox II - dSPACE montato sul veicolo. La soluzione proposta è un controllore a due livelli che gestisce separatamente le dinamiche ad alta e bassa frequenza. Il livello superiore è responsabile dell’inseguimento della traiettoria e della minimizzazione dell’energia. Il problema di allocazione viene risolto in due fasi. Un LTV-MPC risolve il problema dell’inseguimento della traiettoria e assegna le forze alle ruote tenendo conto delle perdite di energia agli pneumatici dovute al loro scorrimento longitudinale e laterale. Il secondo passo rialloca le forze longitudinali tra l’asse anteriore e quello posteriore considerando ciascun lato del veicolo in modo indipendente per minimizzare le perdite di energia nei motori. Il livello inferiore è responsabile della trasformazione delle forze alle ruote in coppia e angolo di sterzo; funziona a una più alta frequenza rispetto al livello superiore per tenere conto delle dinamiche veloci delle ruote. Infine, la strategia di controllo viene testata in simulazione per quanto riguarda le prestazioni di inseguimento della traiettoria e di minimizzazione dell’energia, e successivamente su MircoAutoBox II montato sull’RCV-E per valutare le prestazioni in tempo reale.