This thesis includes two topics. The first one is the architecture as well as the circuit implementation of an ultra low-power direct digital frequency synthesizer (DDFS) based on the straight line approximation. The second one is the circuit implementation of the low-power DDFS with an error compensation. The proposed approximation technique replaces the conventional ROM-based phase-to-amplitude conversion circuitry and the linear digital-to-analog converter with a nonlinear digital-to-analog converter (DAC) to realize a simple approximation of the sine function. Thus, the overall power dissipation as well as hardware complexity can be significantly reduced. Besides, by adding the error compensation, the spurious-free dynamic range (SFDR) of the synthesized output signal can be raised drastically.

Recently, multimedia applications are used widely in many embedded and portable systems, such as mobile phones, MP3 player and PDA, which require lower power consumption within high performance constraints. Therefore, power-efficient design becomes a more important objective in Very Large Scale Integration (VLSI) designs. Moreover, the multiplication unit always lies on the critical path and ultimately determines the performance and power consumption of arithmetic computing systems. To achieve high-performance and lengthen the battery lifetime, it is crucial to develop a multiplier with high-speed and low power consumption. In multimedia and digital signal processing (DSP) applications, many low-power approaches have been presented to lessen the power consumption of multipliers by eliminating spurious computations. Moreover, the multiplication operations adopted in these systems usually allow accuracy loss to output data so as to achieve more power savings. Based on these conceptions, this dissertation considers input data characteristics and the arithmetic features of multiplications in various multimedia and DSP applications and presents novel power reduction and truncation techniques to design power-efficient multipliers and high-accuracy fixed-width multipliers. In the design of array and tree multipliers, we first propose a low power pipelined truncated multiplier which dynamically deactivates non-effective circuitry based on input range. Moreover, the proposed multiplier offers a flexible tradeoff between power reduction and product precision. This reconfigurable characteristic is very useful to systems which have different requirement on output precision. Second, a low-power configurable Booth multiplier that supports several multiplication modes and eliminates the redundant computations of sign bits in multipliers as much as possible is developed. This architecture can efficaciously decrease the power consumption of systems which demand computing performance and flexibility simultaneously. Although these two kinds of low power multipliers can achieve significant power savings, the hardware complexity of error compensation circuits and error performance in terms of the mean error and mean-square error are unsuitable for many multimedia systems composed of a large amount of multiply-accumulate operations. To efficiently improve the accuracy with less hardware complexity, we propose new error compensation circuits for fixed-width tree multipliers and fixed-width modified Booth multipliers. In the design of floating-point multipliers, we propose a low power variable-latency floating-point multiplier which is compliant with IEEE 754-1985 and suitable for 3-D graphics and multimedia applications. In the architecture, the significand multiplier is first partitioned into the upper and lower parts. Next, an efficient prediction scheme for the carry bit, sticky bit, and the upper part of significand product is developed. While the correct prediction occurs, the computation of lower part of significand multiplier is shut down and therefore the floating-point multiplication can consume less power and be completed early. In the design of modular multipliers, we propose an efficient modular multiplication algorithm to devise a high performance and low power modular multiplier. The proposed algorithm adopts the quotient pipelining and superfluous-operation elimination technique to discard the data dependency and redundant computational cycles of radix-2 Montgomery¡¦s multiplication algorithm so that the operation speed, power dissipation, and energy consumption of modular multipliers can be significantly improved.

Additive manufacturing (AM) is a relatively new domain of manufacturing processes that began with its first patent in 1986. Since then, AM processes quickly grew in popularity due to their flexibility, superior efficiency in high mix low volume manufacturing settings, and lower material costs compared to more subtractive processes. Despite its increasing popularity, AM processes remain behind subtractive processes in terms of quality and the speed at which new technologies are integrated. Introducing Industry 4.0 technologies is an excellent opportunity to address the need for quality assurance tools for AM processes. First, the question of how the quality of additively manufactured parts can be increased to match parts created through subtractive processes must be asked. In this dissertation, two machine learning (ML) models are developed and utilized in a federated environment to mimic what one would see in a production setting. The proposed models increase AM part quality by (1) predicting the resulting geometry of an AM process and (2) compensating for geometric errors by altering the initial stereolithography (STL) file before slicing. In addition to performing geometric error prediction and compensation, the models were enhanced to be resilient to changes in geometry by training on segments of a 3D object rather than the whole object. Next, process parameters from fused-filament fabrication (FFF) processes were added to the ML models to add resilience process parameter variance. Lastly, the ML models were deployed in a federated environment created from three FFF 3D printers that collaboratively created a dataset for the ML models. Collectively, these works expand the research area created by AM, federated learning, and error compensation. This proposal addresses research gaps in the current literature by first setting the prediction and compensation resolution of voxel-based ML methods to a static 100 µm, thereby reducing the error associated with each voxel. Secondly, process parameters are introduced to the model, further increasing prediction and compensation accuracy compared to predicting on the geometry alone. Lastly, the models are deployed in a federated AM environment with multiple 3D printers acting as clients to reduce each client's time spent generating data while maintaining model performance. / Doctor of Philosophy / Additive manufacturing (AM) is a relatively new field where parts are created by extruding material to build a product in the desired shape. A key advantage of such a process is that it is more flexible than those subtractive processes, which remove material from a part. On the other hand, parts produced by AM processes generally have lower quality due to the very specific environments necessary to obtain high-quality parts. Because there is an increased desire to make customized parts (high mix) in small amounts (low volume), AM processes are seeing a rise in popularity, but there is still a need to improve the quality of these produced parts. Furthermore, these environments where AM is utilized generally have multiple 3D printers that manufacturers can leverage to create comprehensive datasets for model development. This dissertation uses machine learning (ML) to collect data from AM processes and reduce AM process errors. By comparing the process's input with the process's output, an ML model can estimate the result of the AM process, including potential defects. This dissertation addresses research gaps in current literature by reducing the error associated with converting the input and output 3D objects to voxels, using parameters to the AM process in the ML models, and using the ML models with 3D printers in a networked environment while forbidding sharing private data.

The primary barrier to the production of better machined parts is machine tool error. Present day applications are requiring closer machine part tolerances. The errors in dimensional part accuracy derive from the machine, in this case, a vertical two axis CNC lathe. A two axis vertical lathe can be utilized to produce a variety of parts ranging from cylindrical features to spherical features. A vertical lathe requires a spindle to rotate the work at speeds reaching 3000rpm, while simultaneously requiring the machine tool to be positioned in such a manner to remove material and produce an accurate part. For this to be possible, the machine tool must be precisely controlled in order to produce the correct contours on the part. There are many sources of errors to be considered in the two axis vertical lathe. Each axis of importance contains six degrees of freedom. The machine has linear displacement, angular, spindle thermal drift, straightness, parallelism, orthogonal, machine tool offset and roundness error. These error components must be measured in order to determine the resultant error. The characterization of the machine addresses thermal behavior and geometric errors. This thesis presents the approach of determining the machine tool errors and using these errors to transform the actual tool path closer to the nominal tool path via compensation schemes. One of these schemes uses a laser interferometer in conjunction with a homogenous transformation matrix to construct the compensated path for a circular arc, facing and turning. The other scheme uses a ball bar system to directly construct the compensated tool path for a circular arc. Test parts were created to verify the improvement of the part accuracy using the compensated tool paths.

No description available.

The thesis deals with a development and application of laser interferometer system for the online error calibration of CNC machine tool. The term „online“ means, that laser interferometer is permanently built in the machine tool. Therefore particular error measurements can be done in very short time period.

This thesis, for the first time in the literature, presents the effect of quadrature error compensation on the performance of a fully decoupled MEMS gyroscope and provides experimental data on the sources of quadrature error. Dedicated quadrature error cancellation electrodes operating with only differential DC potentials are designed. Gyroscopes with intentionally placed imperfections are fabricated with SOG based SOI process which provides higher yield and uniformity compared to SOG process. Tests show that the fully closed loop system with quadrature cancellation operates as expected. Gyroscope performance is improved up to 7.8 times for bias instability, 10 times for angle random walk (ARW) and 800 times for output offset with quadrature cancellation. The actual improvement is higher since some sensors cannot be operated without quadrature cancellation and they are not included in improvement calculations. The best obtained performance is bias instability of 0.39

In this thesis, several machining strategies to remove axially symmetric form error with small wavelength by Hydrodynamic Polishing process (abbreviated as HDP) were proposed. Three strategies were proposed progressively in the study so as to remove axially symmetric form error with small wavelength. The first and second tactics were based on a basic algorithm, say, directly solving of a set of simultaneous equations. In the first strategy, a set of simultaneous equations was constructed by relating the total machining action of each dwelling point to the corresponding initial error. Subsequently, a set of dwelling time was obtained by directly solving the simultaneous equations. The second strategy evaluates solutions in a similar way like the first one but more restrictions were concerned in solution evaluation. The third strategy is an optimal based method. A set of dwelling time was obtained by minimizing an objective function with given constraints. A series of computer simulations were conducted to estimate the residual error and examine the validity of the strategies. From the computer simulation, the first and second strategies were confronted with negative-time problem, so that merely limited improving of form precision was obtained. The proposed optimal strategy was shown to have high potential for improving the machining precision by the HDP process. Based on the proposed strategies, a better form precision of the work surface with small wavelength can be obtained.

Precision control of translational motion is vital for many CNC machine tools as the motion of the machinery affects the dimensional tolerance of the manufactured goods. However, the direct measurement along with the accurate motion control of machine usually requires relatively expensive sensors i.e. potentiometers, linear scales, laser interferometers. Hence, this study attempts to develop reference models utilizing low-cost sensors (i.e. rotary encoders) for accurate position estimation. First, an indirect measurement performance is investigated on a Timing Belt driven carriage by a DC Motor with a backlash included Gearbox head. An advanced interpolated technique is proposed to compensate the position errors while using indirect measurement to reduce the total cost. Then, a similar study was realized with a ball screw driven system. Next, a cable drum driven measurement technique is proposed to the machines which have long travel distance like plasma cutters. A test setup is proposed and manufactured to investigate the capstan drive systems. Finally, characteristics of Optical Mouse Sensors are investigated from different point of views and a test setup is proposed and manufactured to evaluate their performances in long terms. Beside all of these parts, motion control algorithms and motion control integrated circuits are designed and manufactured to realize experimental studies in a detailed manner.

Submitted by Maike Costa (maiksebas@gmail.com) on 2017-05-22T13:42:24Z No. of bitstreams: 1 arquivo total.pdf: 4721146 bytes, checksum: 62290d20efdd12371f2308dd6752ec65 (MD5) / Made available in DSpace on 2017-05-22T13:42:24Z (GMT). No. of bitstreams: 1 arquivo total.pdf: 4721146 bytes, checksum: 62290d20efdd12371f2308dd6752ec65 (MD5) Previous issue date: 2016-02-26 / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior - CAPES / The computer numerical control machine tools, or CNC machine tools, emerged due to the need of the aviation industry to produce increasingly complex and accurate parts. The retrofitting of machine tools is the modification of a traditional machine for a computer numerical control one. Due to the popularization of computers, electronic components decreased costs, Internet expansion and open source projects, the retrofitting has become increasingly widespread in industry as an option for the purchase of new machine tools with CNC included. The objective of this study was to implement the retrofit on a 3-axis machine from the Precision Engineering Laboratory of the Federal University of Paraíba. For this adaptation, the machine has been modified to use a kit with interface drivers from HobbyCNC and new stepper motors. After the retrofit, it used a 80-XL Laser system for measuring position errors. The tests were performed on each axis, commanding the machine to five positions and measuring the actual positions reached and, then, the same tests were carried out in reverse direction. With the measured results, the positioning errors, hysteresis, repeatability and accuracy calculated by ISO 230-2 standard. It was conducted other tests in compensating the previously measured errors on the Y axis. There was a significant improvement on the Y-axis accuracy after compensation. Also, angular errors tests were carried out, with the use of an electronic level Talyvel 5, along the axis Y. The results of the test were satisfactory and the retrofitting reached its expectations, providing the possibility of further research in the area of numerical control. / As máquinas-ferramentas com controle numérico computadorizado, ou máquinasferramentas CNC, surgiram devido à necessidade da indústria da aviação para produzir peças cada vez mais complexas e precisas. O retrofitting de máquina-ferramenta é a modificação de uma máquina tradicional para uma com controle numérico computadorizado. Devido à popularização dos computadores, diminuição de custos dos componentes eletrônicos, expansão da Internet e projetos de código aberto, o retrofitting tornou-se uma opção cada vez mais comum na indústria como alternativa para a compra de novas máquinas-ferramentas com CNC incluso. O objetivo deste estudo foi a implementação do retrofitting em uma máquina de 3 (três) eixos no Laboratório de Engenharia de Precisão da Universidade Federal da Paraíba. Para essa adaptação, a máquina foi modificada para utilizar um Kit com drivers de interface da HobbyCNC e novos motores de passo. Após o retrofitting, foi utilizado um sistema Laser XL-80 para medição dos erros de posicionamento. Os testes foram realizados, em cada eixo, comandando-se a máquina para 5 posições e medindo-se as posições reais atingidas e, depois, foram realizados os mesmos testes no sentido inverso. Com os resultados medidos, são calculados os erros de posicionamento, histerese, repetitividade e exatidão conforme a norma ISO 230-2. No eixo Y foi realizado outros testes com a compensação dos erros medidos anteriormente. Houve uma melhora significativa na exatidão do eixo Y após a compensação. Também foram realizados testes de erros angulares, com a utilização de um nível eletrônico Talyvel 5, ao longo do eixo Y. Os resultados obtidos no teste foram satisfatórios e o retrofitting atingiu suas expectativas, por proporcionar a possibilidade de realizar mais pesquisas, na área de Comando Numérico Computadorizado.