To further improve performances of machine systems, mechatronics offers some opportunities. Traditionally, mechatronics deals with how to integrate mechanics and electronics without a systematic approach. This thesis generalizes the concept of mechatronics into a new concept called hybrid intelligent machine system. A hybrid intelligent machine system is a system where two or more elements combine to play at least one of the roles such as sensor, actuator, or control mechanism, and contribute to the system behaviour. The common feature with the hybrid intelligent machine system is thus the presence of two or more entities responsible for the system behaviour with each having its different strength complementary to the others. The hybrid intelligent machine system is further viewed from the systems structure, behaviour, function, and principle, which has led to the distinction of (1) the hybrid actuation system, (2) the hybrid motion system (mechanism), and (3) the hybrid control system. <p>This thesis describes a comprehensive study on three hybrid intelligent machine systems. In the case of the hybrid actuation system, the study has developed a control method for the true hybrid actuation configuration in which the constant velocity motor is not mimicked by the servomotor which is treated in literature. In the case of the hybrid motion system, the study has resulted in a novel mechanism structure based on the compliant mechanism which allows the micro- and macro-motions to be integrated within a common framework. It should be noted that the existing designs in literature all take a serial structure for micro- and macro-motions. In the case of hybrid control system, a novel family of control laws is developed, which is primarily based on the iterative learning of the previous driving torque (as a feedforward part) and various feedback control laws. This new family of control laws is rooted in the computer-torque-control (CTC) law with an off-line learned torque in replacement of an analytically formulated torque in the forward part of the CTC law. This thesis also presents the verification of these novel developments by both simulation and experiments. Simulation studies are presented for the hybrid actuation system and the hybrid motion system while experimental studies are carried out for the hybrid control system.

To further improve performances of machine systems, mechatronics offers some opportunities. Traditionally, mechatronics deals with how to integrate mechanics and electronics without a systematic approach. This thesis generalizes the concept of mechatronics into a new concept called hybrid intelligent machine system. A hybrid intelligent machine system is a system where two or more elements combine to play at least one of the roles such as sensor, actuator, or control mechanism, and contribute to the system behaviour. The common feature with the hybrid intelligent machine system is thus the presence of two or more entities responsible for the system behaviour with each having its different strength complementary to the others. The hybrid intelligent machine system is further viewed from the systems structure, behaviour, function, and principle, which has led to the distinction of (1) the hybrid actuation system, (2) the hybrid motion system (mechanism), and (3) the hybrid control system. <p>This thesis describes a comprehensive study on three hybrid intelligent machine systems. In the case of the hybrid actuation system, the study has developed a control method for the true hybrid actuation configuration in which the constant velocity motor is not mimicked by the servomotor which is treated in literature. In the case of the hybrid motion system, the study has resulted in a novel mechanism structure based on the compliant mechanism which allows the micro- and macro-motions to be integrated within a common framework. It should be noted that the existing designs in literature all take a serial structure for micro- and macro-motions. In the case of hybrid control system, a novel family of control laws is developed, which is primarily based on the iterative learning of the previous driving torque (as a feedforward part) and various feedback control laws. This new family of control laws is rooted in the computer-torque-control (CTC) law with an off-line learned torque in replacement of an analytically formulated torque in the forward part of the CTC law. This thesis also presents the verification of these novel developments by both simulation and experiments. Simulation studies are presented for the hybrid actuation system and the hybrid motion system while experimental studies are carried out for the hybrid control system.

Com o presente projeto se pretende desenvolver um protótipo de máquina de usinagem para atender a fabricação de pequenos lotes (10~20 peças), Esta máquina terá características intermediárias entre as máquinas universal (manual) e de controle numérico (CN); conjugando as vantagens funcionais destas duas: alta eficiência e flexibilidade. A máquina projetada terá uma operação manual (trajetória), e seu posicionamento será servo-assistido. Entenda-se \"desenvolver\" como: a) Propor uma estratégia de usinagem; b) Propor uma configuração de máquina que funcione segundo esta estratégia; c) desenvolver um protótipo e; d) validar a estratégia e a configuração através de testes no protótipo. A estratégia de posicionamento aqui proposta, é baseada em um posicionamento manual, ou seja, o operador define livremente o movimento da ferramenta com relação à peça a se fabricar. Porém, um computador monitora constantemente a posição da ferramenta e não permite a entrada desta numa região, nomeada \"Região Proibida\"; que corresponde ao perfil da peça. A região proibida é definida diretamente a partir de um desenho de CAD, dispensando o uso de alguma ferramenta computacional de geração automática de trajetória de ferramenta. Deste modo, o operador realiza a usinagem de desbaste. O acabamento é realizado automaticamente pelo computador, que faz com que a ferramenta contorne o perfil da peça, uma vez que o operador envia um sinal de partida. Uma possível configuração de máquina para alcançar esta estratégia é apresentada. E consiste de uma mesa XY servo controlada, adaptada a uma furadeira de bancada, onde operador comanda o movimento da mesa mediante um joystick. Através de ensaios de usinagem, o trabalho demonstra a eficácia da estratégia proposta. / Present project aims the development of a machine tool prototype for attend the manufacturing of small lots (10~20 pieces), This machine will have characteristics intermediate between the universal and the numerical control (CN) machines. The desired machine conjugates the functional advantages of both types of machines: high efficiency and flexibility. The machine, thus designed, will have a manual operation (the tool path is defined by the operator), and its positioning will be servoassisted. Here, \"to develop\" includes: a) to propose a machining strategy; b) to propose an arrangement of machine that works according to this strategy; c) to develop a prototype and; d) to validate the strategy and the arrangement through tests with the prototype. The positioning strategy, is based on a manual positioning, i.e., the operator defines freely the motion of the tool with respect to the work piece. However, a computer monitores constantly the tool position, not permitting the entrance of it inside the area, here called \"prohibited region\", corresponding to the profile of the part to be machined. Outside that region, the computer enables operator to move the tool as he wants. The prohibited region is defined directly from a CAD draft, eliminating the necessity of any kind of computer tools for generating automatically the tool path. Thus, the operator executes the rough machining. The finishing path is executed automatically by the computer that makes the tool contour the profile of the part, according to the start-up command given by the operator. In the work, one possible arrangement of machine to achieve this strategy is presented. It consists of servo controlled XY table and adjusted to a bench drill in which, the operator commands the table motion by means a joy-stick. By machining tests, this work shows the efficiency of the proposed strategy.

Com o presente projeto se pretende desenvolver um protótipo de máquina de usinagem para atender a fabricação de pequenos lotes (10~20 peças), Esta máquina terá características intermediárias entre as máquinas universal (manual) e de controle numérico (CN); conjugando as vantagens funcionais destas duas: alta eficiência e flexibilidade. A máquina projetada terá uma operação manual (trajetória), e seu posicionamento será servo-assistido. Entenda-se \"desenvolver\" como: a) Propor uma estratégia de usinagem; b) Propor uma configuração de máquina que funcione segundo esta estratégia; c) desenvolver um protótipo e; d) validar a estratégia e a configuração através de testes no protótipo. A estratégia de posicionamento aqui proposta, é baseada em um posicionamento manual, ou seja, o operador define livremente o movimento da ferramenta com relação à peça a se fabricar. Porém, um computador monitora constantemente a posição da ferramenta e não permite a entrada desta numa região, nomeada \"Região Proibida\"; que corresponde ao perfil da peça. A região proibida é definida diretamente a partir de um desenho de CAD, dispensando o uso de alguma ferramenta computacional de geração automática de trajetória de ferramenta. Deste modo, o operador realiza a usinagem de desbaste. O acabamento é realizado automaticamente pelo computador, que faz com que a ferramenta contorne o perfil da peça, uma vez que o operador envia um sinal de partida. Uma possível configuração de máquina para alcançar esta estratégia é apresentada. E consiste de uma mesa XY servo controlada, adaptada a uma furadeira de bancada, onde operador comanda o movimento da mesa mediante um joystick. Através de ensaios de usinagem, o trabalho demonstra a eficácia da estratégia proposta. / Present project aims the development of a machine tool prototype for attend the manufacturing of small lots (10~20 pieces), This machine will have characteristics intermediate between the universal and the numerical control (CN) machines. The desired machine conjugates the functional advantages of both types of machines: high efficiency and flexibility. The machine, thus designed, will have a manual operation (the tool path is defined by the operator), and its positioning will be servoassisted. Here, \"to develop\" includes: a) to propose a machining strategy; b) to propose an arrangement of machine that works according to this strategy; c) to develop a prototype and; d) to validate the strategy and the arrangement through tests with the prototype. The positioning strategy, is based on a manual positioning, i.e., the operator defines freely the motion of the tool with respect to the work piece. However, a computer monitores constantly the tool position, not permitting the entrance of it inside the area, here called \"prohibited region\", corresponding to the profile of the part to be machined. Outside that region, the computer enables operator to move the tool as he wants. The prohibited region is defined directly from a CAD draft, eliminating the necessity of any kind of computer tools for generating automatically the tool path. Thus, the operator executes the rough machining. The finishing path is executed automatically by the computer that makes the tool contour the profile of the part, according to the start-up command given by the operator. In the work, one possible arrangement of machine to achieve this strategy is presented. It consists of servo controlled XY table and adjusted to a bench drill in which, the operator commands the table motion by means a joy-stick. By machining tests, this work shows the efficiency of the proposed strategy.