Delta 3D printers can significantly increase throughput in additive manufacturing by enabling faster and more precise motion compared to conventional serial-axis 3D printers. Further improvements in motion speed and part quality can be realized through model-based feedforward vibration control, as demonstrated on serial-axis 3D printers. However, delta machines have not benefited from model-based controllers because of the difficulty in accurately modeling their position-dependent, coupled nonlinear dynamics. In this paper, we propose an efficient framework to obtain accurate linear parameter-varying models of delta 3D printers at any position within their workspace from a few frequency response measurements. We decompose the dynamics into two sub-models–(1) an experimentally-identified sub-model containing decoupled vibration dynamics; and (2) an analytically-derived sub-model containing coupled dynamics–which are combined into one using receptance coupling. We generalize the framework by extending the analytical model of (2) to account for differing mass profiles and dynamic models of the printer’s end-effector. Experiments demonstrate reasonably accurate predictions of the position-dependent dynamics of a commercial delta printer, augmented with a direct drive extruder, at various positions in its workspace. Note to Practitioners—This work aims to equip high-speed 3D printers, like delta machines, with model-based controllers to complement their speed with high-accuracy. Due to the coupled kinematic chains of the delta, complex control methodologies, some of which require real-time state measurements, are often used to achieve satisfactory control performance. Our modeling approach provides an efficient methodology for obtaining accurate linear models without the need for real-time measurements, thus enabling practitioners to design linear model-based feedforward controllers to achieve the high throughput and accuracy desired in additive manufacturing (AM). The models we develop in this paper are intended for use with feedforward vibration compensation methods, which can be beneficial for both industrial-scale AM machines that have high-powered servo motors and feedback controllers, as well as consumer-grade AM machines which use stepper motors in feedforward control.
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Numerical Assessment of Polynomial Nonlinear State-Space and Nonlinear-Mode Models for Near-Resonant Vibrations
In the present article, we follow up our recent work on the experimental assessment of two data-driven nonlinear system identification methodologies. The first methodology constructs a single nonlinear-mode model from periodic vibration data obtained under phase-controlled harmonic excitation. The second methodology constructs a state-space model with polynomial nonlinear terms from vibration data obtained under uncontrolled broadband random excitation. The conclusions drawn from our previous work (experimental) were limited by uncertainties inherent to the specimen, instrumentation, and signal processing. To avoid these uncertainties in the present work, we pursued a completely numerical approach based on synthetic measurement data obtained from simulated experiments. Three benchmarks are considered, which feature geometric, unilateral contact, and dry friction nonlinearity, respectively. As in our previous work, we assessed the prediction accuracy of the identified models with a focus on the regime near a particular resonance. This way, we confirmed our findings on the strengths and weaknesses of the two methodologies and derive several new findings: First, the state-space method struggles even for polynomial nonlinearities if the training data is chaotic. Second, the polynomial state-space models can reach high accuracy only in a rather limited range of vibration levels for systems with non-polynomial nonlinearities. Such cases demonstrate the sensitivity to training data inherent in the method, as model errors are inevitable here. Third, although the excitation does not perfectly isolate the nonlinear mode (exciter-structure interaction, uncontrolled higher harmonics, local instead of distributed excitation), the modal properties are identified with high accuracy.
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- Award ID(s):
- 1847130
- NSF-PAR ID:
- 10273517
- Date Published:
- Journal Name:
- Vibration
- Volume:
- 3
- Issue:
- 3
- ISSN:
- 2571-631X
- Page Range / eLocation ID:
- 320 to 342
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
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- Free Publicly Accessible Full Text
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Accepted Manuscript1.0
- Journal Article:
- https://doi.org/10.3390/vibration3030022
