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1. Closed-Loop High-Fidelity Simulation Integrating Finite Element Modeling With Feedback Controls in Additive Manufacturing

   https://doi.org/10.1115/1.4048364  

   Wang, Dan ; Chen, Xu ( February 2021 , Journal of Dynamic Systems, Measurement, and Control)

   null (Ed.)

   Abstract A high-precision additive manufacturing (AM) process, powder bed fusion (PBF) has enabled unmatched agile manufacturing of a wide range of products from engine components to medical implants. While finite element modeling and closed-loop control have been identified key for predicting and engineering part qualities in PBF, existing results in each realm are developed in opposite computational architectures wildly different in time scale. This paper builds a first-instance closed-loop simulation framework by integrating high-fidelity finite element modeling with feedback controls originally developed for general mechatronics systems. By utilizing the output signals (e.g., melt pool width) retrieved from the finite element model (FEM) to update directly the control signals (e.g., laser power) sent to the model, the proposed closed-loop framework enables testing the limits of advanced controls in PBF and surveying the parameter space fully to generate more predictable part qualities. Along the course of formulating the framework, we verify the FEM by comparing its results with experimental and analytical solutions and then use the FEM to understand the melt-pool evolution induced by the in- and cross-layer thermomechanical interactions. From there, we build a repetitive control (RC) algorithm to attenuate variations of the melt pool width. 

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2. Distributed Temperature Control in Laser-Based Manufacturing

   https://doi.org/10.1115/1.4046154  

   Zheng, Chengjian ; Wen, John T. ; Diagne, Mamadou ( June 2020 , Journal of Dynamic Systems, Measurement, and Control)

   Abstract Temperature control is essential for regulating material properties in laser-based manufacturing. Motion and power of the scanning laser affect local temperature evolution, which in turn determines the a posteriori microstructure. This paper addresses the problem of adjusting the laser speed and power to achieve the desired values of key process parameters: cooling rate and melt pool size. The dynamics of a scanning laser system is modeled by a one-dimensional (1D) heat conduction equation, with laser power as the heat input and heat dissipation to the ambient. Since the model is 1D, length and size are essentially the same. We pose the problem as a regulation problem in the (moving) laser frame. The first step is to obtain the steady-state temperature distribution and the corresponding input based on the desired cooling rate and melt pool size. The controller adjusts the input around the steady-state feedforward based on the deviation of the measured temperature field from the steady-state distribution. We show that with suitably defined outputs, the system is strictly passive from the laser motion and power. To avoid over-reliance on the model, the steady-state laser speed and power are adaptively updated, resulting in an integral-like update law for the feedforward. Moreover, the heat transfer coefficient to the ambient may be uncertain, and can also be adaptively updated. The final form of the control law combines passive error temperature field feedback with adaptive feedforward and parameter estimation. The closed-loop asymptotical stability is shown using the Lyapunov arguments, and the controller performance is demonstrated in a simulation. 

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3. Control-Oriented Modeling and Repetitive Control in In-Layer and Cross-Layer Thermal Interactions in Selective Laser Sintering

   https://doi.org/10.1115/1.4046367  

   Wang, Dan ; Jiang, Tianyu ; Chen, Xu ( January 2021 , ASME Letters in Dynamic Systems and Control)

   null (Ed.)

   Abstract Although laser-based additive manufacturing (AM) has enabled unprecedented fabrication of complex parts directly from digital models, broader adoption of the technology remains challenged by insufficient reliability and in-process variations. In pursuit of assuring quality in the selective laser sintering (SLS) AM, this paper builds a modeling and control framework of the key thermodynamic interactions between the laser source and the materials to be processed. First, we develop a three-dimensional finite element simulation to understand the important features of the melt pool evolution for designing sensing and feedback algorithms. We explore how the temperature field is affected by hatch spacing and thermal properties that are temperature-dependent. Based on high-performance computer simulation and experimentation, we then validate the existence and effect of periodic disturbances induced by the repetitive in- and cross-layer thermomechanical interactions. From there, we identify the system model from the laser power to the melt pool width and build a repetitive control algorithm to greatly attenuate variations of the melt pool geometry. 

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4. Internal models in control, bioengineering, and neuroscience

   Bin.M. ; Huang, J. ; Isidori, A. ; Marconi, L. ; Mischiati, M. ; E. D. Sontag, E.D. ( October 2021 , Annual review of control robotics and autonomous systems)

   Cells respond to biochemical and physical internal as well as external signals. These signals can be broadly classified into two categories: (a) ``actionable'' or ``reference'' inputs that should elicit appropriate biological or physical responses such as gene expression or motility, and (b) ``disturbances'' or ``perturbations'' that should be ignored or actively filtered-out. These disturbances might be exogenous, such as binding of nonspecific ligands, or endogenous, such as variations in enzyme concentrations or gene copy numbers. In this context, the term robustness describes the capability to produce appropriate responses to reference inputs while at the same time being insensitive to disturbances. These two objectives often conflict with each other and require delicate design trade-offs. Indeed, natural biological systems use complicated and still poorly understood control strategies in order to finely balance the goals of responsiveness and robustness. A better understanding of such natural strategies remains an important scientific goal in itself and will play a role in the construction of synthetic circuits for therapeutic and biosensing applications. A prototype problem in robustly responding to inputs is that of ``robust tracking'', defined by the requirement that some designated internal quantity (for example, the level of expression of a reporter protein) should faithfully follow an input signal while being insensitive to an appropriate class of perturbations. Control theory predicts that a certain type of motif, called integral feedback, will help achieve this goal, and this motif is, in fact, a necessary feature of any system that exhibits robust tracking. Indeed, integral feedback has always been a key component of electrical and mechanical control systems, at least since the 18th century when James Watt employed the centrifugal governor to regulate steam engines. Motivated by this knowledge, biological engineers have proposed various designs for biomolecular integral feedback control mechanisms. However, practical and quantitatively predictable implementations have proved challenging, in part due to the difficulty in obtaining accurate models of transcription, translation, and resource competition in living cells, and the stochasticity inherent in cellular reactions. These challenges prevent first-principles rational design and parameter optimization. In this work, we exploit the versatility of an Escherichia coli cell-free transcription-translation (TXTL) to accurately design, model and then build, a synthetic biomolecular integral controller that precisely controls the expression of a target gene. To our knowledge, this is the first design of a functioning gene network that achieves the goal of making gene expression track an externally imposed reference level, achieves this goal even in the presence of disturbances, and whose performance quantitatively agrees with mathematical predictions. 

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5. Closed-Loop Simulation Integrating Finite Element Modeling With Feedback Controls in Powder Bed Fusion Additive Manufacturing

   https://doi.org/10.1115/ISFA2020-9611  

   Wang, Dan ; Chen, Xu ( September 2020 , Proceedings of ASME/ISCIE International Symposium on Flexible Automation)

   null (Ed.)

   Powder bed fusion (PBF) additive manufacturing has enabled unmatched agile manufacturing of a wide range of products from engine components to medical implants. While high-fidelity finite element modeling and feedback control have been identified key for predicting and engineering part qualities in PBF, existing results in each realm are developed in opposite computational architectures wildly different in time scale. Integrating both realms, this paper builds a first-instance closed-loop simulation framework by utilizing the output signals retrieved from the finite element model (FEM) to directly update the control signals sent to the model. The proposed closed-loop simulation enables testing the limits of advanced controls in PBF and surveying the parameter space fully to generate more predictable part qualities. Along the course of formulating the framework, we verify the FEM by comparing its results with experimental and analytical solutions and then use the FEM to understand the melt-pool evolution induced by the in-layer thermomechanical interactions. From there, we build a repetitive control algorithm to greatly attenuate variations of the melt pool width.

    

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