FPGA based control system for coupled highly dynamic axes in ultra-precision machining

The requirements for the dynamics of mechatronic axis systems used in production machines for high-end applications increase steadily. Additionally, in ultra-precision machining a high positioning accuracy is requested. One application example of highly dynamic axes is the manufacturing of non-rotationally symmetric optical components in a turning process. These optics or molding tools are manufactured by diamond machining to achieve a very low surface roughness. In the turning process the non-rotationally symmetric part of the work piece geometry requires a highly dynamic movement of the cutting tool. Especially structured geometries need very high frequencies for an economical process. The applied highly dynamic axes, either if integrated into the machine system or used as auxiliary axes, usually cannot be controlled with standard servo control systems. Especially piezo-based mechatronic systems require high bandwidth feedback control loops.