This application claims priority to Chinese Patent Application No. 202310751744.6 with a filing date of Jun. 25, 2023. The content of the aforementioned application, including any intervening amendments thereto, is incorporated herein by reference.
The present disclosure relates to a motion stage control system and method, and in particular, to a learning control system and method for a nano-precision motion stage, pertaining to the field of ultra-precision equipment manufacturing technology.
With the increasing demand for high yield and high quality in production, the performance requirements for ultra-precision equipment have become increasingly stringent. Taking ultra-precision wafer stage as an example, a shorter adjustment time for a motion stage to transition from an acceleration phase to a constant speed scanning phase leads to a higher chip yield per unit time. A lower motion error during the constant speed scanning phase indicates a smaller minimum feature size, leading to higher chip quality. The demanding requirements for control performance have forced the feedback control bandwidth to approach a first-order mechanical flexible mode. However, due to limitations in the mechanical processing technology, it is difficult to further improve the mechanical flexible mode, resulting in limited feedback control bandwidth and restricting further enhancement of control performance.
High-end CNC machine tools, assembly line robots, and other high-end manufacturing equipment, due to the repetitiveness of the motion process, often use iterative learning-based feedforward control methods to assist feedback control in overcoming the shortcomings of traditional feedback control. The basic idea is to learn from control quantities and control error information generated in previous motion processes to adjust control quantities required for current motion, gradually reducing motion errors through continuous learning. However, existing iterative learning control methods generally operate in the time domain, with learning gains typically being a high-dimensional matrix. The learning algorithms have high computational complexity, making it inconvenient for practical applications. Furthermore, the learning gains in iterative learning control are generally designed based on inverse models, requiring a complex and cumbersome modeling process. Data-driven methods estimate the inverse model by measuring data during the iteration process. However, the model estimation accuracy of the existing methods is sensitive to external disturbances and measurement noise, which can affect the final convergence performance.
To address the problem of limited control performance due to the sensitivity of model-based iterative learning control methods to external random noise and the inability of data-based iterative learning control methods to eliminate the impact of external repetitive disturbances on model estimation accuracy in existing ultra-precision equipment, the present disclosure provides a learning control system and method for a nano-precision motion stage, which can effectively suppress the influence of external noise and disturbances, and improve convergence performance. Moreover, the present disclosure requires less computation, achieves simple determination of learning gains and strong robustness, and is convenient for engineering applications.
To achieve the above objective, the present disclosure adopts the following technical solutions:
A learning control system for a nano-precision motion stage is provided, including a closed-loop feedback section Sfb and a feedforward section Sff.
The closed-loop feedback section Sfb includes a motion trajectory generator Cr, a feedback controller Cfb, a motion stage P, and a first Fourier transformer Cfft1. The motion trajectory generator Cr generates a desired motion trajectory r(t) The desired motion trajectory r(t) minus a position measurement signal yj(t) results in a motion error signal ej(t). The motion error signal ej(t) added to a feedforward signal uff,j(t) results in a feedback input signal efb,j(t). The feedback input signal efb,j(t) is input into the feedback controller Cfb to generate a feedback control signal ufb,j(t). The feedback control signal ufb,j(t) added to a disturbance signal dj(t) results in a total control signal uall,j(t). The total control signal uall,j(t) is input into the motion stage P to generate an actual position signal yp,j(t). The actual position signal yp,j(t) added to a measurement noise signal v (t) results in a position measurement signal yj(t). The position measurement signal yj(t) is transformed into a frequency domain position measurement signal γj(w) by the first Fourier transformer Cfft1.
The feedforward section Sff includes a second Fourier transformer Cfft2, a learning controller CICL, an iteration backward shift operator Cz, and a Fourier inverse transformer Cifft. The second Fourier transformer Cfft2 is configured to transform the motion error signal ej(t) into a frequency domain error signal ζj(w). The frequency domain error signal ζj(w) and a j-th frequency domain feedforward signal μff,j(w) are jointly input to the learning controller CILC to obtain a (j+1)-th frequency domain feedforward signal μff,j1(w). The (j+1)-th frequency domain feedforward signal μff,j+1(w) is input into the iteration backward shift operator Cz to generate the j-th frequency domain feedforward signal μff,j(w). The j-th frequency domain feedforward signal μff,j(w) is transformed into the feedforward signal uff,j(t) by the Fourier inverse transformer Cifft.
The subscript j represents an iteration experiment count, j≥1, t represents time, and w represents frequency.
In one embodiment, a learning control method for a nano-precision motion stage is provided. According to this method, a learning controller CILC is designed using a frequency domain iterative learning method, to determine an iteration relation of a (j+1)-th frequency domain feedforward signal μff,j+1(w) and a j-th frequency domain feedforward signal μff,j(w) with respect to a frequency domain error signal ζj(w). The learning control method includes the following steps:
represents a learning coefficient, and βj is determined as follows:
where β1≥1, χ represents a conditional function; χ=1 when (Ej)T Ej−1<0; otherwise, χ=0, Ej=[ej(0)ej(1)ej(2) . . . ej(N−1)]T, and N represents the number of sampling points; and
Compared to the prior art, the present disclosure has the following the beneficial effects: Traditional iterative learning control methods are sensitive to external noise and disturbances and have poor robustness, while the present disclosure provides a learning control system and method for a nano-precision motion stage from a frequency domain perspective. An adaptive mechanism is introduced in model-based learning control to mitigate the impact of external random noise, and a differential method is used in data-based learning control to estimate an inverse model, which can effectively suppress the influence of external noise and disturbances, thereby improving convergence performance. Motion errors can be significantly reduced through a finite number of iterations. Furthermore, the present disclosure requires less computation, and achieves simple determination of learning gains and strong robustness against external noise and disturbances. A frequency domain method is employed to calculate feedforward signals, resulting in lower modeling costs. Control quantities are updated in a fully data-driven manner, which achieves nanometer-level control accuracy, making it suitable for engineering applications.
The technical solutions in the embodiments of the present disclosure are clearly and completely described below with reference to the accompanying drawings in the embodiments of the present disclosure. Apparently, the described embodiments are merely a part rather than all of the embodiments of the present disclosure. All other embodiments derived from the embodiments in the present disclosure by a person of ordinary skill in the art without creative efforts should fall within the protection scope of the present disclosure.
As shown in
The closed-loop feedback section Sfb includes a motion trajectory generator Cr, a feedback controller Cfb, a motion stage P, and a first Fourier transformer Cfft1. The motion trajectory generator Cr generates a desired motion trajectory r(t) The desired motion trajectory r(t) minus a position measurement signal yj(t) results in a motion error signal ej(t). The motion error signal ej(t) added to a feedforward signal uff,j(t) results in a feedback input signal efb,j(t). The feedback input signal efb,j(t) is input into the feedback controller Cfb to generate a feedback control signal ufb,j(t). The feedback control signal ufb,j(t) added to a disturbance signal dj(t) results in a total control signal uall,j(t). The total control signal uall,j(t) is input into the motion stage P to generate an actual position signal yp,j(t). The actual position signal yp,j(t) added to a measurement noise signal vj(t) results in a position measurement signal yj(t). The position measurement signal yj(t) is transformed into a frequency domain position measurement signal γj(w) by the first Fourier transformer Cfft1.
The feedforward section Sff includes a second Fourier transformer Cfft2, a learning controller CILC, an iteration backward shift operator Cz, and a Fourier inverse transformer Cifft. The second Fourier transformer Cfft2 is configured to transform the motion error signal ej(t) into a frequency domain error signal ζj(w). The frequency domain error signal ζj(w) and a j-th frequency domain feedforward signal μff,j(w) are jointly input to the learning controller CILC to obtain a (j+1)-th frequency domain feedforward signal μff,j+1(w). The (j+1)-th frequency domain feedforward signal μff,j+1(w) is input into the iteration backward shift operator Cz to generate the j-th frequency domain feedforward signal μff,j(w). The j-th frequency domain feedforward signal μff,j (w) is transformed into the feedforward signal uff,j(t) by the Fourier inverse transformer Cifft.
The subscript j represents an iteration experiment count, j≥1, t represents time, and w represents frequency.
As shown in
In step 1, an iteration experiment count j is initialized as j=1, and the j-th frequency domain feedforward signal μff,j (w) is initialized to 0.
In step 2, the j-th frequency domain feedforward signal μff,j(w) is transformed into a feedforward signal uff,j(t) by a Fourier inverse transformer Cifft; a closed-loop feedback section Sfb is run to collect a motion error signal ej(t) and a frequency domain position measurement signal γj(w); the motion error signal ej(t) is transformed into the frequency domain error signal ζj(w) by a second Fourier transformer Cfft2; and when the motion error signal ej(t) meets a control error requirement or the iteration experiment count j reaches a set maximum value, iterations are stopped; otherwise, the following steps are performed.
In step 3, the (j+1)-th frequency domain feedforward signal μff,j+1 (w) is updated using a model-based approach:
μff,j+1(w)=μff,j(w)+ρjL(w)ζj(w)
where L(w) represents a learning gain,
represents a learning coefficient, and βj is determined as follows:
where β1≥1, χ represents a conditional function; χ=1 when (Ej)TEj−1<0; otherwise, χ=0, Ej=[ej(0)ej(1)ej(2) . . . ej(N−1)]T, and N represents the number of sampling points.
The learning gain L(w) is determined in the following manner:
When frequency domain models of the motion stage P and the feedback controller
where P(w) is the frequency domain model of the motion stage P and Cfb(w) is the frequency domain model of the feedback controller Cfb.
When the frequency domain models of the motion stage P and the feedback controller Cfb are unknown, L(w) is determined through frequency sweep before step 1: setting the feedforward signal uff,j(t) to zero, generating a white noise signal rn(t) by using the motion trajectory generator Cr, with a signal length of the white noise signal rn(t) being the same as the length of the desired motion trajectory r(t), and running the closed-loop feedback section Sfb to collect a frequency domain position measurement signal γn(w) under the white noise signal, where
and rn(w) is a frequency domain signal obtained after Fourier transformation of the white noise signal rn(t); and after L(w) is obtained, generating the desired motion trajectory r(t) using the motion trajectory generator Cr, and then performing step 1.
In step 4, the iteration experiment count j is incremented by 1 and step 2 is then performed.
Additionally, when frequency domain models of the motion stage P and/or the feedback controller Cfb are unknown and frequency sweep experiments are not feasible, the (j+1)-th frequency domain feedforward signal μff,j+1(w) can be updated using a data-based approach in step 3:
where 0<σj≤1, and r(w) is a frequency domain signal obtained after Fourier transformation of the desired motion trajectory r(t).
In this embodiment, the motion trajectory generator Cr is a 5th-order S-shaped motion trajectory generator. The desired motion trajectory r(t) generated by the motion stage P is as shown in
where s represents a Laplace operator, and by replacing s with iw (i is an imaginary unit), frequency domain models Cfb(w) and P(w) of the feedback controller Cfb and the motion stage P are obtained.
The measurement noise signal vj(t) is a white noise signal with a variance of 0.1×10−9 and a mean of 0. The disturbance signal dj(t) is a signal that is periodic with respect to an actual position signal yp,j(t), used to simulate disturbances such as cable force disturbances, actuator torque fluctuations, and other disturbing forces present in real scenarios.
A learning controller CILC is designed using a frequency domain iterative learning method to correct the feedforward signal uff,j(t) through iteration experiments, in order to gradually reduce the motion error signal ej(t), as detailed below:
In step 1, an iteration experiment count j is initialized as j=1, and the j-th frequency domain feedforward signal μff,j (w) is initialized to 0. In this case, the feedforward signal uff,j(t) is zero, the feedforward section Sff is inactive, and the learning control system consists of the closed-loop feedback section Sfb only.
In step 2, the j-th frequency domain feedforward signal μff,j(w) is transformed into a feedforward signal uff,j(t) by a Fourier inverse transformer Cifft; a closed-loop feedback section Sfb is run to collect a motion error signal ej(t) and a frequency domain position measurement signal yj(w); the motion error signal ej(t) is transformed into the frequency domain error signal ζj(w) by a second Fourier transformer Cfft2; and when the motion error signal ej(t) meets a control error requirement or the iteration experiment count j reaches a set maximum value, iterations are stopped; otherwise, the following steps are performed. In this embodiment, the maximum iteration count is set to 50.
In step 3, the (j+1)-th frequency domain feedforward signal μff,j+1(w) is updated using a model-based approach:
μff,j+1(w)=μff,j(w)+ρjL(w)ζj(w)
where L(w) represents a learning gain,
represents a learning coefficient, and βj is determined as follows:
where β1≥1, χ represents a conditional function; χ=1 when (Ej)T Ej−1<0; otherwise, χ=0, Ej=[ej(0)ej(1)ej(2) . . . ej(N−1)]T, and N represents the number of sampling points; in this embodiment, β1=1.5.
Simulations are conducted using a model-based approach and a data-based approach, which are specifically as follows:
1. In the model-based approach, when the frequency domain models of the motion stage P and the feedback controller Cfb are known, the learning gain is as follows:
where P(w) is the frequency domain model of the motion stage P and Cfb(w) is the frequency domain model of the feedback controller Cfb.
Since the exact model P(w) is usually unknown in real scenarios, an approximate model of P(w) is used in this embodiment as follows:
2. In the data-based approach, when the frequency domain models of the motion stage P and/or the feedback controller Cfb are unknown and frequency sweep experiments are not feasible, the (j+1)-th frequency domain feedforward signal μff,j+1(w) is updated as follows:
where 0<σj≤1, and r(w) is a frequency domain signal obtained after Fourier transformation of the desired motion trajectory r(t); in this embodiment, σj=0.9.
In step 4, the iteration experiment count j is incremented by 1 and step 2 is then performed.
Ultimately, simulation results of the model-based approach are shown in
Comparing the model-based learning control method of the present disclosure with the existing model-based frequency domain learning control method, as shown in
Comparing the data-based learning control method of the present disclosure with the existing data-based frequency domain learning control method, as shown in
With reference to the results shown in
It will be apparent to those skilled in the art that the present disclosure is not limited to the details of the exemplary embodiments described above, but that the present disclosure can be embodied in other specific forms without departing from the spirit or essential characteristics of the present disclosure. Accordingly, the embodiments should be regarded in all points of view as exemplary and not restrictive, the scope of the present disclosure being defined by the appended claims rather than the foregoing description, and it is therefore intended that all changes falling within the meaning and scope of equivalent elements of the claims should be included in the present disclosure. Any reference numerals in the claims should not be considered as limiting the involved claims.
In addition, it should be understood that although this specification is described in accordance with the implementations, not each implementation only contains an independent technical solution, and this description in the specification is only for clarity. Those skilled in the art should take the specification as a whole. The technical solutions in the embodiments can also be properly combined to form other implementations that can be understood by those skilled in the art.
Number | Date | Country | Kind |
---|---|---|---|
202310751744.6 | Jun 2023 | CN | national |
Number | Name | Date | Kind |
---|---|---|---|
20090000908 | Brain et al. | Jan 2009 | A1 |
20090222109 | Takagi | Sep 2009 | A1 |
20230118578 | Sreenivasan et al. | Apr 2023 | A1 |
Number | Date | Country |
---|---|---|
113485123 | Oct 2021 | CN |
113759721 | Dec 2021 | CN |