Combined servo error pre-compensation and feedrate optimization -- with application to a 3D printer and precision motion stage

Abstract: Servo error pre-compensation and feedrate optimization are often performed independently to improve the accuracy and speed of manufacturing machines. However, this independent approach leads to unnecessary trade-offs between productivity and quality in manufacturing. This paper proposes a novel linear programming approach for combined servo error pre-compensation and feedrate optimization, subject to contour error (tolerance) and kinematic constraints. The incorporation of servo error pre-compensation into feedrate optimization allows for faster motions without violating tolerance constraints. Experiments carried out on a 3D printer and precision motion stage are respectively used to demonstrate up to 43% and 47% reduction in cycle time without compromising part quality using the proposed compared to the independent approach.