Free-space optical satellite communication terminals rely on accurate metrology of their pointing mirrors to correctly aim their laser to a counter terminal, while at the same time requiring simple, lightweight and low-cost sensors. The aim of this paper is to develop an automated procedure for the calibration of these sensors in a mass production setting, using a pointing test bench (PTB) to automatically calibrate the angular sensors of many Coarse Pointing Assemblies (CPAs), which position pointing mirrors over a large field-of-regard. The PTB and CPA are aligned using feedback over an external optical position sensor (OPS) and an inverse kinematic model is learned from data, after which Gaussian Process regression models are created to predict and correct sensor errors, taking into account propagation of calibration errors from the PTB to the CPA. Experimental results show that the CPA sensor errors are reduced by two orders of magnitude by this automated calibration approach, even at orientations at which the PTB itself is uncalibrated. The developed framework is generalizable to calibration of arbitrary 2 degree of freedom (2-DOF) rotary systems and is not limited to specific types of position sensors, thereby enabling significant cost savings and increased accuracy in mass production of satellite communication terminals.

Piezo-stepper actuators enable accurate positioning through the sequential contraction and expansion of piezoelectric elements, generating a walking motion. The aim of this paper is to reduce velocity ripples caused by parasitic effects, due to hysteresis in the piezoelectric material and mechanical misalignments, through suitable feedforward control. The presented approach involves the integration of a rate-dependent hysteresis model with a position-dependent feedforward learning scheme to compensate for these effects. Experimental results show that this approach leads to a significant reduction in the velocity ripples, even when the target velocity is changed. These results enable the use of piezo-stepper actuators in applications requiring high positioning accuracy and stiffness over a long stroke, without requiring expensive position sensors for high-gain feedback.

Iterative learning control (ILC) techniques are capable of improving the tracking performance of control systems that repeatedly perform similar tasks by utilizing data from past iterations. The aim of this paper is to design a systematic approach for learning parameterized feedforward signals with limited complexity. The developed method involves an iterative learning control in conjunction with a data-driven sparse subset selection procedure for basis function selection. The ILC algorithm that employs sparse optimization is able to automatically select relevant basis functions and is validated on an industrial flatbed printer.

Linear Hall sensors are a cost-effective alternative to optical encoders for measuring the rotor positions of actuators, with the main challenge being that they exhibit position-dependent inaccuracies resulting from manufacturing tolerances. This paper develops a data-driven calibration procedure for linear analog Hall sensors that enables accurate online estimates of the rotor angle without requiring expensive external encoders. The approach combines closed-loop data collection with nonlinear identification to obtain an accurate model of the sensor inaccuracies, which is subsequently used for online compensation. Simulation results show that when the flux density model structure is known, measurement errors are reduced to the sensor noise floor, and experiments on an industrial setup demonstrate a factor of 2.6 reduction in the root-mean-square measurement error. These results confirm that Hall sensor inaccuracies can be calibrated even when no external encoder is available, improving their practical applicability.

Iterative learning control (ILC) is typically applied in practice combined with a feedback controller for time-domain stability. In this closed-loop design with actuator constraints, existing constrained ILC designs suffer from determining the exact input constraint on the ILC controller. This issue brings in an important gap between the existing constrained ILC designs and their real-world applications. This paper gives a systematic consideration of the input constraint problem in the closed-loop ILC design with actuator saturation. A constraint-aware ILC is developed to autonomously determine the constraint on the feedforward controller. The convergence of the constrained ILC process is proved under the framework of alternating projection. Finally, the effectiveness of the developed method is verified on a numerical simulation.

Switched Reluctance Motors (SRMs) are widely used for their simplicity and cost-effectiveness, for example, in coarse laser pointing for free-space optical (FSO) communication, with torque ripple being a challenge in their implementation. This paper introduces an automated, modelfree approach to minimize torque ripple in SRMs despite manufacturing variations. Using an extremum-seeking approach, the commutation parameters are adapted online to mitigate the position-dependent velocity ripple through gradient descent. Simulations show that the method's effectiveness is consistent across different SRMs, rendering it applicable to mass production, and experimental results verify that torque ripple is almost entirely eliminated in several hours. The developed approach enables accurate SRM control with minimal expert knowledge, functioning as a crucial step toward their deployment in constellation projects for FSO communication.

Cross-coupled iterative learning control (ILC) can improve the contour tracking performance of manufacturing systems significantly. This paper aims to develop a framework for norm-optimal cross-coupled ILC that enables intuitive tuning of time- and iteration-varying weights of the exact contour error and its tangential counterpart. This leads to an iteration-varying ILC algorithm for which convergence conditions are developed. In addition, a resource-efficient implementation is developed that reduces the computational load significantly and enables the use of long reference signals. The approach is experimentally validated on an industrial flatbed printer.

Actuators that require commutation algorithms, such as the switched reluctance motor (SRM) considered in this paper and employed in the coarse pointing assembly (CPA) for free-space optical communication, often have torque-ripple disturbances that are periodic in the commutation-angle domain that deteriorate the positioning performance. The aim of this paper is to model the torque ripple as a Gaussian Process (GP) in the commutation-angle domain and consequently compensate for it at arbitrary velocity. The approach employs repetitive control (RC) at a constant velocity. A spatial GP with a periodic kernel is trained using data that is obtained from the RC step resulting in a static non-linear function for compensation at arbitrary velocity. Stability conditions are provided for both steps. The approach is successfully applied to a CPA prototype to improve the tracking performance for laser communication, where the torque ripple is compensated at arbitrary velocity.

Switched Reluctance Motors (SRMs) are cost-effective electric actuators that utilize magnetic reluctance to generate torque, with torque ripple arising from unaccounted manufacturing defects in the rotor tooth geometry. This paper aims to design a versatile, resource-efficient commutation function for accurate control of a range of SRMs, mitigating torque ripple despite manufacturing variations across SRMs and individual rotor teeth. The developed commutation function optimally distributes current between coils by leveraging the variance in the torque-current-angle model and is designed with few parameters for easy integration on affordable hardware. Monte Carlo simulations and experimental results show a tracking error reduction of up to 31% and 11%, respectively. The developed approach is beneficial for applications using a single driver for multiple systems and those constrained by memory or modeling effort, providing an economical solution for improved tracking performance and reduced acoustic noise.

Switched Reluctance Motors (SRMs) enable power-efficient actuation with mechanically simple designs. This paper aims to identify the nonlinear relationship between torque, rotor angle, and currents, to design commutation functions that minimize torque ripple in SRMs. This is achieved by conducting specific closed-loop experiments using purposely imperfect commutation functions and identifying the nonlinear dynamics via Bayesian estimation. A simulation example shows that the presented method is robust to position-dependent disturbances, and experiments suggest that the identification method enables the design of commutation functions that significantly increase performance. The developed approach enables accurate identification of the torque-current-angle relationship in SRMs, without the need for torque sensors, an accurate linear model, or an accurate model of position-dependent disturbances, making it easy to implement in production.

Sensors in high-precision mechatronic systems require accurate calibration, which is achieved using test beds that, in turn, require even more accurate calibration. The aim of this paper is to develop a cascaded calibration method for position sensors of mechatronic systems while taking into account the variance of the calibration model of the test bed. The developed calibration method employs Gaussian Process regression to obtain a model of the position-dependent sensor inaccuracies by combining prior knowledge of the sensor with data using Bayesian inference. Monte Carlo simulations show that the developed calibration approach leads to significantly higher calibration accuracy when compared to alternative regression techniques, especially when the number of available calibration points is limited. The results indicate that more accurate calibration of position sensors is possible with fewer resources.

Switched reluctance motors are appealing because they are inexpensive in both construction and maintenance. The aim of this paper is to develop a commutation function that linearizes the nonlinear motor dynamics in such a way that the torque ripple is reduced. To this end, a convex optimization problem is posed that directly penalizes torque ripple in between samples, as well as power consumption, and Gaussian Process regression is used to obtain a continuous commutation function. The resulting function is fundamentally different from conventional commutation functions, and closed-loop simulations show significant reduction of the error. The results offer a new perspective on suitable commutation functions for accurate control of reluctance motors.

Feedforward control is essential to achieving good tracking performance in positioning systems. The aim of this paper is to develop an identification strategy for inverse models of systems with nonlinear dynamics of unknown structure using input-output data, which can be used to generate feedforward signals for a-priori unknown tasks. To this end, inverse systems are regarded as noncausal nonlinear finite impulse response (NFIR) systems, and modeled as a Gaussian Process with a stationary kernel function that imposes properties such as smoothness. The approach is validated experimentally on a consumer printer with friction and shown to lead to improved tracking performance with respect to linear feedforward.

Machine learning techniques, including Gaussian processes (GPs), are expected to play a significant role in meeting speed, accuracy, and functionality requirements in future data-intensive mechatronic systems. This paper aims to reveal the potential of GPs for motion control applications. Successful applications of GPs for feedforward and learning control, including the identification and learning for noncausal feedforward, position-dependent snap feedforward, nonlinear feedforward, and GP-based spatial repetitive control, are outlined. Experimental results on various systems, including a desktop printer, wirebonder, and substrate carrier, confirmed that data-based learning using GPs can significantly improve the accuracy of mechatronic systems.