High-precision motion platforms, such as industrial wire bonders used in semiconductor packaging, face demanding speed and accuracy requirements that challenge the inherent performance limits of Linear Time-Invariant (LTI) control, such as Bode's gain-phase relationship and the waterbed effect. Reset control strategies, particularly the Constant in Gain Lead in Phase (CGLP) architecture, offer a compelling solution by providing broadband phase lead without the gain penalty associated with linear lead filters. However, the inherent nonlinearity of reset elements introduces higher-order harmonics into the control loop. In precision motion control, these harmonics can shift reset timing, induce additional zero-crossings per excitation period, and invalidate the fundamental modeling assumptions of closed-loop sinusoidal-input describing function (HOSIDF) analysis.

To overcome these nonlinear limitations and prevent unreliable reset behavior, this thesis utilizes a shaping filter framework to strategically control the frequency-domain distribution of higher-order harmonics. By suppressing low-frequency harmonic distortion while preserving necessary phase lead around the crossover frequency, the proposed shaping filter formulation keeps zero-crossing proximity metrics within reliable bounds, thereby validating the underlying analytical HOSIDF modeling assumptions. Furthermore, this study investigates and validates the fundamental trade-offs between steady-state tracking precision and transient settling performance in shaped reset systems.

Building upon these theoretical insights, a systematic design guideline is established to synthesize reset controllers with shaping filters tailored to spectral error distributions across distinct motion phases. Following these proposed guidelines, a constraint-compliant reset controller featuring a sixth-order shaping filter was synthesized and evaluated on an industrial wire bonder motion stage. The experimental results demonstrate that the designed controller eliminates low-frequency disturbance energy without compromising closed-loop robustness margins, achieving an average improvement of 10.1% in stationary RMS tracking error and 7.2% in settling time across the complete set of operational references when compared to the state-of-the-art unshaped reset baseline. These findings confirm that performance-oriented nonlinearity distribution successfully reconciles transient speed with high steady-state positioning accuracy in industrial motion systems. ... Read more