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<p>The pursuit of high form accuracy and efficiency in ultra-precision diamond turning of microlens arrays (MLAs) is often limited by suboptimal motion trajectory planning and constrained servo control performance. To address these challenges, this study proposes a novel control strategy that integrates bidirectional minimum-time trajectory optimization with pre-limitation (BMTOP) and direct feedforward control (DFC) within a custom PID framework. BMTOP generates time-efficient trajectories under kinematic constraints by incorporating a pre-limitation mechanism that suppresses infeasible accelerations, substantially reducing optimization time. DFC analytically computes the desired motion states directly from the optimized trajectory, avoiding numerical differentiation and improving axis tracking accuracy. Implemented on an industrial ultra-precision lathe, the proposed method achieves a 90% reduction in optimization execution time, a 30% decrease in tracking error, and up to 10% improvement in machining efficiency. In MLA fabrication experiments, the form error was reduced from 0.928&#xa0;μm to 0.603&#xa0;μm, and machining time was shortened by 17.5%. These results demonstrate the method’s effectiveness in enhancing both precision and throughput for high-performance optical component manufacturing.</p>

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Direct feedforward control with optimal trajectory for diamond turning of microlens array

  • 期刊论文

  • 发表日期：

    2026年7月1日

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  • Zhiyue Wang,
  • Zheli Lin,
  • Hao Wu,
  • Zhenhua Jiang,
  • Limin Zhu,
  • Xinquan Zhang

摘要

The pursuit of high form accuracy and efficiency in ultra-precision diamond turning of microlens arrays (MLAs) is often limited by suboptimal motion trajectory planning and constrained servo control performance. To address these challenges, this study proposes a novel control strategy that integrates bidirectional minimum-time trajectory optimization with pre-limitation (BMTOP) and direct feedforward control (DFC) within a custom PID framework. BMTOP generates time-efficient trajectories under kinematic constraints by incorporating a pre-limitation mechanism that suppresses infeasible accelerations, substantially reducing optimization time. DFC analytically computes the desired motion states directly from the optimized trajectory, avoiding numerical differentiation and improving axis tracking accuracy. Implemented on an industrial ultra-precision lathe, the proposed method achieves a 90% reduction in optimization execution time, a 30% decrease in tracking error, and up to 10% improvement in machining efficiency. In MLA fabrication experiments, the form error was reduced from 0.928 μm to 0.603 μm, and machining time was shortened by 17.5%. These results demonstrate the method’s effectiveness in enhancing both precision and throughput for high-performance optical component manufacturing.