Integrating topology optimization in precision motion system design for optimal closed-loop control performance

In pursuit of better accuracy, higher speed and larger scale, manufacturers of high-performance devices increasingly rely on components which have been designed with a multidisciplinary approach from the outset. In the context of motion systems, this means that for instance structural mechanics, control engineering and thermal analysis are considered early in the design. In addition, the prospect of producing freeform device components using additive manufacturing at full scale allows designers to even further refine components to a specific purpose, or even integrate multiple functions into a single component. The design freedom offered by additive manufacturing is far greater than that offered by traditional techniques. To exploit this freedom a topology optimization framework is proposed that allows to determine the optimal material quantity and distribution within a design volume. In particular, this article focuses on the closed-loop control performance of a motion system component, while simultaneously ensuring that mechanical requirements are met. Based on an example, it is demonstrated that this leads to nontrivial and non-intuitive designs which provide improved performance at lower structural mass compared to eigenfrequency designs. The framework allows rapid development of prototype designs, which may eliminate some of the costly design iterations which are currently made in industrial practice.