Modeling Dual-Drive Gantry Stages with Heavy-Load and Optimal Synchronous Controls with Force-Feed-Forward Decoupling

The application of precision dual-drive gantry stages in intelligent manufacturing is increasing. However, the loads of dual drive motors can be severely inconsistent due to the movement of heavy loads on the horizontal crossbeam, resulting in synchronization errors in the same direction movement of dual-drive motors. This phenomenon affects the machining accuracy of the gantry stage and is an critical problem that should be immediately solved. A novel optimal synchronization control algorithm based on model decoupling is proposed to solve the problem. First, an accurate physical model is established to obtain the essential characteristics of the heavy-load dual-drive gantry stage in which the rigid-flexible coupling dynamic is considered. It includes the crossbeam’s linear motion and rotational motion of the non-constant moment of inertia. The established model is verified by using the actual system. By defining the virtual centroid of the crossbeam, the cross-coupling force between dual-drive motors is quantified. Then, the virtual-centroid-based Gantry Synchronization Linear Quadratic Regulator (GSLQR) optimal control and force-Feed-Forward (FF) decoupling control algorithm is proposed. The result of the comparative experiment shows the effectiveness and superiority of the proposed algorithm.