Intelligent Feedrate Optimization using an Uncertainty-aware Digital Twin within a Model Predictive Control Framework

The future of intelligent manufacturing machines involves autonomous selection of process parameters to maximize productivity while maintaining quality within specified constraints. To effectively optimize process parameters, these machines need to adapt to existing uncertainties in the physical system. This paper proposes a novel framework and methodology for feedrate optimization that is based on a physics-informed data-driven digital twin with quantified uncertainty. The servo dynamics are modeled using a digital twin, which incorporates the known uncertainty in the physics-based models and predicts the distribution of contour error using a data-driven model that learns the unknown uncertainty on-the-fly by sensor measurements. Using the quantified uncertainty, the proposed feedrate optimization maximizes productivity while maintaining quality under desired servo error constraints and stringency (i.e., the tolerance for constraint violation under uncertainty) using a model predictive control framework. Experimental results obtained using a 3-axis desktop CNC machine tool and a desktop 3D printer demonstrate significant cycle time reductions of up to 38% and 17% respectively, while staying close to the error tolerances compared to the existing methods.