![]() The integration includes not only the hardware connection but also the intelligent coordination of different modules. However, those modules often possess proprietary hardware and software interfaces and the lack of plug-and-play solutions lead to tremendous difficulty in system integration, which will result in complex and inflexible CNC system, as well as a high developing cost and long lead time. Machine developers tend to choose those modules from different vendors to satisfy the performance and cost requirements. Moreover, there is a growing trend for the hybrid micro-machines to integrate more functional modules, in addition to the modules for the add-on processes, for even higher efficiency and accuracy, such as the in-line metrology system for in-process surface measurement and material handling system for efficient handling of such miniature 3D micro-products. ![]() To achieve the desired hybrid process, a wide range of functional modules should be integrated, such as EDM, laser, ultrasonic actuator, and so forth. Therefore, it provides new possibilities for high-efficiency and high-accuracy machining of some materials. The benefits of the hybrid process include the following : (1) It can improve the machinability of the difficult-to-machine materials, such as ceramics, hardened steel, super alloys, and so forth (2) It eliminates the re-alignment errors and the set-up time if the workpiece should go through sequential processes on different machines. In recent years, hybrid micro-machining technology has been developed to integrate several micro-manufacturing processes on one platform to tackle these manufacturing challenges, as it can achieve the so-called “1 + 1 = 3” effect, which means that the advantages of the hybrid process are more than double the advantages of the single processes. Although conventional stand-alone micro-manufacturing processes, such as micro-milling, laser machining, electrical discharge machining (EDM), and so forth, have been the major approaches in manufacturing the aforementioned products, the predictability, producibility, and productivity remain big issues. These products are usually made of a wide range of engineering materials and possess complex freeform surfaces with tight tolerance on form accuracy and surface finish. High value-added 3D micro-products such as optics, molds/dies, biomedical implants, and so forth are increasingly in demand. Thus, it provides invaluable guidelines for the development of next-generation CNC systems for hybrid micro-machines. ![]() The effectiveness of the proposed control architecture has been successfully verified through the integration of a six-axis hybrid micro-machine. The component design also improves the scalability and maintainability of the whole system. The proposed control architecture enhances the flexibility of the computer numerical control (CNC) system to accommodate a broad range of functional modules. The interaction of hardware is encapsulated into software components, while the data flow among different components is standardized. This paper proposes a novel three-layer control architecture for the first time for the system integration of hybrid micro-machines. However, the lack of plug-and-play solutions leads to tremendous difficulty in system integration. Hybrid micro-machines tend to integrate multiple functional modules from different vendors for the best value and performance. Hybrid micro-machining, which integrates several micro-manufacturing processes on one platform, has emerged as a solution to utilize the so-called “1 + 1 = 3” effect to tackle the manufacturing challenges for high value-added 3D micro-products.
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