Practical simulator generation using a simple feedforward element design method for precision motion systems

The growing demand for automation and labor-saving solutions has intensified interest in digital technology applications that replicate real-world systems and utilize analytical results in physical settings. Fulfilling these needs requires the development of a high-precision simulator that can be automatically and effortlessly generated from data easily obtainable from a physical machine. This paper proposes an innovative method for generating a precision simulator for motion systems. The proposed method uses feedforward elements derived through our feedforward design methodology. In this approach, following a specified procedure, a learning controller distinguishes four operational characteristics based on specific types of motion profiles, and the derived elements are combined according to predetermined rules to produce a simulator. We applied this method to a ball-screw mechanism and assessed the performance of the generated simulator by comparing it with experimental data. In the experimental setup, we observed position-dependent submicrometer vibrations, which cannot be represented by conventional mechanical models. The simulator, constructed by combining FF elements from high-resolution measured or reconstructed data, replicated vibrations with similar frequencies. However, its ability to effectively mimic certain responses, including the observed submicrometer vibrations, was limited. Notably, the vibration amplitude varied with velocity. Nevertheless, the results demonstrated that straightforward refinement of the simulator generation process could produce a simulator with high simulation accuracy. • This study introduced a novel method for automatic precision simulator generation • Simulator generation was simplified using feedforward elements from learning controllers • This addresses the need for accurate, easy-to-generate simulators in industry • The simulator effectively replicates the submicrometer-level microvibrations • The proposed method will aid the design of high-precision simulators