As machine users generally only define the start and end point of the movement, a large trajectory optimization potential rises for single axis mechanisms performing repetitive tasks. However, a descriptive mathematical model of the mechanism needs to be defined in order to apply existing optimization techniques. This is usually done with complex methods like virtual work or Lagrange equations. In this paper, a generic technique is presented to optimize the design of point-to-point trajectories by extracting position dependent properties with CAD motion simulations. The optimization problem is solved by a genetic algorithm. Nevertheless, the potential savings will only be achieved if the machine is capable of accurately following the optimized trajectory. Therefore, a feedforward motion controller is derived from the generic model allowing to use the controller for various settings and position profiles. Moreover, the theoretical savings are compared with experimental data from a physical setup. The results quantitatively show that the savings potential is effectively achieved thanks to advanced torque feedforward with a reduction of the maximum torque by 12.6% compared with a standard 1/3-profile.

Cyber-physical systems are becoming increasingly complex. In these advanced systems, the different engineering domains involved in the design process become more and more intertwined. In these situations, a traditional (sequential) design process becomes inefficient in finding good designs options. Instead, an integrated approach is needed where parameters in both the control and embedded domain can be chosen, evaluated and optimized to have a good solution in both domains. However, in such an approach, the combined design space becomes vast. As such, methods are needed to mitigate this problem. In this paper, we show how domain knowledge can be used to guide the design-space exploration process for an advanced control system and its deployment on embedded hardware. We use domain knowledge, captured in an ontology, to reason about the relationships between parameters in the different domains. This leads to a stepwise design space-exploration process where this domain knowledge is used to quickly reduce the design space to a subset of likely good candidates. In this process, we make use of cross-domain evaluation to find feasible design options with good system-level performance.

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