In recent years, there is a growing trend on integrating Computer Aid Design (CAD] Computer Aid Manufacturing (CAM) and Computer Aided Inspection (CAI). This thesi presents a new shape adaptive motion control system that integrates part measurement wit! motion control. The proposed system consists of five blocks:​ surface measurement;​ surfao reconstruction;​ tool trajectory planning;​ axis motion control and part alignment.

In this thesis, the key technology used in surface measurement and surface reconstruction i spatial spectral analysis. In the surface measurement block, a new spectral spectrun comparison method is proposed to find out an optimal digitizing frequency. In the surfac( reconstruction block, different interpolation methods are compared in the spatial spectra domain. A spatial spectral B-Spline method is presented. In the tool trajectory planning blocl a method is developed to select the motion profile first and then determine the tool location according to the reconstructed surface in order to improve the accuracy of the planned path In the part alignment, a three-point alignment method is presented to align the par coordinates with the machine coordinates.

Based on the proposed methods, a software package is developed and implemented on th( polishing robot constructed at Ryerson University. The effectiveness of the proposed systen has been demonstrated by the experiment on edge polishing. In this experiment, the shape o the part edges is measured first, and then constructed as a wire-frame CAD model, based oi which tool trajectory is planned to control the tool to polish the edges.