Machines

In order to improve the volumetric efficiency of the axial piston pump, this paper proposes a novel stacked roller 2D piston pump. It utilizes the alternate communication between the distribution cylinder and the oil intake and discharge ports of the housing to realize the flow distribution. While removing the independent flow distribution mechanism of the traditional piston pump, the leakage loss at the distribution friction pair can be reduced to improve the volumetric efficiency. Based on the flow distribution principle, an analytical model of the volumetric efficiency of the stacked roller 2D piston pump was established. Then, a co-simulation model of the whole pump was built using both the Simulink and AMESim software. The variation curve of output flow and leakage flow under different load pressures and rotational speeds was obtained, as well as the influence of backflow, axial leakage, and circumferential leakage on the volumetric efficiency. On this basis, a prototype of the stacked roller 2D pump was designed and manufactured in order to measure the output flow under different load pressures and rotational speeds, and a dedicated test bench was established. The experimental results are consistent with the simulation results; when the rotational speed is 6000 rpm and the load pressure is 5 MPa, the volumetric efficiency of the prototype pump can reach 98.6%. The research work validates that the novel stacked roller 2D piston pump has high volumetric efficiency. Full article

The existing publications on the analysis of power quality indicators in modern electric power supply systems are void of a comprehensive approach to improving these indicators in power systems by implementing multipulse connections. To the authors’ knowledge, this paper is the first to analyze current harmonic distortions in an 18-pulse connection of three-level active front-ends (AFE) featuring a programmed PWM. Raw data were obtained from, and current quality was analyzed for the power circuit of the main electric drive actuating the rolls in the rolling stand of a plate mill. The key feature of such circuitry is that the synchronous motor of each work roll is connected to the grid with an 18-pulse connection that uses three phase-shift transformers, where the phase shifts are 0° (delta/delta), 20° (delta/polygon) and −20° (delta/polygon). The circuitry connects three frequency converters (FC) with the AFEs in parallel. Phase-shift transformers were found to periodically overheat in the process. When overheating occurred, a programmed PWM voltage waveform was applied where harmonics 17 and 19 were eliminated. The goal and objectives were to analyze why the transformer would overheat and to find out how the issue could be addressed. The authors developed a simulation model of the research object in order to assess power quality parameters. Simulation results obtained in Matlab/Simulink were used to estimate the total harmonic distortions (THD) and individual harmonic factors for up to the 50th secondary transformer winding and grid harmonic with four different programmed AFE PWM voltage waveforms. The results helped find the best such waveform to prevent phase-shift transformers from overheating; one with harmonics 5, 7, 17 and 19 eliminated. The experimental and mathematical modeling results in the paper were confirmed by positive effects after industrial implementation of the system. Research performed directly on the operating equipment has been classified by the company and is not publicly available. These results are highly versatile and could be used in similar research on other circuitries to ensure the electromagnetic compatibility of nonlinear power-consuming devices. Full article

There is a growing interest towards multi-body modelling and simulation that play a critical role in the development and testing of new mechanical systems, in general, and formula cars specifically to avoid expensive and time-consuming experimental track testing. Recent advances in computer-aided engineering packages, allows one not only to evaluate the basic properties that define the dynamic behavior of a newly-designed formula car, but as well as to investigate the impact on the performance of the many adjustable parameters that collectively are referred to as the car set-up. Therefore, by providing a rapid feedback of a given set-up expectation, optimal configurations can be obtained ensuring the highest level of performance. In this paper, a Formula SAE vehicle is expressly targeted. First, a full multi-body model of the prototype is described detailing the properties of each subassembly, e.g., suspensions and antiroll bars, steering system, and powertrain. Then, the basic handling characteristics are obtained via simulated track testing. Based on vehicle dynamics principles, the fine tuning of the vehicle setup is thoroughly discussed to gain the best performance in each of the contest events of the Formula SAE competition. For example, in the skidpad event where cars are required to drive along an eight-shaped track, an almost 2 km/h gain in the maximum travel velocity can be achieved by adjusting the camber angles of all tires. Full article

Rotary compressors have been employed in heating and cooling for more than a century and are ubiquitous in daily life but there has not been any comprehensive record of their development and technological advances. This review paper attempts to provide a comprehensive account of the advances in R&D and design evolution of these rotary compressors since their inception, namely the sliding vane compressor, rolling piston compressor, and their design variants in open literature. This is to showcase the current state-of-the-art for these compressors so that researchers can use it as a basis for future work. Based on authors’ insight, inter-disciplinary research combined with advancements in ‘disruptive’ technology such as artificial intelligence and advancements in additive manufacturing might be a promising research direction to bring about improvements in rotary compressor performance to meet mankind’s growing needs for cooling and heating applications. Full article

Currently, permanent-magnet-type traction motors drive most electric vehicles. However, the potential demagnetization of magnets in these motors limits the performance of an electric vehicle. It is well known that during severe duty, the magnets are demagnetized if they operate beyond a ‘knee point’ in the B(H) curve. We show herein that the classic knee point definition can degrade a magnet by up to 4 grades. To prevent consequent excessive loss in performance, this paper defines the knee point k as the point of intersection of the B(H) curve and a parallel line that limits the reduction in its residual flux density to 1%. We show that operating above such a knee point will not be demagnetizing the magnets. It will also prevent a magnet from degenerating to a lower grade. The flux density at such a knee point, termed demag flux density, characterizes the onset of demagnetization. It rightly reflects the value of a magnet, so can be used as a basis to price the magnets. Including such knee points in the purchase specifications also helps avoid the penalty of getting the performance of a low-grade magnet out of a high-grade magnet. It also facilitates an accurate demagnetization analysis of traction motors in the worst-case conditions. Full article

Precise frequency measurement plays an essential role in many industrial and robotic systems. However, different effects in the application’s environment cause signal noises, which make frequency measurement more difficult. In small signals or rough environments, even negative Signal-to-Noise Ratios (SNRs) are possible. Thus, frequency measuring methods, which are suited for low SNR signals, are in great demand. While denoising methods such as autocorrelation do not suffice for small signal with low SNR, frequency measurement methods such as Fast-Fourier Transformation or Continuous Wavelet Transformation suffer from Heisenberg’s uncertainty principle, which makes simultaneous high frequency and time resolutions impossible. In this paper, the cross-correlation spectrum is presented as a new frequency measuring method. It can be used in any frequency domain, and provides greater denoising than autocorrelation. Furthermore, frequency and time resolutions are independent from one another, and can be set separately by the user. In simulations, it achieves an average deviation of less than 0.1% on sinusoidal signals with a SNR of −10 dB and a signal length of 1000 data points. When applied to “self-mixing”-interferometry signals, the method can reach a normalized root-mean square error of 0.2% with the aid of an estimation method and an averaging algorithm. Therefore, further research of the method is recommended. Full article

Tool temperature variation in flank milling usually causes excessive tool wear, shortens tool life, and reduces machining accuracy. The heat source is the primary factor of the machine thermal error in the process of cutting components. Moreover, the accuracy of the thermal error modeling is greatly influenced by the formation mechanism of the heat source. However, the tool heat caused by the potential energy of the tool bending and twisting has essentially not been taken into consideration in previous research. In this paper, a new heat source that causes the thermal error of the cutting tools is proposed. The potential energy of the tools’ bending and twisting is calculated using experimental data, and how tool potential energy is transformed into heat via friction is explored based on the energy conservation. The temperature rise of the cutting tool is simulated by a lattice-centered finite volume method. To verify the model, the temperature separation of a tool edge is measured experimentally under the given cutting load. The results of the numerical analysis show that the rise in tool temperature caused by the tool’s potential energy is related to the time and position of the cutting edge involved in milling. For the same conditions, the predicted results are consistent with the experimental results. The proportion of temperature rise due to tool potential energy is up to 6.57% of the total tool temperature rise. The results obtained lay the foundation for accurate thermal error modeling, and also provide a theoretical basis for the force–thermal coupling process. Full article

This paper presents a framework for the motion planning and control of redundant manipulators with the added task of collision avoidance. The algorithms that were previously studied and tested by the authors for planar cases are here extended to full mobility redundant manipulators operating in a three-dimensional workspace. The control strategy consists of a combination of off-line path planning algorithms with on-line motion control. The path planning algorithm is used to generate trajectories able to avoid fixed obstacles detected before the robot starts to move; this is based on the potential fields method combined with a smoothing interpolation that exploits Bézier curves. The on-line motion control is designed to compensate for the motion of the obstacles and to avoid collisions along the kinematic chain of the manipulator; this is realized using a velocity control law based on the null space method for redundancy control. Furthermore, an additional term of the control law is introduced which takes into account the speed of the obstacles, as well as their position. In order to test the algorithms, a set of simulations are presented: the redundant collaborative robot KUKA LBR iiwa is controlled in different cases, where fixed or dynamic obstacles interfere with its motion. The simulated data show that the proposed method for the smoothing of the trajectory can give a reduction of the angular accelerations of the motors of the order of $90\%$, with an increase of less than $15\%$ of the calculation time. Furthermore, the dependence of the on-line control law on the speed of the obstacle can lead to reductions in the maximum speed and acceleration of the joints of approximately $50\%$ and $80\%$, respectively, without significantly increasing the computational effort that is compatible for transferability to a real system. Full article

This paper presents the analytical calculation of the heat transfer coefficient of a complex housing shape of a Totally Enclosed Fan-Cooled (TEFC) industrial machine when it works below 20% of its nominal speed or close to stall. Therefore, passive cooling is dominant, and most of the heat is extracted by the combination of natural convection and radiation phenomena. Under these conditions, the area-based composite approach was used for the development of the analytical calculation method. A test rig using a TEFC Synchronous Reluctance Motor (SynRM) was constructed, and the collected experimental data was used to validate the proposed analytical method successfully. Full article

As an essential perceptual device, the tactile sensor can efficiently improve robot intelligence by providing contact force perception to develop algorithms based on contact force feedback. However, current tactile grasping technology lacks high-performance sensors and high-precision grasping prediction models, which limits its broad application. Herein, an intelligent robot grasping system that combines a highly sensitive tactile sensor array was constructed. A dataset that can reflect the grasping contact force of various objects was set up by multiple grasping operation feedback from a tactile sensor array. The stability state of each grasping operation was also recorded. On this basis, grasp stability prediction models with good performance in grasp state judgment were proposed. By feeding training data into different machine learning algorithms and comparing the judgment results, the best grasp prediction model for different scenes can be obtained. The model was validated to be efficient, and the judgment accuracy was over 98% in grasp stability prediction with limited training data. Further, experiments prove that the real-time contact force input based on the feedback of the tactile sensor array can periodically control robots to realize stable grasping according to the real-time grasping state of the prediction model. Full article

The rotational motion of the medium granules under the influence of an impeller installed in the bottom of a cylindrical reservoir is considered. The dependencies of the circulation velocity of the abrasive granules, as well as the dependence of the pressure in the circulation flow of the granules on the radius of the vibrating machine cylindrical reservoir for different speeds of the impeller rotation are obtained. Furthermore, the velocities of the abrasive granules at various distances from the center of the cylindrical reservoir of the vibrating machine have been determined. The amplitudes of the tangential and radial components of the velocity of movement of pseudo-gas from abrasive granules are obtained. The total pressure on the surface of the processed part and the average velocity of the abrasive granules colliding with it are determined. The graphical dependencies of the integral metal removal on the amplitude and frequency of oscillations of the walls of the vibrating machine reservoir are given for various values of the angular velocities of the impeller rotation. Full article

The study provides a solution to a dimensional synthesis problem for a hexapod-type reconfigurable parallel mechanism, which can change its configuration to realize different trajectories of its output link while having a single drive. The work presents an original procedure to find the dimensions of some mechanism’s links and their initial configuration to reproduce these trajectories. After describing the mechanism, the paper examines kinematic relations representing the basis for the subsequent synthesis algorithm. Next, the obtained expressions are extended and provide a system of equations to be solved. The structure of this equation system allows it to be solved effectively by numerical methods, which is demonstrated with an example. The proposed algorithm of dimensional synthesis does not require solving the optimization problems, in contrast to the familiar methods of dimensional synthesis of parallel mechanisms. Further, the suggested approach to the synthesis problem allows finding solution in a fast and computationally efficient manner. Full article

Causes of the in-service damage to hydrocylinder liners were investigated, and the requirements to their working surfaces were systematized. Roughness parameter Ra was found not to provide a precise estimate of the surface quality because its reduction did not affect surface microgeometry. Additionally, the surface quality was assessed by the Abbott-Firestone curve during the finishing operation. The optimized manufacturing technology for obtaining hydrocylinder liners was offered based on having the required microgeometry and surface quality provided by cutting operations. The quality and service characteristics of internal surfaces of hydrocylinder liners were improved by changing technological operations. In particular, the semi-finish turning was chosen to provide for the surface roughness parameter Ra within 6.3–8.0 μm and the roughness pitch parameter S within 0.4–0.6 mm and homogeneous surface structure. The finishing rolling was replaced by burnishing to form a regular microrelief. Full article

In this paper, a method to suppress the vibration of a double-beam system with nonlinear synchronized switch damping on the inductor via a network (SSDI-net) is proposed. Unlike the classical linear piezoelectric shunt damping, SSDI-net is a nonlinear piezoelectric damping. A double-beam system with SSDI-net was simplified to a lumped parameter electromechanical coupling model and analyzed by using the multi-harmonic balance method, at first with alternating frequency–time techniques (MHBM/AFT). Then, a new lower-power autonomous switching control circuit board was designed, based on SSD technique, and vibration control experiments using a double-beam system with an SSDI network are conducted, to verify the validity of the proposed analysis method and its calculation results. The nonlinear switching piezoelectric network proposed in this article can increase the voltage inversion factor. Furthermore, future applications of this switching piezoelectric network technology in the vibration suppression of bladed-disk structures in aero engines can reduce the number of switches by at least half and obtain almost the same damping effect. Full article

This paper presents the two-phase condensation heat transfer and pressure drop characteristics of R-513A as an alternative refrigerant to R-134a in a 9.52-mm OD horizontal microfin copper tube. The test facility had a straight, horizontal test section with an active length of 2.0 m and was cooled by cold water circulated in a surrounding annular space. The annular-side heat transfer coefficients were obtained using the Wilson plot method. The average heat transfer coefficient and pressure drop data are presented at the condensation temperature of 35 °C in the range of 100–440 kg·m⁻²·s⁻¹ mass flux. The test data of R-513A are compared with those of R-134a, R-1234yf, and R-1234ze(E). The average condensation heat transfer coefficients of the R-513A and R-1234ze(E) refrigerants were similar to R-134a at the lower mass flux (100~150 kg·m⁻²·s⁻¹), while they were up to 10% higher than R-134a as the mass flux increased. The pressure drop of R-513A was similar to R-1234yf and 10% lower than that of R-134a at the higher mass flux. The R-1234ze(E) pressure drops were 20 % higher compared to those of R-134a at the higher mass flux. Full article

In a human–robot collaboration scenario, operator safety is the main problem and must be guaranteed under all conditions. Collision avoidance control techniques are essential to improve operator safety and robot flexibility by preventing impacts that can occur between the robot and humans or with objects inadvertently left within the operational workspace. On this basis, collision avoidance algorithms for moving obstacles are presented in this paper: inspired by algorithms already developed by the authors for planar manipulators, algorithms are adapted for the 6-DOF collaborative manipulators by Universal Robots, and some new contributions are introduced. First, in this work, the safety region wrapping each link of the manipulator assumes a cylindrical shape whose radius varies according to the speed of the colliding obstacle, so that dynamical obstacles are avoided with increased safety regions in order to reduce the risk, whereas fixed obstacles allow us to use smaller safety regions, facilitating the motion of the robot. In addition, three different modalities for the collision avoidance control law are proposed, which differ in the type of motion admitted for the perturbation of the end-effector: the general mode allows for a 6-DOF perturbation, but restrictions can be imposed on the orientation part of the avoidance motion using 4-DOF or 3-DOF modes. In order to demonstrate the effectiveness of the control strategy, simulations with dynamic and fixed obstacles are presented and discussed. Simulations are also used to estimate the required computational effort in order to verify the transferability to a real system. Full article

The paper at hand presents a novel and versatile method for tracking the pose of varying products during their manufacturing procedure. By using modern Deep Neural Network techniques based on Attention models, the most representative points to track an object can be automatically identified using its drawing. Then, during manufacturing, the body of the product is processed with Aluminum Oxide on those points, which is unobtrusive in the visible spectrum, but easily distinguishable from infrared cameras. Our proposal allows for the inclusion of Artificial Intelligence in Computer-Aided Manufacturing to assist the autonomous control of robotic handlers. Full article

Generally, in the laser measurement of gears, the laser beam passes through the center of the gear, and the laser displacement sensor reads the spatial distance from the gear involute tooth surface to the laser displacement sensor. However, in this method, the angle between the laser beam and the normal vector of the measured tooth surface is too large, which affects the accuracy of the measurement and the stability of the data. This paper proposes an offset laser measurement method. The laser beam is offset from the center of the gear by a certain distance to form a larger incident angle with the tooth surface, which can effectively address the problem and increase the measurement accuracy. Through a selection of the optimal offset distance, the range of optimal offset measurement positions was obtained and clarified by experiments. We solved the data conversion problem caused by the change in measuring position, and we measured the pitch deviation and helix angle of the gear to confirm the feasibility of this method. According to the theoretical calculation and experimental verification, it was found that this method has the advantages of better measurement accuracy and less fluctuation in measurement data. It is, thus, suitable for precision gear measurement. Full article

Most existing finger rehabilitation robots are structurally complex and cannot be adapted to multiple work conditions, such as clinical and home. In addition, there is a lack of attention to active adduction/abduction (A/A) movement, which prevents stroke patients from opening the joint in time and affects the rehabilitation process. In this paper, an end-effector finger rehabilitation robot (EFRR) with active A/A motion that can be applied to a variety of applications is proposed. First, the natural movement curve of the finger is analyzed, which is the basis of the mechanism design. Based on the working principle of the cam mechanism, the flexion/extension (F/E) movement module is designed and the details used to ensure the safety and reliability of the device are introduced. Then, a novel A/A movement module is proposed, using the components that can easily individualized design to achieve active A/A motion only by one single motor, which makes up for the shortcomings of the existing devices. As for the control system, a fuzzy proportional-derivative (PD) adaptive impedance control strategy based on the position information is proposed, which can make the device more compliant, avoid secondary injuries caused by excessive muscle tension, and protect the fingers effectively. Finally, some preliminary experiments of the prototype are reported, and the results shows that the EFRR has good performance, which lays the foundation for future work. Full article