Machines — Open Access Journal

In large rotor-bearing systems, the rolling element bearings act as a considerable source of subcritical vibration excitation. Simulation of such rotor bearing systems contains major sources of uncertainty contributing to the excitation, namely the roundness profile of the bearing inner ring and the clearance of the bearing. In the present study, a simulation approach was prepared to investigate carefully the effect of varying roundness profile and clearance on the subcritical vibration excitation. The FEM-based rotor-bearing system simulation model included a detailed description of the bearings and asymmetricity of the rotor. The simulation results were compared to measured responses for validation. The results suggest that the simulation model was able to capture the response of the rotor within a reasonable accuracy compared to the measured responses. The bearing clearance was observed to have a major effect on the subcritical resonance response amplitudes. In addition, the simulation model confirmed that the resonances of the 3rd and 4th harmonic vibration components in addition to the well-known 2nd harmonic resonance (half-critical resonance) can be significantly high and should thus be taken into account already in the design phase of large subcritical rotors. Full article

With the advent of agriculture 3.0 and 4.0, in view of efficient and sustainable use of resources, researchers are increasingly focusing on the development of innovative smart farming and precision agriculture technologies by introducing automation and robotics into the agricultural processes. Autonomous agricultural field machines have been gaining significant attention from farmers and industries to reduce costs, human workload, and required resources. Nevertheless, achieving sufficient autonomous navigation capabilities requires the simultaneous cooperation of different processes; localization, mapping, and path planning are just some of the steps that aim at providing to the machine the right set of skills to operate in semi-structured and unstructured environments. In this context, this study presents a low-cost, power-efficient local motion planner for autonomous navigation in vineyards based only on an RGB-D camera, low range hardware, and a dual layer control algorithm. The first algorithm makes use of the disparity map and its depth representation to generate a proportional control for the robotic platform. Concurrently, a second back-up algorithm, based on representations learning and resilient to illumination variations, can take control of the machine in case of a momentaneous failure of the first block generating high-level motion primitives. Moreover, due to the double nature of the system, after initial training of the deep learning model with an initial dataset, the strict synergy between the two algorithms opens the possibility of exploiting new automatically labeled data, coming from the field, to extend the existing model’s knowledge. The machine learning algorithm has been trained and tested, using transfer learning, with acquired images during different field surveys in the North region of Italy and then optimized for on-device inference with model pruning and quantization. Finally, the overall system has been validated with a customized robot platform in the appropriate environment. Full article

This study investigates the dynamic behavior of a recently developed counterbalance forklift truck. The final objective is creating virtual testing tools based on numerical multibody models to evaluate the dynamic stresses experienced by the forklift family of interest during a reference operating cycle, defined by the manufacturer’s testing protocols. This work aims at defining sufficiently accurate and easy-to-implement modelling approaches and validation procedures. It focuses on a specific test, namely the passage of a speed-bump-like obstacle at high velocity, which represents one of the most severe conditions within the reference cycle. Indeed, unlike most of the other wheeled vehicles, forklifts typically do not have advanced suspension systems and their dynamic response is significantly affected by ground irregularities. To this end, a preliminary model of the complete forklift, featuring rigid bodies and a simplified tire–ground contact model, is implemented with a commercial software. Experimental tests are conducted on the forklift to measure the vehicle vibrations when running on the obstacle, for model validation purposes. After model updating, the results provided by the numerical simulations match the experimental data satisfactorily. Hence, the modelling and validation strategies are proven viable and effective. Full article

Fatigue is one of the main causes for in service failure of mechanical components and structures. With the development of new materials, such as high strength aluminium or titanium alloys with different microstructures from steels, materials no longer have a fatigue limit in the classical sense, where it was accepted that they would have ‘infinite life’ from 10 million (107) cycles. The emergence of new materials used in critical mechanical parts, including parts obtained from metal additive manufacturing (AM), the need for weight reduction and the ambition to travel greater distances in shorter periods of time, have brought many challenges to design engineers, since they demand predictability of material properties and that they are readily available. Most fatigue testing today still uses uniaxial loads. However, it is generally recognised that multiaxial stresses occur in many full-scale structures, being rare the occurrence of pure uniaxial stress states. By combining both Ultrasonic Fatigue Testing with multiaxial testing through Single-Input-Multiple-Output Modal Analysis, the high costs of both equipment and time to conduct experiments have seen a massive improvement. It is presently possible to test materials under multiaxial loading conditions and for a very high number of cycles in a fraction of the time compared to non-ultrasonic fatigue testing methods (days compared to months or years). This work presents the current status of ultrasonic fatigue testing machines working at a frequency of 20 kHz to date, with emphasis on multiaxial fatigue and very high cycle fatigue. Special attention will be put into the performance of multiaxial fatigue tests of classical cylindrical specimens under tension/torsion and flat cruciform specimens under in-plane bi-axial testing using low cost piezoelectric transducers. Together with the description of the testing machines and associated instrumentation, some experimental results of fatigue tests are presented in order to demonstrate how ultrasonic fatigue testing can be used to determine the behaviour of a steel alloy from a railway wheel at very high cycle fatigue regime when subjected to multiaxial tension/torsion loadings. Full article

Powered-two-wheelers (PTWs) are increasingly popular because of their lower cost compared to cars, and therefore the riders’ exposure risk is increasing. Due to their complex dynamics characterized by high non-linearity and inherent instability, PTWs are more difficult to control compared to four-wheeled vehicles. Wobble is a high-frequency instability mode affecting the steering assembly of the PTW, and which often causes the rider to lose control and crash when it occurs. In this paper, we present the design of a new motorcycle semi-active steering damper integrated into the steering column and utilizing a magnetorheological fluid (MRF) for variable damping torque. An analytical model of the concept was first used to perform the preliminary sizing, followed by concept validation using a 3D FE multiphysics magnetic-fluid analysis. The final innovative design offers several advantages compared to traditional steering dampers: (i) a wide range of adjustable damping torque values, with a multiplication factor up to 10 with a maximum electrical current of 2 A; (ii) total integration into the motorcycle steering column enabled by its axial design and limited radius; (iii) a simple chamber geometry that allows for easy manufacture; (iv) longer seal life due to the absence of direct contact between seals and the MRF. Full article

In this paper, we present a kineto-static analysis on a wrist rehabilitation robot to compensate for joint misalignment between human and robot joints. Since joint misalignment has proved to generate user–device interaction forces, which reduce the comfort and safety of the wearable devices and limit the user’s willingness to use it. The use of compliance and the addition of passive joints for joint misalignment compensation are discussed. In order to study the effect of the initial offset, we find that the initial offset in the direction perpendicular to the forearm causes a larger unwanted force. In addition, the use of the softest compliance can minimize unwanted force by 38% compared to the case without compliance. Furthermore, the effect of the addition of passive joints to the exoskeleton is investigated. From the analysis results, the soft part of the human being is regarded as a passive joint with the ability to compensate for joint misalignment. Moreover, the influence of the soft characteristics of human limbs should be considered when designing a wearable robot. This soft property, causing the movement of the braces, results in reducing the angular range of the wrist. Through the analysis results, we provide effective ideas for joint misalignment compensation to fulfill a comfortable and safer robot design. Full article

The fault tolerant control (FTC) technique is widely used in many industries to provide tolerance to systems so that they can operate when a system fault occurs. This paper presents a technique for FTC based on the observer signal application, which is used for a high-speed auto core adhesion mounting machine. The utilization of the observer signal information of the linear encoder fault is employed to adjust the gain parameters to achieve the appropriate gain value while maintaining the required performance of the system. The dynamic modeling of the servo motor system design utilizing a pole placement technique was designed to support the proposed method. A scaling gain fault step size adjustment from −1% to 1% with increments of 0.2% is used to simulate the fault conditions of the linear encoder. The statistical mean value of the observer error signal is used to train the artificial neural network (ANN) model. The results showed that the control system design successfully tracked the dynamic response. Furthermore, the ANN model, with more than 98% confidence, was satisfactory in classifying the linear encoder fault condition. The gain compensation was successful in reducing position error by more than 95% compared with the system without compensated gain. Full article

The article considers the calculation of the flow of a viscous incompressible fluid in piston seals of piston hybrid power machines. The most widely used and effective seals are considered: a smooth gap seal and a step-type gap seal, and—based on the references analyses—the initial boundary conditions for their calculation are determined. The laminar and turbulent flows in gap seals are calculated based on the well-known analytical relationships, experimental studies and flow models, including the k-ε, Menter’s Shear StressTransport (SST) and Reynolds Stress (RSM) turbulence models. The effectiveness of using each model to determine average velocities, flow rates, and velocity plots in the cross section of a gap seal, as well as the adequacy of the description of known physical laws, is estimated. The results proved that the RSM turbulence model is better for the gap seals of different types under different modes of motion. Full article

Electric machines are critical components of the drivetrains of electric vehicles. Over the past few years the majority of traction drive systems have converged toward containing some form of a permanent magnet machine. There is increasing tendency toward the improvement of power density and efficiency of traction machines, thereby giving rise to innovative designs and improvements of basic machine topologies and the emergence of new classes of machines. This paper provides an overview of present trends toward high specific power density machines for traction drive systems. The focus will be on current technology and the trends that are likely to be pursued in the near future to achieve the high specific power goals set for the industry. The paper discusses machines that are applied in both hybrid and battery electric drivetrains without distinction and does not discuss the associated power electronic inverters. Future electric machine trends that are likely to occur are also projected. Full article

Operator assistance systems can help to reduce disturbance-related machine downtime in food production and packaging processes, especially when combined with machine learning algorithms. These assistance systems analyze the available sensor signals of the process control over time to help operators identify the causes of disturbances. Training such systems requires sufficient test data, which often are hardly available. Thus, this paper presents a study to investigate how test data for teaching machine learning algorithms can be generated by numerical simulation. The potential of using virtual commissioning (VC) software for simulating disturbances of discrete processes is examined, considering the example of a friction and collision-afflicted sub-process from an intermitting wrapping machine for confectionary. In this study the software industrialPhysics (iP) is analyzed regarding accuracy of static and dynamic friction and restitution. The values are verified by setting up virtual substitute tests and comparing the results with analytically determined values. Subsequently, prerecorded disturbances are classified, and seven selected elements are simulated in VC software, recording visual effects and switching the characteristics of sensors. The verification shows that VC software is generally adequate for the assigned task. Restrictions occur regarding the computing power required of the built-in physics engine and the resulting reduction of the machine to be simulated. Full article

Ball screw mechanisms are commonly designed and adopted to work for a high number of cycles, so that one of their most relevant characteristics is mechanical endurance. State-of-art experimental setups designed to characterize these mechanisms under operational load conditions require a layout able to withstand high loads and a relevant power to actuate the ball screw, therefore, being rather complex and expensive. To overcome these issues, this paper proposes an innovative test bench exploiting the recirculating power principle, designed for testing a ball screw under operational loads. It enables (at the same time) a reduction of loads on the test rig frame and a reduction of the mechanical power required to actuate the screw. The concept and the design of the proposed test bench are presented, as well as a simplified model to calculate the motor torque and the forces transmitted at the supports. An experimental setup is then realized and tested under actual loads for endurance tests. The results show that the use of the recirculating principle is promising to realize a test rig for endurance tests on a ball screw, thanks to the effectiveness of the solution and the simplicity of the realization of the system even under heavy loads. Among all the measuring instruments adopted (accelerometers, strain gauges, thermocouples and laser sensors for distance measurement on the test bench), the adoption of accelerometers on the nuts seems to be the most promising for condition monitoring, allowing to detect an incipient fault before a macroscopic failure of the ball screw system occurs. Full article

The selection of electric machines for an Electric Vehicle (EV) is mainly based on reliability, efficiency, and robustness, which makes the 5-phase Permanent Magnet Synchronous Motor (PMSM) among the best candidates. However, control performance of any motor drive can be deeply affected by both: (1) internal disturbances caused by parametric variations and model uncertainties and (2) external disturbances related to sensor faults or unexpected speed or torque variation. To ensure stability under those conditions, an Active Disturbance Rejection Controller (ADRC) based on an online dynamic compensation of estimated internal and external disturbances, and a Linear ADRC (LADRC) are investigated in this paper. The control performance was compared with traditional controller and evaluated by considering parametric variation, unmodeled disturbances, and speed sensor fault. The achieved results clearly highlight the effectiveness and high control performance of the proposed ADRC-based strategies. Full article

This paper describes a measurement method for the quality control of cylinders for printing machines based on roll-to-roll presses. If the surface finishing of the cylinders is not adequate, the printing is unacceptable, and the defective cylinders must be reworked. The performed quality check of the cylinder surface roughness by means of contact methods was unable to identify the cylinder defects, and acceptance of the manufactured cylinders before integration was demanded to the visual inspection performed by trained operators. In this work a contactless measurement method based on the eddy current displacement sensor was proposed and validated as a tool for quality check as an alternative to optical roughness measurements. A test bench for the characterization of printer cylinders was designed and manufactured, allowing for the validation of the proposed method on different batches of cylinders and the identification of a threshold to guide the acceptance of tested cylinders prior to mounting on the roll-to-roll press. Full article

The rising mobility demand of today’s society leads to an increasing strain of noise and pollutant emissions on people and the environment. An increasing environmental awareness and the scarcity of fossil fuels are increasingly placing alternative-powered vehicles in the focus of politics, research and development. Electric vehicles represent a promising solution to this problem. The electric machine represents a design control lever for the optimization of the electric powertrain with regard to efficiency, power, weight and size. Therefore, accurate and realistic machine design tools for the design of electric machines are becoming increasingly important. In this paper, the authors present an electric machine design tool for electric machines using MATLAB^® in order to enable an automated machine design. The electric machine design tool is published under an LGPL open source license. Full article

This paper presents a sensorless control method of a permanent magnet synchronous machine (PMSM) with magnetic saliency estimation. This is based on a high-frequency injection (HFI) technique applied on the modified PMSM model in the γδ reference frame. Except for sensorless control, an emphasis is placed on the magnetic saliency estimation to indicate a practical approach in tracking PMSM inductance variations. The magnetic saliency is determined using calculations embedded in the speed and position algorithm through current measurements. A notable characteristic of the modified PMSM model is that the corresponding rotor flux integrates both permanent magnet and saliency term fluxes. In applying a HFI technique for sensorless control, the structure of the PMSM flux model is formatted accordingly. A novel inductance matrix is derived that is completely compatible with the HFI methodology, since its elements include terms of angle error differential and average inductances. In addition, a sliding mode observer (SMO) is designed to estimate the speed and angle of rotor flux based on equivalent control applying a smooth function of the angle error instead of a sign one to reduce the chattering phenomenon. The control strategy is principally based on the adequacy of the proposed modified model and on the appropriateness of the SMO structure to successfully track the rotor flux position with the required stability and accuracy. Simulation results demonstrate the performance of the PMSM sensorless control verifying the effectiveness of the proposed algorithm to detect PMSM saliency, speed and position in steady state and transient modes successfully. Full article

Although electrical discharge machining (EDM) is one of the first established non-conventional machining processes, it still finds many applications in the modern industry, due to its capability of machining any electrical conductive material in complex geometries with high dimensional accuracy. The current study presents an experimental investigation of ED machining aluminum alloy Al5052. A full-scale experimental work was carried out, with the pulse current and pulse-on time being the varying machining parameters. The polishing and etching of the perpendicular plane of the machined surfaces was followed by observations and measurements in optical microscope. The material removal rate (MRR), the surface roughness (SR), the average white layer thickness (AWLT), and the heat affected zone (HAZ) micro-hardness were calculated. Through znalysis of variance (ANOVA), conclusions were drawn about the influence of machining conditions on the EDM performances. Finally, semi empirical correlations of MRR and AWLT with the machining parameters were calculated and proposed. Full article

The vibrational behavior of components in mechanical systems like drives and robots can become critical under changes in the system properties or loading in operation. Such undesired vibration can lead to detrimental conditions including excess wear, fatigue, discomfort, and acoustic emissions. Systems are designed to avoid certain frequencies to avoid such problems, but system parameters can change during operation due damage, wear, or change in loading. An example is the change in system properties or operation state that then activates resonance frequencies in our system. Therefore, this work has the goal of modifying the modal behavior of a system to avoid vibrational problems. Methods of design optimization are applied to find a new optimum design for this altered condition. Here, this is limited to the addition of mass in order to move the resonance frequency out of critical ranges. This though requires a new formulation of the optimization problem. We propose a new constraint formulation to avoid frequency ranges. To increase efficiency, a reduced analytical sensitivity analysis is introduced. This methodology is demonstrated on two test cases: a two-mass oscillator followed by a test case of higher complexity which is a gear housing considering over 15,000 design variables. The results show that the optimization solution gives the position and amount of mass added, which is a discrete solution that is practically implementable. Full article

Enhancing energy efficiency is one of the main challenges of today’s industrial robotics and manufacturing technology. In this paper a task-related analysis of the energetic performance of a 4-DOF industrial parallel robot is presented, and the optimal location of a predefined task with respect to the robot workspace is investigated. An optimal position of the task relative to the robot can indeed reduce the actuators’ effort and the energy consumption required to complete the considered operation. The dynamic and electro-mechanical models of the manipulators are developed and implemented to estimate the energy consumption of a parametrized motion with trapezoidal speed profile, i.e., a pick-and-place operation. Numerical results provide energy consumption maps that can be adopted to place the starting and ending points of the task in the more energy-efficient location within the robot workspace. Full article