Machines

Jointing Condition-Based Maintenance (CBM) with the Proportional Hazards Model (PHM), asset-intensive industries often monitor vital covariates to predict failure rate, the reliability function, and maintenance decisions. This analysis requires defining the transition probabilities of asset conditions evolving among states over time. When only one covariate is assessed, the model’s parameters are commonly obtained from expert opinions to provide state bands directly. However, the challenge lies within multiple covariate problems, where arbitrary judgment can be difficult and debatable, since the composite measurement does not represent any physical magnitude. In addition, selecting covariates lacks procedures to prioritize the most relevant ones. Therefore, the present work aimed to determine multiple covariate bands for the transition probability matrix via supervised classification and unsupervised clustering. We used Machine Learning (ML) to strengthen the PHM model and to complement expert knowledge. This paper allows obtaining the number of covariate bands and the optimal limits of each one when dealing with predictive maintenance decisions. This novel proposal of an ML condition assessment is a robust alternative to the expert criterion to provide accurate results, increasing the expectation of the remaining useful life for critical assets. Finally, this research has built an enriched bridge between the decision areas of predictive maintenance and Data Science. Full article

Biomechanical overload is considered a significant occupational risk in manufacturing and a potential cause of musculoskeletal disorders. This research aims to introduce new methodologies for the quantitative risk evaluation of biomechanical risk by combining surface electromyography with a motion acquisition system based on inertial measurement units. Due to the lack of experimental data in the literature acquired in a real industrial environment during the working shift, an on-the-field study regarding an automotive assembly line workstation has been carried out in collaboration with Fiat Chrysler Automobiles Italy S.p.A. Data related to the trunk flexion forward and the erector spinae muscle activity have been acquired for several consecutive working cycles by considering three different workers. Data analyses indicated kinematic and muscular activity patterns consistent with those expected and that the proposed wearable technologies can be integrated and used simultaneously during work activities. Furthermore, the results demonstrated data repeatability, strengthening the feasibility and usefulness of the combined use of kinematic and electromyography technologies to assess biomechanical overload in production lines. This study could lay the bases for the future definition of a method for assessing biomechanical overload due to awkward postures. Full article

With the exponential growth of electric vehicle sales worldwide over the past years and progress in technology and actions to combat climate change by reducing greenhouse gas emissions, the trend is expected to continue with a significant increase in the deployment of electric vehicles and plug-in hybrids. Given these circumstances, it is essential to identify the constraints that this increase in the number of electric vehicle charging stations poses for the electricity system. Therefore, the analysis developed in this paper discusses the effect of integrating electric vehicle charging stations in a real distribution network with different penetration levels. For this purpose, a typical electric system in Greece, managed by the Greek distribution system operator (HEDNO), is modeled and simulated in DIgSILENT PowerFactory software, one of the most widely used simulation tools in the electricity sector. To study the feasibility of connecting electric vehicle charging stations to the network, different case studies are presented, showing changes in the quantity of electric vehicles feeding power into the network through vehicle-to-grid technology. Quasi-dynamic simulations are used to analyze and discuss the voltage profiles of the system nodes, active power flows with the external source and power losses of the distribution network to determine whether the system is capable of supporting the increase in load produced by the electric vehicle charging stations and to promote awareness of the benefits of implementing vehicle-to-grid connections. Full article

As a temporary means of water transportation, floating bridges play an important role in the military and other fields. However, traditional floating bridges have limitations such as large size, heavy weight, and slow construction time. In this paper, we propose a rigid-flexible composite folding floating bridge. The main structure of the floating bridge consists of three layers: the bridge deck, airbag, and water bag. The floating bridge units are connected by flexible connectors to allow for pre-connection and folding of the bridge, reducing storage and transportation space, and improving construction efficiency. The proposed floating bridge also has a complete engineering application design and has been checked for safety and reliability (including the strength, buoyancy, and bearing capacity of the connections). We used AQWA software to simulate and analyze the anchorage scheme of the floating bridge and its response to wave loads and conducted a ballast test on a floating bridge model to verify its feasibility as a main bearing body. The results show that the floating bridge we designed has the advantages of being lightweight, having fewer consumables, having a small storage and transportation space, and being able to be constructed quickly. Full article

Although robotic systems have found their place in agriculture, there are still many challenges, especially in the area of localization in semi-structured environments. A robotic system has been developed and tested to perform various tasks in the steep vineyards of the Mediterranean region. In this paper, we describe a method for vine trunk localization, based solely on the visual recognition of vine trunks by neural networks fed by an RGB camera. Assuming that the height of the first wire in the vineyard is known, the proposed method is used to determine the location of vines in the immediate vicinity of the all-terrain mobile manipulator—ATMM-VIV—needed for spraying and bud suckering. The experiment was conducted in a slightly inclined vineyard to evaluate the proposed localization method. Full article

Gears are fundamental components used to transmit power and motion in modern industry. Their health condition monitoring is crucial to ensure reliable operations, prevent unscheduled shutdowns, and minimize human casualties. From this standpoint, the present study proposed a one-dimensional convolutional neural network (1-D CNN) model to diagnose tooth root cracks for standard and asymmetric involute spur gears. A 6-degrees-of-freedom dynamic model of a one-stage spur gear transmission was established to achieve this end and simulate vibration responses of healthy and cracked (25%–50%–75%–100%) standard (20°/20°) and asymmetric (20°/25° and 20°/30°) spur gear pairs. Three levels of signal-to-noise ratios were added to the vibration data to complicate the early fault diagnosis task. The primary consideration of the present study is to investigate the asymmetric gears’ dynamic characteristics and whether tooth asymmetry would yield an advantage in detecting tooth cracks easier to add to the improvements it affords in terms of impact resistance, bending strength, and fatigue life. The findings indicated that the developed 1-D CNN model’s classification accuracy could be improved by up to 12.8% by using an asymmetric (20°/30°) tooth profile instead of a standard (20°/20°) design. Full article

In order to solve the problem that the design constraints of the conjugated straight-line internal gear pair are unclear, the designing and checking of gear pairs requires repeated trial and error. By analogy with the design of the involute gear pair, the basic design parameters of the conjugated straight-line internal gear pair were clarified. Based on the mathematical model of the gear pair, the constraints on basic design parameters were given according to gear engagement theory and the geometrical relations of the tooth profile. The calculation formula and the constraint of the contact ratio were deduced according to the kinematic relations. Based on Litvin’s undercutting theory, the constraints on avoiding undercutting and end cutting were deduced and their correctness was verified by examples. The judgment method of tooth-overlapping interference and its corresponding numerical calculation flow were presented. The constraint on avoiding radial interference was deduced and analyzed. Based on the above content, the influence laws of design parameters on the design constraints were studied. Last, design examples were given and the effective design flow diagram of the conjugated straight-line internal gear pair was summarized. These research results provide a theoretical basis for the parameter design of conjugated straight-line internal gear pairs, provide guidance to avoid the interference of the gear pair, and promote the design system of the gear pair. Full article

This paper addresses the issue of the verification and comparison of the selected properties of a newly developed electric actuator. This actuator is intended to act as the drive of a walking robot designed for robotic football. Its envisioned placement is inside the robot’s knee joint and in its upper part. An integral part of the actuator is a harmonic precision gearbox and an absolute rotation sensor. The prototype of the newly developed actuator consists of both aluminum and 3D-printed parts. The selected parameters were verified according to the selected characteristics of ISO standard 9283, namely a one-directional pose accuracy and repeatable pose accuracy. The obtained data were compared with those of the standard actuator used thus far in constructing robots for robotic football. The implemented verification is based on the need to improve the performance parameters of the actuator while ensuring the sufficient accuracy of stopping the actuator in the required position. This is ensured by the use of a more accurate harmonic reducer and rotation sensor compared to the standard actuator. Full article

The automotive industry demands high quality at very low prices. To this end, it is necessary to constantly innovate, making processes increasingly competitive, while continuing to ensure high levels of quality. Model diversification has forced the automotive industry to make its manufacturing processes more flexible, without losing competitiveness. This has been the case for car seats, where the quantities to be produced per batch are significantly lowering due to the diversity of existing models. The objective of this work was to increase the production rate of bent wires used in car seat cushions and increase the flexibility of changing wire types in production. After benchmarking the existing solutions so far, it was verified that none are capable of complying with the required production rate, while also offering the desired flexibility. Thus, it is necessary to start with a new concept of conformation of the wires used in these seat cushions. The new concept developed and integrated some of the previously known solutions, developing other systems capable of providing the desired response in terms of productivity and flexibility. To this end, new mechanical solutions and automated systems were developed, which, together with other existing ones, made it possible to design equipment that complies with all the necessary requirements. The developed concept is innovative and can be employed to other types of products in which it can be applied. The new concept developed yields a production rate of 950 parts/hour (initial goal: 800 parts/hour), features a setup time of around 30 min, ensuring the desired flexibility, and the tool costs about 90% less than traditional tools. The payback period is around 5 months, given that the equipment cost was EUR 122.000 in terms of construction and assembly, and generated a gain of EUR 280.000 in the first year of service. Full article

The calibration of kinematic parameters has been widely used to improve the pose (position and orientation) accuracy of the robot arm. Intelligent measuring equipment with high accuracy is usually provided for the industrial manipulator. Unfortunately, large noise exists in the vision measurement system, which is provided for space manipulators. To overcome the adverse effect of measuring noise and improve the optimality of calibrating time, a calibration method based on extended Kalman filter (EKF) for space manipulators is proposed in this paper. Firstly, the identification model based on the Denavit–Hartenberg (D-H) modeling method is established. Then, the camera which is rigidly attached to the end-effector takes pictures of a calibration board that is settled around the manipulator. The actual pose of the end-effector is calculated based on the pictures of the calibration board. Subsequently, different data between the actual pose and theoretical pose as input, whilst error parameters are estimated by EKF and compensated in the kinematic algorithm. The simulation result shows that the pose accuracy has been improved by approximately 90 percent. Compared with the calibration method of the least squares estimate (LSE), EKF is beneficial to further optimize the calibrating time with a faster computation speed and ensure the stability of the calibration. Full article

In the field of precision machining, temperature fluctuation tends to cause the most significant machining errors. In particular, heat, which is generated in the nut of the ball screw feed system during movement, can deform the screw shaft significantly. In order to calculate and evaluate the thermal deformation of the ball screw shaft, the rate of the heat transfer from the nut to the screw shaft must be known. This rate can be calculated by subtracting the heat transfer rate to the nut raceway from the heat generation rate of the nut. Hence, it is necessary to calculate the heat flux from the nut to the nut raceway. This paper introduces a novel method to calculate the heat flux from the nut to the nut raceway. The new approach also enables calculations for different operating conditions. Furthermore, an experimental setup is established to measure the temperature increase, from 0 to 180 s after the nut starts moving, for various operating conditions. It is then theoretically shown that the 0–180 s temperature increase/heat flux curves for the nut are “universal”, i.e., the curve remains unchanged for the different operating conditions. Subsequently, a thermal model using the finite element method (FEM) is developed to simulate the nut temperature increase over time, which is then compared with the experimental data. As a result, it becomes possible to determine the heat flux from the nut to the nut raceway and calculate the 0–180 s temperature increase/heat flux curve (${\widetilde{\Delta \mathrm{T}}}_{0~180\mathrm{s},\mathrm{Training}\mathrm{Data}}$) for the training group. Finally, the heat flux from the nut to the nut raceway is calculated for ten different operating conditions in the test group using the 0–180 s temperature increase/heat flux curve of the training group (${\widetilde{\Delta \mathrm{T}}}_{0~180\mathrm{s},\mathrm{Training}\mathrm{Data}}$). The corresponding temperature curves are then calculated by inputting the values of the heat fluxes into the FEM model. The highest root mean square error (RMSE) between the calculated and experimentally measured temperature increase was 0.16 °C for Test 7 (the error was 10.7%). This result indicates that the new method is valid and feasible for calculating the heat flux from a ball screw nut to the nut raceway. Full article

In the short/vertical take-off and landing aircraft propulsion system, the vertical take-off/landing and rapid flight are switched through the engagement and disconnection of the dry friction clutch. The smooth and rapid connection of the friction clutch is crucial for the mobility and reliability of this type of aircraft. However, the friction clutch vibrates and generates a large amount of heat at high speed, which affects the engagement performance of the clutch. In practice, when the engagement pressure rises quickly, the clutch engagement time is short, and the temperature rise is small, but the impact torque is large, and vice versa. In view of this problem, with a short/vertical take-off aircraft dry friction clutch as the research object, considering the nonlinear variation of friction coefficient and lift fan load torque, the dynamics model and temperature field model of the high speed difference dry friction clutch are established to analyze the clutch engagement time, impact torque, and temperature change. The engagement test at the high speed of the clutch shows that the simulation results of the kinetic model and temperature field model are consistent with the test results. To realize low temperature rise, low impact torque, and short engagement time, the variable slope engagement pressure control method is proposed. Compared with the traditional fixed slope engagement pressure, the proposed variable slope engagement pressure can reduce the engagement time, impact torque and temperature rise simultaneously. The research results can provide a reference for the friction clutch engagement control of short-range take-off and landing aircraft, reduce the development cost of such aircraft, and improve the reliability of the design. Full article

To investigate the formation mechanism of the white layer on the machined surface during high-speed milling of nickel-based superalloy GH4169, several cutting parameters were selected for milling experiments. Energy dispersive spectroscopy (EDS), X-ray diffraction (XRD), and electron backscattered diffraction (EBSD) were employed to characterize element distribution, phase transformation, and microstructure changes in the machined surface of the superalloy and then reveal the formation mechanism of the white layer on the machined surface. The results show that the white layer appears on the machined surface of GH4169, which is dense and has no obvious structural features. The total amount of elements in the white layer remains unchanged, but the distribution of elements such as C, N, O, Fe, and Ni changes due to phase change. The formation mechanism of the white layer is due to the dynamic recovery and dynamic recrystallization caused by the heat–force coupling effect, which leads to the grain refinement of the material and thus forms the white layer. This investigation can provide theoretical support to improve the service life of the parts in actual machining. Full article

One of the most common issues in inverters are open-circuit faults (OPF). In this scenario, a proper fault-tolerant technique must be used to improve the motor performance. Although basic fault-tolerant modulation techniques are normally preferred, this paper proposes a discontinuous pulse-width modulation algorithm (HD-PWM) to operate five-phase inverters under a single OPF. In particular, loss equalization between the remaining switches after a fault occurs is the main objective of the HD-PWM algorithm, thus preventing future faults from occurring. The efficiency and harmonic distortion of the proposed technique are compared to the well-known sinusoidal PWM by simulation and experimentation under OPF conditions. The results obtained show a great performance of the proposed modulation technique, obtaining a relevant efficiency improvement. Full article

This paper presents a comparison among path tracking controllers on low-friction roads for autonomous vehicles. There are two goals in this paper. The first is to check the performance of path tracking controllers on low-friction roads, and the second is to check the effectiveness of four-wheel steering (4WS) for path tracking. To fully investigate the performance of path-tracking controllers on low-friction roads in this paper, the pure pursuit method, Stanley method, PID control, linear quadratic regulator, sliding mode control and model predictive control are designed and compared in terms of some measures. Front and four-wheel steering are adopted as actuators for path tracking. To utilize 4WS in the pure pursuit method, Stanley method and PID control, a yaw rate tracking control is adopted. With the designed path tracking controllers, a simulation is conducted on vehicle simulation software. From the simulation results, it is shown that most path tracking controllers are effective for path tracking on low-friction roads if finely tuned, and that 4WS is not recommended for path tracking on low-friction roads. Full article

Cascaded control structures are prevalent in industrial systems with many disturbances to obtain stable control but are cumbersome and challenging to tune. In this work, we propose cascaded constrained residual reinforcement learning (RL), an intuitive method that allows to improve the performance of a cascaded control structure while maintaining safe operation at all times. We draw inspiration from the constrained residual RL framework, in which a constrained reinforcement learning agent learns corrective adaptations to a base controller’s output to increase optimality. We first revisit the interplay between the residual agent and the baseline controller and subsequently extend this to the cascaded case. We analyze the differences and challenges this structure brings and derive some principle insights from this into the stability and operation of the cascaded residual architecture. Next, we propose a novel actor structure to enable efficient learning under the cascaded setting. We show that the standard algorithm is suboptimal for application to cascaded control structures and validate our method on a high-fidelity simulator of a dual motor drivetrain, resulting in a performance improvement of 14.7% on average, with only a minor decrease in performance occurring during the training phase. We study the different principles constituting the method and examine and validate their contribution to the algorithm’s performance under the considered cascaded control structure. Full article

A four-blade-passage numerical model was developed for a two-stage axial-flow compressor with an inlet guide vane (IGV) for the purpose of studying the steady and dynamic characteristics of the compressor approaching its stability limit. The flow-field information indicated that the tip-leakage flow decreased more rapidly from the blade’s leading edge to the trailing edge, with a decreasing flow rate. The leakage flow was verified to be driven via the blade load over the whole operating range. Further research on the blade load was carried out. The magnitude of the highest blade load in the leading-edge portion of the first-stage rotor determined the lowest flow rate with steady-simulation analysis. The circumferential grooves on the rotor improved the rotor’s stable range via reducing the blade load. Unsteady-simulation results showed that the extreme blade load appeared first at the front of the first stage, with a decreasing flow rate. The second stage played a positive compensative role through releasing some of the load from the first stage. It can be generalized that the lowest flow rate at a specific speed is determined via not only any single stage but also other stages in a multistage axial-flow compressor. Full article

Spherical roller bearings (SRBs) are widely used under self-aligning operating conditions, such as rotor bending or an angular misalignment between inner and outer rings due to their self-aligning function. However, the characterization of SRBs’ self-aligning function is often ignored in the present models. The reason for this is that the self-aligning condition is essentially a fault condition, and many scholars have assumed SRBs are in an ideal operating condition. Although there is nothing wrong with this analysis theoretically, it is incapable of characterizing SRBs’ service behavior comprehensively. In this work, the Lagrange equation was introduced to model the relationship among the rollers and the inner and outer rings. The contact region in particular was characterized in detail in order to solve the problems of undetermined contact status (UCS) and the varying law of the self-aligning contact angle (SAC angle). For the experiment, a novel SRBs pedestal with a self-aligning operating condition was designed, and the relevant self-aligning function testing was carried out. A good agreement was shown between the theoretical and experimental results. The results pointed out that, if taking no account of the self-aligning function, SRBs can be regarded as angular contact ball bearings or cylinder roller bearings. The amplitude of the inner-ring motion orbit is determined by the external load, but the shape is influenced by the direction and magnitude of the SAC angle. In the example of this paper, the values of the main frequency equal 136.8 Hz. Some additional frequencies are clearly aroused under the self-aligning operating condition, whose value is approximately equal to 8.3 Hz or its integer multiples. The dynamic performance of SRBs will be substantially improved by a light axial load plus an anticlockwise self-aligning contact angle rather than a large axial preload. Full article