Machines

27 pages, 4000 KiB

Open AccessEditor’s ChoiceArticle

Guiding the Selection of Multi-Vector Model Predictive Control Techniques for Multiphase Drives

by Juan Jose Aciego, Ignacio Gonzalez-Prieto, Mario Javier Duran, Angel Gonzalez-Prieto and Juan Carrillo-Rios

Machines 2024, 12(2), 115; https://doi.org/10.3390/machines12020115 - 7 Feb 2024

Cited by 13 | Viewed by 1761

Abstract

A diverse group of so-called multi-vector techniques has recently appeared to enhance the control performance of multiphase drives when a direct control strategy is implemented. With different numbers of switching states and approaches for estimating the application times, each multi-vector solution has its [...] Read more.

A diverse group of so-called multi-vector techniques has recently appeared to enhance the control performance of multiphase drives when a direct control strategy is implemented. With different numbers of switching states and approaches for estimating the application times, each multi-vector solution has its own nature and merits. Previous studies have individually tested each version of the proposed finite-control-set model predictive control (FCS-MPC) strategies using a single experimental setup with specific parameters and, in some cases, using a limited range of operating conditions and focusing exclusively on some control aspects. Although such works provide partial contributions, the control performance is highly affected by the test and rig conditions, being dependent on the machine parameters, the switching frequency and the range of operation. Consequently, it becomes difficult to extract some universal conclusions that guide the control designer on the best alternative for each application. Aiming to enrich the knowledge in this field and provide a broader picture, this work performs a global analysis with different multi-vector techniques, various machine parameters, multiple operating points and a complete set of indices. Experimental results confirm that the selection of the most adequate control strategy is not a trivial task because the degree to which multi-vector techniques are affected by the test conditions is variable and complex. Some tables with a qualitative analysis, based on the extensive empirical tests, contribute with a more complete insight and guide eventual control designers on the decision about the optimal regulation approach to be chosen. Full article

(This article belongs to the Section Electrical Machines and Drives)

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15 pages, 23883 KiB

Open AccessEditor’s ChoiceArticle

A Portable Artificial Robotic Nose for CO₂ Concentration Monitoring

by Christyan Cruz Ulloa, David Orbea, Jaime del Cerro and Antonio Barrientos

Machines 2024, 12(2), 108; https://doi.org/10.3390/machines12020108 - 5 Feb 2024

Viewed by 2868

Abstract

The technological advancements in sensory systems and robotics over the past decade have facilitated the innovation of centralized systems for optimizing resource utilization and monitoring efficiency in inspection applications. This paper presents a novel system designed for gas concentration sensing in environments by [...] Read more.

The technological advancements in sensory systems and robotics over the past decade have facilitated the innovation of centralized systems for optimizing resource utilization and monitoring efficiency in inspection applications. This paper presents a novel system designed for gas concentration sensing in environments by implementing a modular artificial nose (emulating the inhalation and exhalation process) equipped with a strategically designed air capture centralization system based on computational fluid dynamics analysis (CFD). The system incorporates three gas identification sensors distributed within the artificial nose, and their information is processed in real-time through embedded systems. The artificial nose is hardware–software integrated with a quadruped robot capable of traversing the environment to collect samples, maximizing coverage area through its mobility and locomotion capabilities. This integration provides a comprehensive perspective on gas distribution in a specific area, enabling the efficient detection of substances in the surrounding environment. The robotic platform employs a graphical interface for real-time gas concentration data map visualization. System integration is achieved using the Robot Operating System (ROS), leveraging its modularity and flexibility advantages. This innovative robotic approach offers a promising solution for enhanced environmental inspection and monitoring applications. Full article

(This article belongs to the Special Issue Advances in Path Planning and Autonomous Navigation)

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21 pages, 30482 KiB

Open AccessEditor’s ChoiceArticle

Design and Testing of a New Type of Planetary Traction Drive Bearing-Type Reducer

by Hongyu Shu, Yijie Yu, Ran Shu, Wenjie Wang and Changjiang Pan

Machines 2024, 12(2), 107; https://doi.org/10.3390/machines12020107 - 4 Feb 2024

Viewed by 2577

Abstract

This paper presents the design and development of a new type of planetary traction drive bearing-type reducer. In this design, the transmission outer ring is replaced with an elastic ring. The design constructs a circular arc at the axial end of the rolling [...] Read more.

This paper presents the design and development of a new type of planetary traction drive bearing-type reducer. In this design, the transmission outer ring is replaced with an elastic ring. The design constructs a circular arc at the axial end of the rolling body’s contour line. This ensures that the contact point of this arc with the reducer’s outer ring and the inner ring’s axial end face is maintained on the radial traction contact line. As a result, it can replace the thrust bearing and provide an axial support function. It has the advantages of simple structure, easy processing, smooth transmission, and low noise. This paper first introduces the design and development process of this bearing-type reducer and presents systematic research on its transmission principle and dynamics. Subsequently, in response to the edge effect phenomenon of the outer ring contact line, the contour line of the outer ring is refined by adopting the shaping method used for bearing rollers, establishing a full circular arc profile shaping method, which significantly improves its edge effect. Finally, in our investigations, combined with experimental tests, a prototype of the bearing-type reducer was fabricated, and the speed ratio, torque, and transmission efficiency of the reducer were studied. The results demonstrate that the bearing-type reducer can achieve high transmission accuracy and efficiency. The transmission performance varies significantly under different lubrication conditions, with the peak efficiency reaching as high as 99.97% when using Santotrac 50 traction oil. The results verify the feasibility of the proposed design method and have the potential to be applied in wheel hub motors and robot joints. Full article

(This article belongs to the Section Electrical Machines and Drives)

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24 pages, 28591 KiB

Open AccessEditor’s ChoiceArticle

A Low-Energy Consumption Planning Method for Multi-Locomotion Wheel-Legged Mobile Robots

by Jinfu Li, Yongxi Liu, Ze Yu, Yuntao Guan, Yingzhuo Zhao, Zheming Zhuang and Tao Sun

Machines 2024, 12(2), 98; https://doi.org/10.3390/machines12020098 - 1 Feb 2024

Cited by 1 | Viewed by 1568

Abstract

Mobile robots can replace humans to fulfill tasks in dangerous environments, which has been a research focus in recent years. This paper proposes a wheel-legged mobile robot with multi-locomotion and a low-energy consumption planning method. Different from the existing wheel-legged mobile robots, it [...] Read more.

Mobile robots can replace humans to fulfill tasks in dangerous environments, which has been a research focus in recent years. This paper proposes a wheel-legged mobile robot with multi-locomotion and a low-energy consumption planning method. Different from the existing wheel-legged mobile robots, it can realize low-energy movement in different terrains with simple structures, and it can realize three modes: synchronous, tumbling, and curl–stretch. Then, based on the kinematics and dynamics model, a low-energy planning method is proposed, and low-energy motion planning is carried out for the three modes to obtain the low-energy driving law in each mode. A robot prototype is developed, and the experimental results show that the robot can move through the three modes with lower energy consumption in all three terrains. The planning method provides an effective reference for applying wheel-legged mobile robots. Full article

(This article belongs to the Section Robotics, Mechatronics and Intelligent Machines)

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19 pages, 7670 KiB

Open AccessEditor’s ChoiceArticle

Automated Maximum Torque per Ampere Identification for Synchronous Reluctance Machines with Limited Flux Linkage Information

by Shuo Wang, Vasyl Varvolik, Yuli Bao, Ahmed Aboelhassan, Michele Degano, Giampaolo Buticchi and He Zhang

Machines 2024, 12(2), 96; https://doi.org/10.3390/machines12020096 - 29 Jan 2024

Cited by 3 | Viewed by 1917

Abstract

The synchronous reluctance machine is well-known for its highly nonlinear magnetic saturation and cross-saturation characteristics. For high performance and high-efficiency control, the flux-linkage maps and maximum torque per ampere table are of paramount importance. This study proposes a novel automated online searching method [...] Read more.

The synchronous reluctance machine is well-known for its highly nonlinear magnetic saturation and cross-saturation characteristics. For high performance and high-efficiency control, the flux-linkage maps and maximum torque per ampere table are of paramount importance. This study proposes a novel automated online searching method for obtaining accurate flux-linkage and maximum torque per ampere Identification. A limited 6 × 2 dq-axis flux-linkage look-up table is acquired by applying symmetric triangle pulses during the self-commissioning stage. Then, three three-dimensional modified linear cubic spline interpolation methods are applied to extend the flux-linkage map. The proposed golden section searching method can be easily implemented to realize higher maximum torque per ampere accuracy after 11 iterations with a standard drive, which is a proven faster solution with reduced memory sources occupied. The proposed algorithm is verified and tested on a 15-kW SynRM drive. Furthermore, the iterative and execution times are evaluated. Full article

(This article belongs to the Special Issue Electrical Machines and Drives: Modeling, Simulation and Testing)

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22 pages, 24921 KiB

Open AccessEditor’s ChoiceArticle

Development of a Compact Incremental Forming Machine

by Tatiana P. Resende, Gustavo P. Carmo, Daniel G. Afonso and Ricardo J. Alves de Sousa

Machines 2024, 12(2), 86; https://doi.org/10.3390/machines12020086 - 23 Jan 2024

Cited by 1 | Viewed by 1866

Abstract

Since the beginning of the 21st century, incremental sheet-metal-forming processes, such as single-point incremental forming (SPIF), have been the subject of extensive research. The SPIF process is highlighted as an efficient and cost-effective solution for producing complex parts with different materials and scales, [...] Read more.

Since the beginning of the 21st century, incremental sheet-metal-forming processes, such as single-point incremental forming (SPIF), have been the subject of extensive research. The SPIF process is highlighted as an efficient and cost-effective solution for producing complex parts with different materials and scales, surpassing conventional methods and being ideal for small series and customized products. Various machines can be used to implement SPIF, such as adapted milling machines, serial robots, and dedicated machines, each with its own advantages. However, although it requires a higher initial investment, a dedicated machine offers superior performance. The objective of this project was the creation of a compact and portable dedicated machine, which included the design of suitable kinematics, a mechanical project, and numerical control. The structural design led to the optimization of the dimensions of the robot arms. Direct and indirect kinematics were analyzed. Finally, the careful selection and adaptation of components were carried out, bearing in mind the support system of the forming punch, including the selection and sizing of motors, reducers, and linear actuators. A functional early prototype was successfully built and tested. Full article

(This article belongs to the Special Issue Advances in Composites Manufacturing: Machines, Systems and Processes)

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17 pages, 12030 KiB

Open AccessEditor’s ChoiceArticle

Experimental Use Validation of the Master Hybrid Haptic Device Dedicated to Remote Center-of-Motion Tasks

by Majdi Meskini, Amir Trabelsi, Houssem Saafi, Abdelfattah Mlika, Marc Arsicault, Juan Sandoval, Saïd Zeghloul and Med Amine Laribi

Machines 2024, 12(1), 80; https://doi.org/10.3390/machines12010080 - 20 Jan 2024

Cited by 1 | Viewed by 1681

Abstract

The main objective of this paper is to discuss the experimental validation of a tele-operation system for remote center-of-motion tasks, such as laparoscopic surgery. This validation is based on the use of an extra sensor placed on the master manipulator. The tele-operation system [...] Read more.

The main objective of this paper is to discuss the experimental validation of a tele-operation system for remote center-of-motion tasks, such as laparoscopic surgery. This validation is based on the use of an extra sensor placed on the master manipulator. The tele-operation system is composed of a new hybrid haptic device (nHH) intended to be used as a master manipulator controlling a collaborative robot, used as a slave surgical robot. The resolution of the forward kinematic model (FKM) of the master device is performed experimentally thanks to the use of an extra sensor. The IMU, as the extra sensor, is installed on the serial part of the nHH device to measure the orientation and is enabled to solve the FKM of the parallel part of the nHH device. The use of an extra sensor reduces the calculation time, improves the accuracy of the KFM, and makes it suitable for real-time applications. The preliminary validation of the force feedback in the nHH workspace is validated. Experiments were conducted on the master–slave platform to validate the proposed approach. The results are promising, which proves that the nHH device presents a suitable performance for the desired task. Full article

(This article belongs to the Special Issue New Trends in Medical and Service Robots—Selected Papers from MESROB 2023)

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15 pages, 4215 KiB

Open AccessEditor’s ChoiceArticle

A Novel Load Extrapolation Method for Multiple Non-Stationary Loads on the Drill Pipe of a Rotary Rig

by Haijin Wang, Zonghai Zhang, Jiguang Zhang, Yuying Shen and Jixin Wang

Machines 2024, 12(1), 75; https://doi.org/10.3390/machines12010075 - 19 Jan 2024

Cited by 3 | Viewed by 1777

Abstract

The drill pipe of a rotary rig is subject to the dynamic influence of non-stationary loads, including rotation torque and applied force. In order to address the challenge of simultaneously extrapolating multiple non-stationary loads, a novel extrapolation framework is proposed. This framework utilizes [...] Read more.

The drill pipe of a rotary rig is subject to the dynamic influence of non-stationary loads, including rotation torque and applied force. In order to address the challenge of simultaneously extrapolating multiple non-stationary loads, a novel extrapolation framework is proposed. This framework utilizes rainflow counting to obtain mean and amplitude sequences of the loads. The extreme values of the amplitude sequence are fitted using the Generalized Pareto Distribution (GPD), while the median values are fitted using the Double Kernel Density Estimation (DKDE). By extrapolating the Inverse Cumulative Distribution Function (ICDF) based on the fitted distribution, a new amplitude sequence can be derived. The combination of this extrapolated amplitude sequence with the original mean sequence forms a new load spectrum. The results of applying the proposed extrapolation method to the drill pipe of a rotary rig demonstrate the ability of the method to yield conservative extrapolation results and accurately capture the variations in damage under the original working conditions. Full article

(This article belongs to the Section Machine Design and Theory)

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48 pages, 1780 KiB

Open AccessEditor’s ChoiceReview

A Review on Wearable Product Design and Applications

by Prodromos Minaoglou, Nikolaos Efkolidis, Athanasios Manavis and Panagiotis Kyratsis

Machines 2024, 12(1), 62; https://doi.org/10.3390/machines12010062 - 16 Jan 2024

Cited by 9 | Viewed by 5525

Abstract

In recent years, the rapid advancement of technology has caused an increase in the development of wearable products. These are portable devices that can be worn by people. The main goal of these products is to improve the quality of life as they [...] Read more.

In recent years, the rapid advancement of technology has caused an increase in the development of wearable products. These are portable devices that can be worn by people. The main goal of these products is to improve the quality of life as they focus on the safety, assistance and entertainment of their users. The introduction of many new technologies has allowed these products to evolve into many different fields with multiple uses. The way in which the design of wearable products/devices is approached requires the study and recording of multiple factors so that the final device is functional and efficient for its user. The current research presents an in-depth overview of research studies dealing with the development, design and manufacturing of wearable products/devices and applications/systems in general. More specifically, in this review, a comprehensive classification of wearable products/devices in various sectors and applications was carried out, resulting in the creation of eight different categories. A total of 161 studies from the last 13 years were analyzed and commented on. The findings of this review show that the use of new technologies such as 3D scanning and 3D printing are essential tools for the development of wearable products. In addition, many studies observed the use of various sensors through which multiple signals and data could be recorded. Finally, through the eight categories that the research studies were divided into, two main conclusions emerged. The first conclusion is that 3D printing is a method that was used the most in research. The second conclusion is that most research directions concern the safety of users by using sensors and recording anthropometric dimensions. Full article

(This article belongs to the Special Issue Editorial Board Members’ Collection Series: "Smart Manufacturing")

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17 pages, 4577 KiB

Open AccessEditor’s ChoiceArticle

An Experimental and Numerical Study of the Laser Ablation of Bronze

by Esmaeil Ghadiri Zahrani, Vasiliki E. Alexopoulou, Emmanouil L. Papazoglou, Bahman Azarhoushang and Angelos Markopoulos

Machines 2024, 12(1), 63; https://doi.org/10.3390/machines12010063 - 16 Jan 2024

Cited by 5 | Viewed by 1747

Abstract

The use of lasers in various precise material removal processes has emerged as a viable and efficient alternative to traditional mechanical methods. However, the laser ablation of materials is a complex, multi-parameter process where scanning paths need to be repeated multiple times. This [...] Read more.

The use of lasers in various precise material removal processes has emerged as a viable and efficient alternative to traditional mechanical methods. However, the laser ablation of materials is a complex, multi-parameter process where scanning paths need to be repeated multiple times. This repetition causes changes in the absorption and temperature distribution along the scanning path, thereby affecting the accuracy of the ablation. Therefore, it is crucial to thoroughly study these phenomena. This article presents an experimental and numerical study on the laser ablation of bronze (DIN: 1705) in a multi-track ablation process. Specifically, six consecutive passes using a ns laser at three different energy densities were conducted. After each pass, measurements of the ablation depth and pile-up height were taken at three distinct points along the track (start, middle, and end) to evaluate the efficiency and quality of the process. To gain a deeper understanding of the underlying physical mechanisms, a numerical simulation model based on the Finite Element Method (FEM) was developed. The effective absorptivity was defined through reverse engineering, and the material’s cooling rates were also estimated. This study’s findings provide significant insights into the influence of machining parameters on the ablation process and its progression with varying numbers of consecutive repetitions. A primarily linear correlation was deduced between the ablation depth, energy density, and number of repetitions, while the relationship with the pile-up height appeared to be more ambiguous and nonlinear. The estimated cooling rates ranged from 10⁶ to 10¹⁰ [K/s]. Additionally, a heat accumulation phenomenon and a gradual temperature increase resulting from consecutive laser scans were also observed. A good agreement between the simulation results and experiments for the ablation depths was observed. Full article

(This article belongs to the Special Issue Advances and Trends in Non-conventional, Abrasive and Precision Machining 2022)

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25 pages, 25756 KiB

Open AccessEditor’s ChoiceArticle

Analysis of the Control Characteristics of the Electro-Hydraulic Vibration System Based on the Single-Neuron Control Algorithm

by Wenang Jia, Zeji Chen, Tongzhong Chen and Sheng Li

Machines 2024, 12(1), 58; https://doi.org/10.3390/machines12010058 - 12 Jan 2024

Viewed by 1752

Abstract

This paper proposes an electro-hydraulic vibration control system based on the single-neuron PID algorithm, which improves the operating frequency of the electro-hydraulic fatigue testing machine and the control accuracy of the load force. Through mathematical modeling of the electro-hydraulic vibration system (EVS), a [...] Read more.

This paper proposes an electro-hydraulic vibration control system based on the single-neuron PID algorithm, which improves the operating frequency of the electro-hydraulic fatigue testing machine and the control accuracy of the load force. Through mathematical modeling of the electro-hydraulic vibration system (EVS), a MATLAB/Simulink simulation, and experimental testing, this study systematically analyzes the output waveform of the EVS as well as the closed-loop situation of load force amplitude and offset under the action of the single-neuron PID algorithm. The results show that: the EVS with a 2D vibration valve as the core, which can control the movement of the spool in the two-degrees-of-freedom direction, can realize the output of an approximate sinusoidal load force waveform from 0 to 800 Hz. The system controlled by the single-neuron PID algorithm is less complex to operate than the traditional PID algorithm. It also has a short rise time for the output load force amplitude curve and a maximum control error of only 1.2%. Furthermore, it exhibits a rapid closed-loop response to the load force offset. The range variability of the load force is measured to be 1.43%. A new scheme for the design of EVS is provided in this study, which broadens the application range of electro-hydraulic fatigue testing machines. Full article

(This article belongs to the Section Machine Design and Theory)

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29 pages, 24569 KiB

Open AccessEditor’s ChoiceArticle

New Method for Precise Measurement of Clamping Plate Deformations on Forming Presses

by Georg Ivanov, Thomas Burkhardt, Lars Penter and Steffen Ihlenfeldt

Machines 2024, 12(1), 40; https://doi.org/10.3390/machines12010040 - 5 Jan 2024

Viewed by 1762

Abstract

The deformation of press bolster plates under load can significantly impact the quality of manufactured workpieces. Consequently, press manufacturers are usually obliged to provide the metric proof of the permissible deformation values during the press commissioning process. Unfortunately, the existing measurement methods for [...] Read more.

The deformation of press bolster plates under load can significantly impact the quality of manufactured workpieces. Consequently, press manufacturers are usually obliged to provide the metric proof of the permissible deformation values during the press commissioning process. Unfortunately, the existing measurement methods for determining bolster plate deformations present flaws in the measurement accuracy, the application flexibility, the metrological effort, and other aspects. These issues have been addressed through the development of a new measurement method using multiple inclination profiles on the surface of the measured object. Based on the difference in the inclination between the unloaded and loaded states, the method approximates the inclination surface and calculates the deformation of the measured object through integration. The measurement method was first used for commissioning tests of forming presses. A comparison with the results obtained with a measurement frame equipped with high-resolution measurement probes demonstrates an accuracy of the new method of less than 20 µm. Full article

(This article belongs to the Special Issue Design and Experimental Activity of Testing Machines and Mechanical Test Rigs)

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22 pages, 8263 KiB

Open AccessEditor’s ChoiceArticle

Research on the Hobbing Processing Method of Marine Beveloid Gear

by Jianmin Wen, Haoyu Yao, Hui Li and Bindi You

Machines 2024, 12(1), 35; https://doi.org/10.3390/machines12010035 - 4 Jan 2024

Cited by 2 | Viewed by 2320

Abstract

Due to the particular structure of the beveloid gear, it cannot be directly hobbed by an ordinary gear hobbing machine. The existing processing method is complex and has a high cost. Therefore, the mass production and industrialization of beveloid gears are limited. To [...] Read more.

Due to the particular structure of the beveloid gear, it cannot be directly hobbed by an ordinary gear hobbing machine. The existing processing method is complex and has a high cost. Therefore, the mass production and industrialization of beveloid gears are limited. To improve the machining efficiency and accuracy of processing beveloid gears, we proposed a hobbing method via the modification of ordinary hobbing machines. At first, we completed the derivation and calculation of the relevant processing parameters of the beveloid gear based on the study of the structural characteristics of the beveloid gear and the principle of hobbing machining. Then, we proposed and designed a beveloid gear hobbing method, and the modification of the ordinary hobbing machine was completed by using a hanging wheel mechanism in synchronous belt type. Finally, we completed the actual hobbing of the beveloid gear, and the feasibility of the proposed method was verified. After that, we analyzed the machining error of the trial-produced beveloid gear; the results showed that the accuracy of the trial-produced beveloid gear met the 6-level standard, which also verified the accuracy of the proposed method. Full article

(This article belongs to the Special Issue Advancements in Mechanical Power Transmission and Its Elements)

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20 pages, 9439 KiB

Open AccessEditor’s ChoiceArticle

Novel Design of Variable Stiffness Pneumatic Flexible Shaft Coupling: Determining the Mathematical-Physical Model and Potential Benefits

by Peter Kaššay, Robert Grega, Matej Urbanský, Jozef Krajňák, Matúš Kačír and Lucia Žuľová

Machines 2024, 12(1), 28; https://doi.org/10.3390/machines12010028 - 31 Dec 2023

Cited by 3 | Viewed by 2250

Abstract

Presently, mechanical system vibroisolation is becoming increasingly important. One of the new approaches is semi-active vibroisolation using elements capable of changing a selected mechanical property. These include, among others, pneumatic flexible shaft couplings capable of changing torsional stiffness during operation. The main goal [...] Read more.

Presently, mechanical system vibroisolation is becoming increasingly important. One of the new approaches is semi-active vibroisolation using elements capable of changing a selected mechanical property. These include, among others, pneumatic flexible shaft couplings capable of changing torsional stiffness during operation. The main goal of the article is to examine the potential advantages of a newly patented pneumatic coupling over a current type with the same pneumatic element arrangement. For comparison, parameters determinable from static load characteristics were selected. These parameters are maximum twist angle and torque, average torsional stiffness, and the percentage of torque transmitted by the bellows rubber shell. In all cases, the new coupling had better properties. Since the prototype of the new coupling has not yet been produced, its parameters were determined from its mathematical-physical model. The article contains a full procedure to obtain the static load characteristic of a new coupling type, beginning with the determination of air bellows force/height and volume/height characteristics, then optimum sizes of coupling with regards to the operating range of elements, the dependency of element height on the coupling’s twist angle, and finally the computation of the static load characteristic considering isothermal gas compression. The presented procedure can be applied to any pneumatic bellows where the force/height characteristics of different pressures are given. Full article

(This article belongs to the Special Issue Research on Rotor Dynamics and Vibration Control)

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17 pages, 4925 KiB

Open AccessEditor’s ChoiceArticle

Design and Control of Autonomous Flying Excavator

by Arif Zaman and Jaho Seo

Machines 2024, 12(1), 23; https://doi.org/10.3390/machines12010023 - 29 Dec 2023

Cited by 2 | Viewed by 2299

Abstract

This study presents a drone-based excavation platform prototype with the key objectives of balancing stability during excavation, sensing, and digging the soil pile autonomously without human intervention. The whole platform was first designed in CAD software, and then each part of the excavator [...] Read more.

This study presents a drone-based excavation platform prototype with the key objectives of balancing stability during excavation, sensing, and digging the soil pile autonomously without human intervention. The whole platform was first designed in CAD software, and then each part of the excavator assembly was 3D printed by using PLA filament. The physical system was then combined with numerous electronic components and linked to various software applications for a drone to perform autonomous excavations. Pixhawk Orange Cube served as the main controller for the drone, while Nvidia Jetson Nano was used for processing data and controlling the tip of the bucket at a specified location for the autonomous excavator. Two scenarios were considered to validate the functionality of the developed platform. In the first scenario, the drone flies independently to a construction site, lands, senses the soil, excavates it, and then travels to another location specified by the mission to deposit the soil. Full article

(This article belongs to the Special Issue Control and Mechanical System Engineering)

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25 pages, 9757 KiB

Open AccessEditor’s ChoiceArticle

Redesign of a Disc-on-Disc Computer Numerical Control Tribometer for a Wide-Range and Shudder-Resistant Operation

by Matija Hoić, Mario Hrgetić, Nenad Kranjčević, Joško Deur and Andreas Tissot

Machines 2024, 12(1), 14; https://doi.org/10.3390/machines12010014 - 26 Dec 2023

Viewed by 1685

Abstract

The paper presents a redesign of the custom disc-on-disc-type tribometer intended for the experimental characterization of the friction and wear of automotive dry clutch friction lining. The redesign is aimed at expanding the operating range at which the machine is not sensitive to [...] Read more.

The paper presents a redesign of the custom disc-on-disc-type tribometer intended for the experimental characterization of the friction and wear of automotive dry clutch friction lining. The redesign is aimed at expanding the operating range at which the machine is not sensitive to shudder vibrations. This is achieved through a set of hardware and software upgrade measures. First, the natural frequency of the normal load-generation linear axis of the machine is increased by enlarging its bending stiffness and reducing the suspended mass. The former is realized by replacing the single, two-axial force/torque piezoelectric sensor with a set of three three-axial piezoelectric force sensors, adding a set of stiff linear guides, and reducing the lengths of the cantilevers of lateral forces acting on the linear axis guide system. The latter is accomplished by reducing the overall dimensions of the cooling disc and redesigning the thermal insulation components. The shudder sensitivity resistance is further reduced through individual normal force-readings-based adjustment of parallelism between friction contact surfaces and the increase in the stiffness of eccentrically positioned water-cooling pipes. Finally, the stability of the coefficient of friction and, consequently, the wear process are boosted by adjusting the control routines to minimize the circumferential and/or radial temperature gradients. These adjustments include the introduction of a clutch lock-up interval at the end of the clutch closing cycle, a minimum cooling delay inserted between two closing cycles, and maximum normal force demand of the clutch torque controller. The performance gain of the upgraded tribometer is demonstrated through a study of the dry clutch friction plate static wear experimental characterization for a wide range of operating conditions. Full article

(This article belongs to the Special Issue Advances in Vehicle Brake and Clutch Systems)

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21 pages, 11951 KiB

Open AccessEditor’s ChoiceArticle

A Control Architecture for Developing Reactive Hybrid Remotely Operated Underwater Vehicles

by Fernando Gómez-Bravo, Alejandro Garrocho-Cruz, Olga Marín-Cañas, Inmaculada Pulido-Calvo, Juan Carlos Gutierrez-Estrada and Antonio Peregrín-Rubio

Machines 2024, 12(1), 1; https://doi.org/10.3390/machines12010001 - 19 Dec 2023

Cited by 1 | Viewed by 2116

Abstract

This article introduces a control architecture designed for the development of Hybrid Remotely Operated Underwater Vehicles. The term ”Hybrid” characterizes Remotely Operated systems capable of autonomously executing specific operations. The presented architecture maintains teleoperation capabilities while enabling two fully autonomous applications. The approach [...] Read more.

This article introduces a control architecture designed for the development of Hybrid Remotely Operated Underwater Vehicles. The term ”Hybrid” characterizes Remotely Operated systems capable of autonomously executing specific operations. The presented architecture maintains teleoperation capabilities while enabling two fully autonomous applications. The approach emphasizes the implementation of reactive navigation by exclusively utilizing data from a Mechanical Scanned Imaging Sonar for control decisions. This mandates the control system to solely react to data derived from the vehicle’s environment, without considering other positioning information or state estimation. The study involves transforming a small-scale commercial Remotely Operated Underwater Vehicle into a hybrid system without structural modifications, and details the development of an intermediate Operational Control Layer responsible for sensor data processing and task execution control. Two practical applications, inspired by tasks common in natural or open-water aquaculture farms, are explored: one for conducting transects, facilitating monitoring and maintenance operations, and another for navigating toward an object for inspection purposes. Experimental results validate the feasibility and effectiveness of the authors’ hypotheses. This approach expands the potential applications of underwater vehicles and facilitates the development of Hybrid Remotely Operated Underwater Vehicles, enabling the execution of autonomous reactive tasks. Full article

(This article belongs to the Special Issue Mobile Robotics: Mathematics, Models and Methods)

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23 pages, 7443 KiB

Open AccessEditor’s ChoiceArticle

A Technique for Bearing Fault Diagnosis Using Novel Wavelet Packet Transform-Based Signal Representation and Informative Factor LDA

by Andrei S. Maliuk, Zahoor Ahmad and Jong-Myon Kim

Machines 2023, 11(12), 1080; https://doi.org/10.3390/machines11121080 - 11 Dec 2023

Cited by 6 | Viewed by 2730

Abstract

This paper proposes a new method for bearing fault diagnosis using wavelet packet transform (WPT)-based signal representation and informative factor linear discriminant analysis (IF-LDA). Time–frequency domain approaches for analyzing bearing vibration signals have gained wide acceptance due to their effectiveness in extracting information [...] Read more.

This paper proposes a new method for bearing fault diagnosis using wavelet packet transform (WPT)-based signal representation and informative factor linear discriminant analysis (IF-LDA). Time–frequency domain approaches for analyzing bearing vibration signals have gained wide acceptance due to their effectiveness in extracting information related to bearing health. WPT is a prominent method in this category, offering a balanced approach between short-time Fourier transform and empirical mode decomposition. However, the existing methods for bearing fault diagnosis often overlook the limitations of WPT regarding its dependence on the mother wavelet parameters for feature extraction. This work addresses this issue by introducing a novel signal representation method that employs WPT with a new rule for selecting the mother wavelet based on the power spectrum energy-to-entropy ratio of the reconstructed coefficients and a combination of the nodes from different WPT trees. Furthermore, an IF-LDA feature preprocessing technique is proposed, resulting in a highly sensitive set of features for bearing condition assessment. The k-nearest neighbors algorithm is employed as the classifier, and the proposed method is evaluated using datasets from Paderborn and Case Western Reserve universities. The performance of the proposed method demonstrates its effectiveness in bearing fault diagnosis, surpassing existing techniques in terms of fault identification and diagnosis performance. Full article

(This article belongs to the Special Issue New Advances in Rotating Machinery)

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18 pages, 6413 KiB

Open AccessEditor’s ChoiceArticle

Modal Balancing of Warped Rotors without Trial Runs Using the Numerical Assembly Technique

by Georg Quinz, Gregor Überwimmer, Michael Klanner and Katrin Ellermann

Machines 2023, 11(12), 1073; https://doi.org/10.3390/machines11121073 - 7 Dec 2023

Cited by 2 | Viewed by 1541

Abstract

The increasing use of high-speed machinery leads to a growing demand for efficient balancing methods for flexible rotors. Conventional balancing methods are costly and time-consuming since they require multiple trial runs. For this reason, recent research focuses on model-based balancing methods, which substitute [...] Read more.

The increasing use of high-speed machinery leads to a growing demand for efficient balancing methods for flexible rotors. Conventional balancing methods are costly and time-consuming since they require multiple trial runs. For this reason, recent research focuses on model-based balancing methods, which substitute measurements with simulations. This work presents and examines a model-based modal balancing method, which utilizes the Numerical Assembly Technique (NAT) for the in situ balancing of warped rotors with flexible behaviour. NAT is a successive modification of discrete–continuous modelling that leads to analytical harmonic solutions and is very computationally efficient. In this version of NAT, internal damping is also included with a viscoelastic material model using fractional time derivatives. The modal balancing procedure is adapted to handle measurements outside of the critical speeds and the effect of the pre-bend on the rotor. The accuracy of the simulations is shown by comparing measured mode shapes and eigenvalues with values calculated with NAT. Furthermore, the first two modes of a rotor test bed are successfully balanced without trial runs. Full article

(This article belongs to the Special Issue New Advances in Rotating Machinery)

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17 pages, 6264 KiB

Open AccessEditor’s ChoiceArticle

ROMI: Design and Experimental Evaluation of a Linear Delta Robotic System for High-Precision Applications

by Xiaoyu Huang, Elizabeth Rendon-Morales and Rodrigo Aviles-Espinosa

Machines 2023, 11(12), 1072; https://doi.org/10.3390/machines11121072 - 6 Dec 2023

Cited by 3 | Viewed by 2456

Abstract

In this paper, the design and experimental evaluation of a parallel robotic system based on a linear delta geometry is presented. The design considers the requirements for high-precision applications including workspace, motion resolution, and payload. The entire design process includes robot kinematics, control, [...] Read more.

In this paper, the design and experimental evaluation of a parallel robotic system based on a linear delta geometry is presented. The design considers the requirements for high-precision applications including workspace, motion resolution, and payload. The entire design process includes robot kinematics, control, and optimization, resulting in the demonstration of a working device. The robot structure offers a versatile and simplified design when compared with state-of-the-art devices being able to be adapted to perform different tasks while keeping the advantages of high precision with reduced complexity. The presented robot prototype was constructed and evaluated experimentally through three proof-of-concept experiments mimicking tasks requiring high motion precision such as microsurgery, semiconductor testing, and optical device alignment. The obtained results in the three experimental scenarios validate that the here-proposed design can achieve an average motion precision of ~3.3 ± 0.3 μm with varying load conditions, thus confirming its potential to be used for high-precision tasks in industrial and medical settings. Full article

(This article belongs to the Special Issue New Trends in Robotics, Automation and Mechatronics)

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22 pages, 10747 KiB

Open AccessEditor’s ChoiceArticle

Bioinspired Design for Lightweighting and Vibration Behavior Optimization in Large-Scale Aeronautical Tooling: A Comparative Study

by Ignacio Laraudogoitia Blanc, Christian Hamm, Maider García de Cortázar, Nils Kaiser, Oleksander Savysko and Franck Andrés Girot Mata

Machines 2023, 11(12), 1067; https://doi.org/10.3390/machines11121067 - 4 Dec 2023

Cited by 2 | Viewed by 2328

Abstract

A comparative study is presented, focusing on three different bioinspired design methodologies applied to a large-scale aeronautical tooling use case. The study aims to optimize the structure in terms of the first vibration mode, minimizing mass, and supporting operational loads. The development of [...] Read more.

A comparative study is presented, focusing on three different bioinspired design methodologies applied to a large-scale aeronautical tooling use case. The study aims to optimize the structure in terms of the first vibration mode, minimizing mass, and supporting operational loads. The development of lightweight metallic components is of great importance for industries such as aerospace, automotive, and energy harvesting, where weight reduction can lead to significant improvements in performance, efficiency, and sustainability. Bioinspired design offers a promising approach to achieving these goals. The study begins with an introduction to natural selection and various bioinspired concepts. It proceeds with a thorough review of the selected bioinspired design methodologies and tools, which are then applied to the chosen use case. The outcomes for each methodology were explored with respect to the design requirements. Subsequently, the most suitable design was selected according to the success criteria defined and its validation is explained. The manufacturing of this design was carried out using an advanced and novel approach specifically tailored to accommodate the large dimensions and complexity of the structure. Finally, modal testing was performed to validate the entire process, and the results obtained demonstrate the potential effectiveness of bioinspired design methodologies in achieving lightweighting and optimizing vibration modes for large-scale aeronautical tooling. Full article

(This article belongs to the Section Machine Design and Theory)

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17 pages, 4492 KiB

Open AccessEditor’s ChoiceArticle

Vibration Analysis for Fault Diagnosis in Induction Motors Using One-Dimensional Dilated Convolutional Neural Networks

by Xiaopeng Liu, Jianfeng Hong, Kang Zhao, Bingxiang Sun, Weige Zhang and Jiuchun Jiang

Machines 2023, 11(12), 1061; https://doi.org/10.3390/machines11121061 - 29 Nov 2023

Viewed by 3313

Abstract

Motor faults not only damage the motor body but also affect the entire production system. When the motor runs in a steady state, the characteristic frequency of the fault current is close to the fundamental frequency, so it is difficult to effectively extract [...] Read more.

Motor faults not only damage the motor body but also affect the entire production system. When the motor runs in a steady state, the characteristic frequency of the fault current is close to the fundamental frequency, so it is difficult to effectively extract the fault current components, such as the broken rotor bar. In this paper, according to the characteristics of electromagnetic force and vibration, when the rotor eccentricity and the broken bar occur, the vibration signal is used to analyze and diagnose the fault. Firstly, the frequency, order, and amplitude characteristics of electromagnetic force under rotor eccentricity and broken bar fault are analyzed. Then, the fault vibration acceleration value collected by a one-dimensional dilated convolution pair is extracted, and the SeLU activation function and residual connection are introduced to solve the problem of gradient disappearance and network degradation, and the fault motor model is established by combining average ensemble learning and SoftMax multi-classifier. Finally, experiments of normal rotor eccentricity and broken bar faults are carried out on 4-pole asynchronous motors. The experimental results show that the accuracy of the proposed method for motor fault detection can reach 99%, which meets the requirements of fault motor detection and is helpful for further application. Full article

(This article belongs to the Special Issue Application of Deep Learning in Intelligent Machines)

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15 pages, 9284 KiB

Open AccessEditor’s ChoiceArticle

An Experimental Investigation into the Performance and Emission Characteristics of a Gasoline Direct Injection Engine Fueled with Isopropanol Gasoline Blends

by Simeon Iliev, Zdravko Ivanov, Radostin Dimitrov, Veselin Mihaylov, Daniel Ivanov, Stoyan Stoyanov and Slavena Atanasova

Machines 2023, 11(12), 1062; https://doi.org/10.3390/machines11121062 - 29 Nov 2023

Cited by 4 | Viewed by 2382

Abstract

Propanol isomers, which are oxygen-rich fuels, possess superior octane ratings and energy density in comparison to methanol and ethanol. Recently, due to advancements in fermentation techniques, these propanol isomers have garnered increased interest as additives for engines. They are being explored to decrease [...] Read more.

Propanol isomers, which are oxygen-rich fuels, possess superior octane ratings and energy density in comparison to methanol and ethanol. Recently, due to advancements in fermentation techniques, these propanol isomers have garnered increased interest as additives for engines. They are being explored to decrease emissions and reduce the usage of conventional fossil fuels. This study delves into this emerging field. One of the alternatives is the use of alcohol fuels in their pure state or as additives to traditional fuels. Alcohols, due to their higher volumetric energy density, are better fuels for spark ignition engines than hydrogen and biogas. Alcohol-blended fuels or alcohol fuels in their pure state may be used in gasoline engines to reduce exhaust emissions. The current research emphasizes the effect of isopropanol gasoline blends on the performance and emissions characteristics of a gasoline direct injection (GDI) engine. This investigation was conducted with different blends of isopropanol and gasoline (by volume: 10% isopropanol [IP10], 20% isopropanol [IP10], 30% isopropanol [IP30], 40% isopropanol [IP40], and 50% isopropanol [IP50]). The reviewed results showed that with increasing isopropanol in the fuel blends, engine brake power increased while BSFC decreased. In terms of emissions, with the increase in isopropanol in the fuel blends, CO and HC emissions decreased while CO₂ and NOx emissions increased. Full article

(This article belongs to the Special Issue Advanced Engine Energy Saving Technology)

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20 pages, 17150 KiB

Open AccessEditor’s ChoiceArticle

Microwave Frequency Offset Induced by Subsurface Damage in Abrasive-Machined Semiconductor Ceramic Waveguide

by Haoji Wang, Jinhua Wei, Bin Lin, Xiaoqi Cui, Hetian Hou, Zhiyuan Fu, Jianchun Ding and Tianyi Sui

Machines 2023, 11(12), 1057; https://doi.org/10.3390/machines11121057 - 28 Nov 2023

Viewed by 1547

Abstract

Ceramic waveguide components play a critical role in modern microwave semiconductor systems. For the first time, this work reports experimental results obtained when dielectric ceramics are abrasive-machined into waveguide components. This process will cause subsurface damage (SSD), resulting in a deviation in their [...] Read more.

Ceramic waveguide components play a critical role in modern microwave semiconductor systems. For the first time, this work reports experimental results obtained when dielectric ceramics are abrasive-machined into waveguide components. This process will cause subsurface damage (SSD), resulting in a deviation in their working frequency which can degrade the performance of the system. For a substrate-integrated waveguide (SIW) resonator working at 10.1 GHz, SSD with a depth of 89 um can cause a maximum frequency offset of 20.2%. For a mm wave component working at 70 GHz, the corresponding frequency offset could increase to 169%. Three resonator SIW filters with SSD are studied, and the results demonstrate that the frequency offset induced by SSD can reduce the pass rate of the filters from 95.4% to 0%. A theoretical analysis is performed to reveal the mechanism and to offer a quantitative estimation of the limiting range of the offset caused by SSD. Feasible methods for reducing the offset caused by SSD, such as structure design, processing optimization, and material reinforcement, are discussed. Full article

(This article belongs to the Special Issue Abrasive Machining of Semiconductor Materials: Equipment, Materials, and Processes)

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15 pages, 8408 KiB

Open AccessEditor’s ChoiceArticle

Analysis and Design of Small-Impact Magnetoelectric Generator

by Shaohua Niu, Bing Li, Bingyang Li, Pengfei Wang and Yuxi Song

Machines 2023, 11(12), 1040; https://doi.org/10.3390/machines11121040 - 22 Nov 2023

Cited by 3 | Viewed by 1668

Abstract

For projectile impact penetration experiment, batteries or capacitors are usually used as power sources for projectile-borne recording devices. However, these power sources are easy to fail under high impact. In this paper, a small-impact magnetoelectric generator is introduced, which converts impact force into [...] Read more.

For projectile impact penetration experiment, batteries or capacitors are usually used as power sources for projectile-borne recording devices. However, these power sources are easy to fail under high impact. In this paper, a small-impact magnetoelectric generator is introduced, which converts impact force into electrical energy to supply power for devices. The influence of generator structure on force–electricity conversion efficiency is analyzed. Based on the analysis, a small-impact magnetoelectric generator with double springs and two-part coils is designed. A hammer test is carried out on the generator. The test results show that this generator structure would achieve higher force–electricity conversion efficiency under small space. Full article

(This article belongs to the Section Electromechanical Energy Conversion Systems)

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16 pages, 6173 KiB

Open AccessEditor’s ChoiceArticle

Melt Pool Monitoring and X-ray Computed Tomography-Informed Characterisation of Laser Powder Bed Additively Manufactured Silver–Diamond Composites

by John Robinson, Abul Arafat, Aaron Vance, Arun Arjunan and Ahmad Baroutaji

Machines 2023, 11(12), 1037; https://doi.org/10.3390/machines11121037 - 21 Nov 2023

Cited by 1 | Viewed by 2184

Abstract

In this study, silver (Ag) and silver–diamond (Ag-D) composites with varying diamond (D) content are fabricated using laser powder bed fusion (L-PBF) additive manufacturing (AM). The L-PBF process parameters and inert gas flow rate are optimised to control the build environment and the [...] Read more.

In this study, silver (Ag) and silver–diamond (Ag-D) composites with varying diamond (D) content are fabricated using laser powder bed fusion (L-PBF) additive manufacturing (AM). The L-PBF process parameters and inert gas flow rate are optimised to control the build environment and the laser energy density at the powder bed to enable the manufacture of Ag-D composites with 0.1%, 0.2% and 0.3% D content. The Ag and D powder morphology are characterised using scanning electron microscopy (SEM). Ag, Ag-D0.1%, Ag-D0.2% and Ag-D0.3% tensile samples are manufactured to assess the resultant density and tensile strength. In-process EOSTATE melt pool monitoring technology is utilised as a comparative tool to assess the density variations. This technique uses in-process melt pool detection to identify variations in the melt pool characteristics and potential defects and/or density deviations. The resultant morphology and associated defect distribution for each of the samples are characterised and reported using X-ray computed tomography (xCT) and 3D visualisation techniques. Young’s modulus, the failure strain and the ultimate tensile strength of the L-PBF Ag and Ag-D are reported. The melt pool monitoring results revealed in-process variations in the build direction, which was confirmed through xCT 3D visualisations. Additionally, the xCT analysis displayed density variations for all the Ag-D composites manufactured. The tensile results revealed that increasing the diamond content reduced Young’s modulus and the ultimate tensile strength. Full article

(This article belongs to the Special Issue Fundamentals and Applications of 3D Printing for Novel Materials)

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27 pages, 11065 KiB

Open AccessEditor’s ChoiceArticle

Monitoring of Tool and Component Wear for Self-Adaptive Digital Twins: A Multi-Stage Approach through Anomaly Detection and Wear Cycle Analysis

by Robin Ströbel, Alexander Bott, Andreas Wortmann and Jürgen Fleischer

Machines 2023, 11(11), 1032; https://doi.org/10.3390/machines11111032 - 19 Nov 2023

Cited by 7 | Viewed by 2501

Abstract

In today’s manufacturing landscape, Digital Twins play a pivotal role in optimising processes and deriving actionable insights that extend beyond on-site calculations. These dynamic representations of systems demand real-time data on the actual state of machinery, rather than static images depicting idealized configurations. [...] Read more.

In today’s manufacturing landscape, Digital Twins play a pivotal role in optimising processes and deriving actionable insights that extend beyond on-site calculations. These dynamic representations of systems demand real-time data on the actual state of machinery, rather than static images depicting idealized configurations. This paper presents a novel approach for monitoring tool and component wear in CNC milling machines by segmenting and classifying individual machining cycles. The method assumes recurring sequences, even with a batch size of 1, and considers a progressive increase in tool wear between cycles. The algorithms effectively segment and classify cycles based on path length, spindle speed and cycle duration. The tool condition index for each cycle is determined by considering all axis signals, with upper and lower thresholds established for quantifying tool conditions. The same approach is adapted to predict component wear progression in machine tools, ensuring robust condition determination. A percentage-based component state description is achieved by comparing it to the corresponding Tool Condition Codes (TCC) range. This method provides a four-class estimation of the component state. The approach has demonstrated robustness in various validation cases. Full article

(This article belongs to the Topic Artificial Intelligence in Smart Industrial Diagnostics and Manufacturing, 2nd Volume)

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16 pages, 9283 KiB

Open AccessEditor’s ChoiceArticle

A Toolpath Planning Method for Optical Freeform Surface Ultra-Precision Turning Based on NURBS Surface Curvature

by Xuchu Wang, Qingshun Bai, Siyu Gao, Liang Zhao and Kai Cheng

Machines 2023, 11(11), 1017; https://doi.org/10.3390/machines11111017 - 9 Nov 2023

Cited by 5 | Viewed by 2455

Abstract

As the applications for freeform optical surfaces continue to grow, the need for high-precision machining methods is becoming more and more of a necessity. Different toolpath strategies for the ultra-high precision turning of freeform surfaces can have a significant impact on the quality [...] Read more.

As the applications for freeform optical surfaces continue to grow, the need for high-precision machining methods is becoming more and more of a necessity. Different toolpath strategies for the ultra-high precision turning of freeform surfaces can have a significant impact on the quality of the machined surfaces. This paper presents a novel toolpath planning method for ultra-precision slow tool servo diamond turning based on the curvature of freeform surfaces. The method analyzes the differential geometric properties of freeform surfaces by reconstructing NURBS freeform surfaces. A mathematical model is constructed based on the parameters of different positions of the freeform surface, toolpath parameters, and tool residual height. Appropriate toolpath parameters can be calculated to generate the optical freeform ultra-precision slow tool servo diamond turning toolpath. Compared with the toolpaths generated by the traditional Archimedes spiral method, the ultra-precision slow tool servo diamond turning toolpath planning method proposed in this paper can generate more uniform toolpaths on the freeform surfaces and keep the residual tool height within a small range. Full article

(This article belongs to the Special Issue Precision Engineering in Manufacturing: Challenges and Future)

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15 pages, 3062 KiB

Open AccessEditor’s ChoiceArticle

An Improved Denoising Method for Fault Vibration Signals of Wind Turbine Gearbox Bearings

by Chaohai Zhang, Xu Zhang, Zufeng Xu, Wei Dai and Jie Lu

Machines 2023, 11(11), 1004; https://doi.org/10.3390/machines11111004 - 1 Nov 2023

Cited by 1 | Viewed by 1476

Abstract

Vibration monitoring (VM) is an important tool for fault diagnosis in key components of wind turbine gearboxes (WTGs). However, due to the influence of white noise and random interference, it is difficult to realize high-quality denoising of WTG-VM signals. To overcome this limitation, [...] Read more.

Vibration monitoring (VM) is an important tool for fault diagnosis in key components of wind turbine gearboxes (WTGs). However, due to the influence of white noise and random interference, it is difficult to realize high-quality denoising of WTG-VM signals. To overcome this limitation, a novel joint denoising method for fault WTG-VM signals is proposed in this article, which we have named EWT_KC-SVD. First, the empirical wavelet transform (EWT) boundary exploration method is used to optimize frequency band allocation and obtain the multiple intrinsic mode functions (IMFs). Second, the sensitive IMFs are selected according to the calculated correlation coefficient and kurtosis index, avoiding IMF redundancy. Finally, the fault WTG-VM signals are obtained using SVD denoising. Using this approach, the proposed method realizes high-quality denoising of WTG-VM signals. Furthermore, it also effectively solves the existing problems of conventional methods, namely, inefficient IMF selection, high noise, false frequencies, mode mixing, and end effect. Finally, the effectiveness, superiority, and reliability of the proposed method are proved using simulation and practical case results. Full article

(This article belongs to the Special Issue Advanced Data Analytics in Intelligent Industry: Theory and Practice)

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19 pages, 70985 KiB

Open AccessEditor’s ChoiceArticle

A Novel Tribometer and a Comprehensive Testing Method for Rolling-Sliding Conditions

by Pedro Amoroso, Aleks Vrček and Matthijn de Rooij

Machines 2023, 11(11), 993; https://doi.org/10.3390/machines11110993 - 26 Oct 2023

Cited by 4 | Viewed by 2002

Abstract

This study introduces a method based on fine torque control to evaluate traction in rolling—liding line contacts under small slide-to-roll ratios (SRRs). To accomplish this, we engineered an innovative testing machine—a two-roller tribometer capable of precisely applying resisting torques to one of the [...] Read more.

This study introduces a method based on fine torque control to evaluate traction in rolling—liding line contacts under small slide-to-roll ratios (SRRs). To accomplish this, we engineered an innovative testing machine—a two-roller tribometer capable of precisely applying resisting torques to one of the rollers. Two types of tests were designed and conducted to validate our method and showcase the capabilities of the novel test setup. The first type, named the “Traction Decay Test”, proved to be effective in evaluating changes in the SRR over time. The second, named the “Torque-Mode Traction Test”, demonstrated its effectiveness in achieving ultra-low SRRs, in the order of 0.01%. As a result, traction curves with high resolution in the low SRR domain were constructed. This advancement provides the means for gaining a deeper understanding of traction coefficients, wear behavior, and tribological performance at ultra-low SRRs across diverse applications. Full article

(This article belongs to the Section Friction and Tribology)

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23 pages, 5139 KiB

Open AccessEditor’s ChoiceArticle

Detection of Inter-Turn Short Circuits in Induction Motors under the Start-Up Transient by Means of an Empirical Wavelet Transform and Self-Organizing Map

by Juan Jose Saucedo-Dorantes, Arturo Yosimar Jaen-Cuellar, Angel Perez-Cruz and David Alejandro Elvira-Ortiz

Machines 2023, 11(10), 958; https://doi.org/10.3390/machines11100958 - 14 Oct 2023

Cited by 6 | Viewed by 1990

Abstract

Due to the importance of induction motors in a wide variety of industrial processes, it is crucial to properly identify abnormal conditions in order to avoid unexpected stops. The inter-turn short circuit (ITSC) is a very common failure produced with electrical stresses and [...] Read more.

Due to the importance of induction motors in a wide variety of industrial processes, it is crucial to properly identify abnormal conditions in order to avoid unexpected stops. The inter-turn short circuit (ITSC) is a very common failure produced with electrical stresses and affects induction motors (IMs), leading to catastrophic damage. Therefore, this work proposes the use of the empirical wavelet transform to characterize the time frequency behavior of the IM combined with a self-organizing map (SOM) structure to perform an automatic detection and classification of different severities of ITSC. Since the amount of information obtained from the empirical wavelet transform is big, a genetic algorithm is implemented to select the modes that allow a reduction in the quantization error in the SOM. The proposed methodology is applied to a real IM during the start-up transient considering four different fundamental frequencies. The results prove that this technique is able to detect and classify three different fault severities regardless of the operation frequency. Full article

(This article belongs to the Special Issue Condition Monitoring and Fault Diagnosis of Induction Motors)

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20 pages, 13286 KiB

Open AccessEditor’s ChoiceArticle

A Novel Exoskeleton Design and Numerical Characterization for Human Gait Assistance

by Cristian Copilusi, Marco Ceccarelli, Sorin Dumitru, Ionut Geonea, Alexandru Margine and Dorin Popescu

Machines 2023, 11(10), 925; https://doi.org/10.3390/machines11100925 - 26 Sep 2023

Cited by 6 | Viewed by 2318

Abstract

This paper addressed attention to the design of a new lower limb exoskeleton that can be used for human gait assistance as based on kinematic considerations. The designed leg exoskeleton had on its own structure a combination of three mechanism types, namely a [...] Read more.

This paper addressed attention to the design of a new lower limb exoskeleton that can be used for human gait assistance as based on kinematic considerations. The designed leg exoskeleton had on its own structure a combination of three mechanism types, namely a Chebyshev mechanism, a pantograph, and a Stephenson six-bar mechanism. The design core focused on inserting the Stephenson six-bar bar mechanism in order to obtain an imposed motion at the ankle joint level. Numerical simulations of the designed lower limb exoskeleton have been developed and the obtained results demonstrate the engineering feasibility of the proposed prototype, with a characterization of satisfactory operation performance. Full article

(This article belongs to the Special Issue New Trends in Medical and Service Robots—Selected Papers from MESROB 2023)

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14 pages, 2309 KiB

Open AccessEditor’s ChoiceArticle

Reliability Assessment for a Spacecraft Landing Buffer Mechanism Based on Small Sample Data

by Ziang Li, Huimin Fu and Qiong Wu

Machines 2023, 11(9), 917; https://doi.org/10.3390/machines11090917 - 21 Sep 2023

Viewed by 1389

Abstract

The landing buffer mechanism (LBM) is a crucial component of aerospace landing explorations, determining the success of the entire mission. Reliability demonstration tests (RDTs) are required to ensure the LBM’s performance meets the design index. However, the RDTs of the LBM often encounter [...] Read more.

The landing buffer mechanism (LBM) is a crucial component of aerospace landing explorations, determining the success of the entire mission. Reliability demonstration tests (RDTs) are required to ensure the LBM’s performance meets the design index. However, the RDTs of the LBM often encounter limited samples and zero-failure data, making traditional binominal test programs and reliability assessment methods based on the maximum likelihood theory unsuitable. This paper introduces a novel small-sample test verification method for the LBM, which transforms traditional binominal tests into more informative metrological tests by measuring the buffer strokes of the LBM’s subsystems. Furthermore, a confidence limit theory for the product of subsystem reliability is developed in conjunction with the reliability series model of the LBM. This theory can use the measurement data of subsystems to assess the confidence limit of the LBM’s reliability. An actual engineering application demonstrates that the proposed method can effectively handle zero-failure data and verifies that the LBM’s reliability exceeds 0.9999 with a confidence of 0.9. Full article

(This article belongs to the Section Automation and Control Systems)

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22 pages, 7035 KiB

Open AccessEditor’s ChoiceArticle

An Adaptive Shift Schedule Design Method for Multi-Gear AMT Electric Vehicles Based on Dynamic Programming and Fuzzy Logical Control

by Xiaodong Liu, Juan Du, Xingqun Cheng, Yan Zhu and Jian Ma

Machines 2023, 11(9), 915; https://doi.org/10.3390/machines11090915 - 20 Sep 2023

Cited by 9 | Viewed by 1952

Abstract

This paper proposes an adaptive shift schedule design framework based on dynamic programming (DP) algorithm and fuzzy logical control to promote the shift schedule’s adaptability whilst improving the comprehensive performance of the multi-gear automated manual transmission (AMT) electric vehicles in real-time application. First, [...] Read more.

This paper proposes an adaptive shift schedule design framework based on dynamic programming (DP) algorithm and fuzzy logical control to promote the shift schedule’s adaptability whilst improving the comprehensive performance of the multi-gear automated manual transmission (AMT) electric vehicles in real-time application. First, the DP algorithm is employed to extract an offline optimal gear-shift schedule based on a set of driving conditions, including 11 groups of typical driving cycles. Second, a fuzzy logical controller is formulated considering the variation in the vehicle load and acceleration, where a velocity increment is exported online to adjust the gear-shift velocity of the predesigned DP-based schedule to develop a Fuzzy-DP shift schedule. In addition, multi-objective particle swarm optimization (MOPSO) is utilized to construct a comprehensive shift schedule by simultaneously considering the dynamic and economic performance of the vehicle. Then, the dynamic and economic shift schedules are deployed as the benchmark to examine the performance of the proposed shift schedule. Finally, the effectiveness of the Fuzzy-DP shift schedule is evaluated by comparison with others under various combined driving cycles (including vehicle load and velocity). The comparisons demonstrate the remarkable promotion in the adaptability of the Fuzzy-DP shift schedule in terms of acceleration time, energy-saving potential, and shift frequency. The most significant improvements in the dynamic, economic, and shift frequency can reach 8.86%, 10.12%, and 8.56%, respectively, in contrast to the MOPSO-based shift schedule. Full article

(This article belongs to the Section Electrical Machines and Drives)

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16 pages, 6374 KiB

Open AccessEditor’s ChoiceArticle

Application of TRIZ Innovation Method to In-Pipe Robot Design

by Qizhi Xie and Qiang Liu

Machines 2023, 11(9), 912; https://doi.org/10.3390/machines11090912 - 16 Sep 2023

Cited by 6 | Viewed by 3126

Abstract

The peristaltic in-pipe robot incorporates multiple actuators, and achieving precise cooperative control among these actuators poses significant complexity. To address these issues, the Theory of Inventive Problem Solving (TRIZ) is applied to identify and resolve physical and technical conflicts in the creative design [...] Read more.

The peristaltic in-pipe robot incorporates multiple actuators, and achieving precise cooperative control among these actuators poses significant complexity. To address these issues, the Theory of Inventive Problem Solving (TRIZ) is applied to identify and resolve physical and technical conflicts in the creative design process of peristaltic in-pipe robots. By highlighting the insights on and technical guidance offered by TRIZ’s inventive principles, this paper examines the method for realizing a single-motor-driven peristaltic in-pipe robot from a transmission perspective. By employing a combination of connecting rods, cam mechanisms, and gear systems, a one-DOF peristaltic in-pipe robot was devised. Subsequently, a prototype was constructed, and successful bidirectional motion tests were conducted within pipes. The findings highlight the efficacy of the TRIZ-based design approach in innovatively designing one-DOF in-pipe robots and the unnecessary employment of complex multi-drive cooperative control in peristaltic in-pipe robots. Full article

(This article belongs to the Section Machine Design and Theory)

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13 pages, 5619 KiB

Open AccessEditor’s ChoiceArticle

A Theoretical and Experimental Identification with Featured Structures for Crucial Position-Independent Geometric Errors in Ultra-Precision Machining

by Li Zhang and Shaojian Zhang

Machines 2023, 11(9), 909; https://doi.org/10.3390/machines11090909 - 14 Sep 2023

Cited by 1 | Viewed by 1238

Abstract

In ultra-precision machining (UPM), position-independent geometric errors (PIGEs), i.e., squareness errors, have a crucial impact upon the form accuracy of a machined surface. Accordingly, more research work has been conducted in PIGE identification, to improve the form accuracy. However, the general identification methods [...] Read more.

In ultra-precision machining (UPM), position-independent geometric errors (PIGEs), i.e., squareness errors, have a crucial impact upon the form accuracy of a machined surface. Accordingly, more research work has been conducted in PIGE identification, to improve the form accuracy. However, the general identification methods were developed without consideration of the specific squareness errors for crucial PIGEs under the form errors of the machining process. Therefore, a new method with featured structures was proposed, to identify crucial PIGEs in UPM. Firstly, a volumetric error model was developed for PIGEs, to discuss the relationship between squareness errors and their resulting machining form errors. Secondly, following the developed model, some featured structures have been proposed with their machining form errors, to significantly indicate crucial PIGEs. Finally, a series of UPM and measuring experiments were conducted for the featured structures, and then their machining form errors were measured and extracted with specific squareness errors for the identification of crucial PIGEs. The theoretical and experimental results revealed that the proposed method is simple and efficient with the featured structures to accurately identify crucial PIGEs in UPM. Significantly, the study offers a deep insight into high-quality fabrication in UPM. Full article

(This article belongs to the Special Issue Precision Engineering in Manufacturing: Challenges and Future)

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19 pages, 3634 KiB

Open AccessEditor’s ChoiceArticle

Sustainable Energy Harvesting Mechanism with Flow-Induced Vibration

by Marvin H. Cheng, Yuejuan Li, Hugo E. Camargo and Ezzat G. Bakhoum

Machines 2023, 11(9), 902; https://doi.org/10.3390/machines11090902 - 11 Sep 2023

Viewed by 1927

Abstract

This study investigates the feasibility of utilizing a flow-induced vibration actuator as a potential energy source using piezoelectric energy harvesting. The focus is on exploring the behavior of piezo films configured as cantilever beams subjected to flow-induced vibration, which can be induced with [...] Read more.

This study investigates the feasibility of utilizing a flow-induced vibration actuator as a potential energy source using piezoelectric energy harvesting. The focus is on exploring the behavior of piezo films configured as cantilever beams subjected to flow-induced vibration, which can be induced with fluid or wind streams. The primary objective is to maximize the harvested energy from the vibrating structure. This paper develops theoretical models to analyze the resonant frequencies and energy-harvesting potential of the piezo films in the context of flow-induced vibration. Experimental validations are conducted to verify the theoretical predictions. The findings indicate that higher operating frequencies in the second mode offer improved energy harvesting efficiency compared with lower modes. With the strategic adjustment of resonant frequencies using attached masses on individual piezo films, the harvestable energy output of a single film can be significantly increased from less than 1 μW to approximately 18 μW. However, the phase differences among individual piezo films can impact frequency measurements, necessitating careful fine-tuning of the physical conditions of individual components. To optimize energy harvesting, this study emphasizes the importance of implementing efficient charging mechanisms. By identifying suitable environmental vibration sources, the required charging duration for a synthesized energy harvesting array can be reduced by 25% as well. Despite certain challenges, such as phase deviations and turbulence, this study demonstrates the promising potential of flow-induced vibration resonators as sustainable energy sources. This work lays the foundation for further advancements in energy harvesting technology, offering environmentally friendly and renewable energy solutions. Full article

(This article belongs to the Section Electromechanical Energy Conversion Systems)

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15 pages, 7641 KiB

Open AccessEditor’s ChoiceArticle

Analysis of Cooling Characteristics of Permanent Magnet Synchronous Motor with Different Water Jacket Design Using Electromagnetic–Thermal Fluid Coupled Analysis and Design of Experiment

by Kyunghun Jeon, Myungwoo Park, Jongjin Park, Hongjun Choi, Ki-Deok Lee, Jeong-Jong Lee and Chang-Wan Kim

Machines 2023, 11(9), 903; https://doi.org/10.3390/machines11090903 - 11 Sep 2023

Cited by 1 | Viewed by 2545

Abstract

Electrical losses are converted into thermal energy in motors, which heats each component. It is a significant factor in decreasing motor mechanical performance. In this paper, the motor cooling characteristics were analyzed according to the design factors of the water jacket to investigate [...] Read more.

Electrical losses are converted into thermal energy in motors, which heats each component. It is a significant factor in decreasing motor mechanical performance. In this paper, the motor cooling characteristics were analyzed according to the design factors of the water jacket to investigate the cooling performance of a permanent magnet synchronous motor (PMSM). First, the electrical losses generated in PMSM were calculated using electromagnetic finite element (FE) analysis. Secondly, a 3D electromagnetic–thermal fluid coupled FE analysis was performed to analyze the temperature distribution inside the motor by applying electrical loss as the heat source. Finally, the motor cooling performance according to the design factors of the water jacket was statistically analyzed using the design of experiment (DOE) method. It was found that the mass flow rate of 0.02547 kg/s and six passes of the water jacket with one inlet and two outlets could be considered the optimum conditions in terms of the maximum motor temperature. Full article

(This article belongs to the Special Issue Electrical Machines in Electric Vehicles)

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23 pages, 23243 KiB

Open AccessEditor’s ChoiceReview

Advanced Manufacturability of Electrical Machine Architecture through 3D Printing Technology

by Ahmed Selema, Mohamed N. Ibrahim and Peter Sergeant

Machines 2023, 11(9), 900; https://doi.org/10.3390/machines11090900 - 10 Sep 2023

Cited by 8 | Viewed by 4318

Abstract

The rapid evolution of electric machines requires innovative approaches to boost performance, efficiency, and sustainability. Additive Manufacturing (AM) has emerged as a transformative technique, reshaping the landscape of electric machine components, ranging from magnetic materials to windings and extending to thermal management. In [...] Read more.

The rapid evolution of electric machines requires innovative approaches to boost performance, efficiency, and sustainability. Additive Manufacturing (AM) has emerged as a transformative technique, reshaping the landscape of electric machine components, ranging from magnetic materials to windings and extending to thermal management. In the area of magnetic materials, AM’s capacity to fabricate intricate structures optimizes magnetic flux dynamics, yielding advanced shape-profile cores and self-coating laminations for superior performance. In windings, AM’s prowess is evident through innovative concepts, effectively mitigating AC conduction effects while reducing weight. Furthermore, AM revolutionizes thermal management, as exemplified by 3D-printed ceramic heat exchangers, intricate cooling channels, and novel housing designs, all contributing to enhanced thermal efficiency and power density. The integration of AM not only transcends conventional manufacturing constraints but also promises to usher in an era of unprecedented electric machine innovation, addressing the intricate interplay of magnetic, winding, and thermal dynamics. Full article

(This article belongs to the Section Advanced Manufacturing)

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19 pages, 27127 KiB

Open AccessEditor’s ChoiceArticle

A Study of Frequency Domain Reflectometry Technique for High-Voltage Rotating Machine Winding Condition Assessment

by Jialu Cheng, Yizhou Zhang, Hao Yun, Liang Wang and Nathaniel Taylor

Machines 2023, 11(9), 883; https://doi.org/10.3390/machines11090883 - 2 Sep 2023

Cited by 3 | Viewed by 2134

Abstract

Detecting and locating local degradations at an incipient stage is very important for mission-critical high-voltage rotating machines. One particular challenge in the existing testing techniques is that the characteristic of a local incipient defect is not prominent due to various factors such as [...] Read more.

Detecting and locating local degradations at an incipient stage is very important for mission-critical high-voltage rotating machines. One particular challenge in the existing testing techniques is that the characteristic of a local incipient defect is not prominent due to various factors such as averaging with the healthy remainder, attenuation in signal propagation, interference, and varied operating conditions. This paper proposes and investigates the frequency domain reflectometry (FDR) technique based on the scattering parameter measurement. The FDR result presents the object length, wave impedance, and reflections due to impedance discontinuity along the measured windings. Experiments were performed on two commercial coils with artificially created defects. These defects include turn-to-turn short, surface creepage, loose coils, insufficient end-winding spacing, and local overheating, which are commonly seen in practice. Two practical water pumps in the field were also selected for investigation. The study outcome shows that FDR can identify and locate structural and insulation degradation in both shielded and unshielded objects with good sensitivity. This makes FDR a complementary technique for machine fault diagnosis and aging assessment. Full article

(This article belongs to the Section Machines Testing and Maintenance)

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27 pages, 23202 KiB

Open AccessEditor’s ChoiceArticle

Circulating Current Control in Interleaved and Parallel Connected Power Converters

by Khalid Javed, Ruben De Croo, Lieven Vandevelde and Frederik De Belie

Machines 2023, 11(9), 878; https://doi.org/10.3390/machines11090878 - 1 Sep 2023

Cited by 2 | Viewed by 2989

Abstract

This article analyzes circulating current control in single-phase power electronic converters, focusing on two different topologies: interleaved and parallel configurations. The study involves a bridgeless interleaving topology with two boost converters for increased efficiency. A parallel connection is also examined for monitoring line [...] Read more.

This article analyzes circulating current control in single-phase power electronic converters, focusing on two different topologies: interleaved and parallel configurations. The study involves a bridgeless interleaving topology with two boost converters for increased efficiency. A parallel connection is also examined for monitoring line current, circulating currents, and power factor control. The article widely explains all current loops, including Common Mode Circulating Currents (CMCC) in the bridgeless interleaved topology and Differential Mode Circulating Currents (DMCC) in parallel-connected interleaved power converters. The proposed control scheme employs voltage and current control loops for output voltage and line current control and introduces CMCC and DMCC compensators to eliminate all types of circulating currents. An efficient Power Factor Correction (PFC) and output voltage control method is presented in this article. The effectiveness of the proposed schemes is validated through comparisons with modern control systems. The results are verified using Simulink/MATLAB and experimental setups with TI Instruments Piccolo prototypes and C2000 (TMS320F28035 microcontroller MCU) microcontrollers in parallel configurations. Full article

(This article belongs to the Special Issue Advanced Power Electronic Technologies in Electric Drive Systems)

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30 pages, 11533 KiB

Open AccessEditor’s ChoiceArticle

Application of UAVs and Image Processing for Riverbank Inspection

by Chang-Hsun Chiang and Jih-Gau Juang

Machines 2023, 11(9), 876; https://doi.org/10.3390/machines11090876 - 1 Sep 2023

Cited by 7 | Viewed by 1941

Abstract

Many rivers are polluted by trash and garbage that can affect the environment. Riverbank inspection usually relies on workers of the environmental protection office, but sometimes the places are unreachable. This study applies unmanned aerial vehicles (UAVs) to perform the inspection task, which [...] Read more.

Many rivers are polluted by trash and garbage that can affect the environment. Riverbank inspection usually relies on workers of the environmental protection office, but sometimes the places are unreachable. This study applies unmanned aerial vehicles (UAVs) to perform the inspection task, which can significantly relieve labor work. Two UAVs are used to cover a wide area of riverside and capture riverbank images. The images from different UAVs are stitched using the scale-invariant feature transform (SIFT) algorithm. Static and dynamic image stitching are tested. Different you only look once (YOLO) algorithms are applied to identify riverbank garbage. Modified YOLO algorithms improve the accuracy of riverine waste identification, while the SIFT algorithm stitches the images obtained from the UAV cameras. Then, the stitching results and garbage data are sent to a video streaming server, allowing government officials to check waste information from the real-time multi-camera stitching images. The UAVs utilize 4G communication to transmit the video stream to the server. The transmission distance is long enough for this study, and the reliability is excellent in the test fields that are covered by the 4G communication network. In the automatic reconnection mechanism, we set the timeout to 1.8 s. The UAVs will automatically reconnect to the video streaming server if the disconnection time exceeds the timeout. Based on the energy provided by the onboard battery, the UAV can be operated for 20 min in a mission. The UAV inspection distance along a preplanned path is about 1 km at a speed of 1 m/s. The proposed UAV system can replace inspection labor, successfully identify riverside garbage, and transmit the related information and location on the map to the ground control center in real time. Full article

(This article belongs to the Special Issue Advanced Control of Unmanned Aerial Vehicles (UAV))

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19 pages, 6638 KiB

Open AccessEditor’s ChoiceArticle

Modeling and Optimization of Surface Integrity and Sliding Wear Resistance of Diamond-Burnished Holes in Austenitic Stainless Steel Cylinder Lines

by Galya Duncheva, Jordan Maximov, Angel Anchev, Vladimir Dunchev, Yaroslav Argirov and Svetlozar Velkov

Machines 2023, 11(9), 872; https://doi.org/10.3390/machines11090872 - 30 Aug 2023

Cited by 5 | Viewed by 1462

Abstract

This article outlines a technology for hole-finishing in short-length cylinder lines to improve wear resistance. The technology is based on an optimized diamond-burnishing (DB) process. The latter was implemented on conventional and CNC lathes, milling machines, and machining centers using a simple burnishing [...] Read more.

This article outlines a technology for hole-finishing in short-length cylinder lines to improve wear resistance. The technology is based on an optimized diamond-burnishing (DB) process. The latter was implemented on conventional and CNC lathes, milling machines, and machining centers using a simple burnishing device with an elastic beam. The material used in this study was AISI 321 austenitic stainless steel. The governing factors used were the radius of the diamond insert, burnishing force and feed rate. The objective functions relating to surface integrity characteristics were selected on the basis of their functional importance relative to the wear resistance of the processed hole surface: height and shape roughness parameters, surface microhardness, and surface residual axial and hoop stresses. The one-factor-at-a-time method (used to reduce the factor space), a planned experiment, and regression analyses were used. The multi-objective optimization tasks, which were defined for three diamond insert radius values of 2, 3, and 4 mm, were solved via the Pareto-optimal solutions approach available for a non-dominated sorting genetic algorithm (NSGA-II). Using the optimal values of the governing factors selected from the Pareto fronts, cylinder lines were processed. Samples were then cut from these cylinder lines for reciprocating sliding wear tests under two modes: dry friction and boundary lubrication friction. Additionally, wear test samples were cut from the cylinder line, which was finished with traditional grinding. A finite element simulation was then used to select an appropriate pressing force. The results obtained from the reciprocating sliding wear tests under both the dry and boundary lubrication friction regimes show that to minimize the wear on cylinder lines made of AISI 321 steel, DB with a diamond insert of radius 2 mm is the optimal finishing process. Full article

(This article belongs to the Special Issue Recent Advances in Surface Processing of Metals and Alloys)

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20 pages, 3294 KiB

Open AccessEditor’s ChoiceArticle

Multiparameter Estimation-Based Sensorless Adaptive Direct Voltage MTPA Control for IPMSM Using Fuzzy Logic MRAS

by Alaref Elhaj, Mohamad Alzayed and Hicham Chaoui

Machines 2023, 11(9), 861; https://doi.org/10.3390/machines11090861 - 28 Aug 2023

Cited by 7 | Viewed by 1638

Abstract

This paper introduces a parameter-estimation-based sensorless adaptive direct voltage maximum torque per ampere (MTPA) control strategy for interior permanent magnet synchronous machines (IPMSMs). In direct voltage control, the motor’s electrical parameters, speed, and rotor position are of great significance. Thus, any mismatch in [...] Read more.

This paper introduces a parameter-estimation-based sensorless adaptive direct voltage maximum torque per ampere (MTPA) control strategy for interior permanent magnet synchronous machines (IPMSMs). In direct voltage control, the motor’s electrical parameters, speed, and rotor position are of great significance. Thus, any mismatch in these parameters or failure to acquire accurate speed or position information leads to a significant deviation in the MTPA trajectory, causing high current consumption and hence affecting the performance of the entire control system. In view of this problem, a fuzzy logic control-based cascaded model reference adaptive system (FLC-MRAS) is introduced to mitigate the effect of parameter variation on the tracking of the MTPA trajectory and to provide precise information about the rotor speed and position. The cascaded scheme consists of two parallel FLC-MRAS for speed and multiparameter estimation. The first MRAS is utilized to estimate motor speed and rotor position to achieve robust sensorless control. However, the speed estimator is highly dependent on time-varying motor parameters. Therefore, the second MRAS is designed to identify the quadratic inductance and permanent magnet flux and continuously update both the speed estimator and control scheme with the identified values to ensure accurate speed estimation and real-time MTPA trajectory tracking. Unlike conventional MRAS, which uses linear proportional-integral controllers (PI-MRAS), an FLC is adopted to replace the PI controllers, ensuring high estimation accuracy and enhancing the robustness of the control system against sudden changes in working conditions. The effectiveness of the proposed scheme is evaluated under different speed and torque conditions. Furthermore, a comparison against the conventional PI-MRAS is extensively investigated to highlight the superiority of the proposed scheme. The evaluation results and our quantitative assessment show the ability of the designed strategy to achieve high estimation accuracy, less oscillation, and a faster convergence rate under different working conditions. The quantitative assessment reveals that the FLC-MRAS can improve the estimation accuracy of speed, permanent magnet flux, and quadratic inductance by 19%, 55.8% and 44.55%, respectively. Full article

(This article belongs to the Section Electromechanical Energy Conversion Systems)

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16 pages, 17947 KiB

Open AccessEditor’s ChoiceArticle

Experimental Study on the Effect of Microchannel Spacing and Fractal Angle on Bubble Growth Behavior

by Xianming Gao, Fangcai Lu, Wang Zhang and Wenxuan Yang

Machines 2023, 11(9), 862; https://doi.org/10.3390/machines11090862 - 28 Aug 2023

Viewed by 1378

Abstract

Bubble growth behavior significantly influences boiling heat transfer performance, and different microchannel structures and configurations affect bubble growth behavior. To explore the impact of microchannel structures and configurations on the growth behavior of boiling bubbles, two types of microchannel test plates were fabricated [...] Read more.

Bubble growth behavior significantly influences boiling heat transfer performance, and different microchannel structures and configurations affect bubble growth behavior. To explore the impact of microchannel structures and configurations on the growth behavior of boiling bubbles, two types of microchannel test plates were fabricated on copper substrates using laser machining technology. It was a parallel configuration plate with five different microchannel spacings and a blade vein configuration plate with four different fractal angles. The bubble growth behavior on these two types of surfaces was studied through visual experiments. The results show that smaller microchannel spacing leads to earlier bubble coalescence and departure times under the same degree of superheat. The 3.00 mm microchannel spacing is the critical interfering distance for the parallel configuration plates, while interference behavior occurs for the bubbles on the simulated vein configuration plates at any fractal angle. Furthermore, in different ranges of superheat, the bubble departure diameter increases with increasing superheat, and the frequency of bubble departure initially increases and then decreases with increasing superheat. This study provides experimental data support and design reference for the design of heat transfer plate structures. Full article

(This article belongs to the Section Micro/Nano Electromechanical Systems (MEMS/NEMS))

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21 pages, 4026 KiB

Open AccessEditor’s ChoiceArticle

Wind/Wave Testing of a 1:70-Scale Performance-Matched Model of the IEA Wind 15 MW Reference Wind Turbine with Real-Time ROSCO Control and Floating Feedback

by Matthew Fowler, Eben Lenfest, Anthony Viselli, Andrew Goupee, Richard Kimball, Roger Bergua, Lu Wang, Daniel Zalkind, Alan Wright and Amy Robertson

Machines 2023, 11(9), 865; https://doi.org/10.3390/machines11090865 - 28 Aug 2023

Cited by 4 | Viewed by 3193

Abstract

Experimental results from the Floating Offshore-wind and Controls Advanced Laboratory (FOCAL) experimental program, which tested a performance-matched model of the IEA Wind 15 MW Reference Turbine on a 1:70 scale floating semisubmersible platform, are compared with OpenFAST simulations. Four experimental campaigns were performed, [...] Read more.

Experimental results from the Floating Offshore-wind and Controls Advanced Laboratory (FOCAL) experimental program, which tested a performance-matched model of the IEA Wind 15 MW Reference Turbine on a 1:70 scale floating semisubmersible platform, are compared with OpenFAST simulations. Four experimental campaigns were performed, and data from the fourth campaign, which focused on wind and wave testing of the scaled floating wind turbine system, are considered. Simulations of wave-only, wind-only, and wind/wave environments are performed in OpenFAST, and results for key metrics are compared with the experiment. Performance of the real-time Reference OpenSource COntroller (ROSCO) in above-rated wind conditions, including the effects of the floating feedback loop, are investigated. Results show good agreement in mean values for key metrics, and hydrodynamic effects are matched well. Differences in the surge resonant behavior of the platform are identified and discussed. The effect of the controller and floating feedback loop is evident in both the experiment and OpenFAST, showing significant reduction in platform pitch response and tower base bending load near the platform pitch natural frequency. Full article

(This article belongs to the Special Issue Wind Turbine Technologies)

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17 pages, 6995 KiB

Open AccessEditor’s ChoiceArticle

Kinematics and Dynamics Analysis of a 3UPS-UPU-S Parallel Mechanism

by Jing-Shan Zhao, Xiao-Cheng Sun and Song-Tao Wei

Machines 2023, 11(8), 840; https://doi.org/10.3390/machines11080840 - 18 Aug 2023

Viewed by 1810

Abstract

In this paper, a two-rotational degrees of freedom parallel mechanism with five kinematic subchains (3UPS-UPU-S) (U, P, and S stand for universal joints, prismatic joints, and spherical joints) for an aerospace product is introduced, and its kinematic and dynamic characteristics are subsequently analyzed. [...] Read more.

In this paper, a two-rotational degrees of freedom parallel mechanism with five kinematic subchains (3UPS-UPU-S) (U, P, and S stand for universal joints, prismatic joints, and spherical joints) for an aerospace product is introduced, and its kinematic and dynamic characteristics are subsequently analyzed. The kinematic and dynamic analyses of this mechanism are carried out in screw coordinates. Firstly, the inverse kinematics is performed through the kinematic equations established by the velocity screws of each joint to obtain the position, posture, and velocity of each joint within the mechanism. Then, a dynamic modeling method with screw theory for multi-body systems is proposed. In this method, the momentum screws are established by the momentum and moment of momentum according to the fundamentals of screws. By using the kinematic parameters of joints, the dynamic analysis can be carried out through the dynamic equations formed by momentum screws and force screws. This method unifies the kinematic and dynamic analyses by expressing all parameters in screw form. The approach can be employed in the development of computational dynamics because of its simplified and straightforward analysis procedure and its high adaptability for different kinds of multi-body systems. Full article

(This article belongs to the Section Automation and Control Systems)

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26 pages, 9870 KiB

Open AccessEditor’s ChoiceArticle

Contactless Method for Measurement of Surface Roughness Based on a Chromatic Confocal Sensor

by Natalia Lishchenko, Garret E. O’Donnell and Mark Culleton

Machines 2023, 11(8), 836; https://doi.org/10.3390/machines11080836 - 17 Aug 2023

Cited by 11 | Viewed by 3796

Abstract

The methodology for assigning and assessing the surface quality is used at various stages of the product life cycle: during the design and technological preparation of production, the production itself, and during the control (testing) of products. The development of advanced technologies requires [...] Read more.

The methodology for assigning and assessing the surface quality is used at various stages of the product life cycle: during the design and technological preparation of production, the production itself, and during the control (testing) of products. The development of advanced technologies requires in situ part control. A non-contact in situ surface roughness measuring system is proposed in this paper. The proposed system utilizes a chromatic confocal sensor, and profile data, waviness data, roughness data, Ra, and Rz parameters are generated in the developed data-processing software. The assembled measuring system based on the chromatic confocal laser sensor showed its performance in assessing the roughness parameter Ra, from 0.34 µm to more than 12 µm, which covers a common range of milling, turning, and grinding. In this range, measurement relative errors can be controlled within 10%. Frequency analysis and correlation analysis of profilograms were performed. Frequency analysis made it possible to establish the dominant frequency components that occur in the profilogram of the samples, while correlation analysis was used to develop a methodology for identifying the deterministic and random components of the processed surface profile signal. The results of the analysis can be further used to develop diagnostic functions for process monitoring based on profilogram estimates, such as the autocorrelation function and the power spectrum density. Full article

(This article belongs to the Special Issue Innovations in the Design, Simulation, and Manufacturing of Production Systems)

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16 pages, 5500 KiB

Open AccessEditor’s ChoiceArticle

High-Precision Detection Algorithm for Metal Workpiece Defects Based on Deep Learning

by Xiujin Xu, Gengming Zhang, Wenhe Zheng, Anbang Zhao, Yi Zhong and Hongjun Wang

Machines 2023, 11(8), 834; https://doi.org/10.3390/machines11080834 - 16 Aug 2023

Cited by 7 | Viewed by 2316

Abstract

Computer vision technology is increasingly being widely applied in automated industrial production. However, the accuracy of workpiece detection is the bottleneck in the field of computer vision detection technology. Herein, a new object detection and classification deep learning algorithm called CSW-Yolov7 is proposed [...] Read more.

Computer vision technology is increasingly being widely applied in automated industrial production. However, the accuracy of workpiece detection is the bottleneck in the field of computer vision detection technology. Herein, a new object detection and classification deep learning algorithm called CSW-Yolov7 is proposed based on the improvement of the Yolov7 deep learning network. Firstly, the CotNet Transformer structure was combined to guide the learning of dynamic attention matrices and enhance visual representation capabilities. Afterwards, the parameter-free attention mechanism SimAM was introduced, effectively enhancing the detection accuracy without increasing computational complexity. Finally, using WIoUv3 as the loss function effectively mitigated many negative influences during training, thereby improving the model’s accuracy faster. The experimental results manifested that the mAP@0.5 of CSW-Yolov7 reached 93.3%, outperforming other models. Further, this study also designed a polyhedral metal workpiece detection system. A large number of experiments were conducted in this system to verify the effectiveness and robustness of the proposed algorithm. Full article

(This article belongs to the Section Advanced Manufacturing)

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17 pages, 7913 KiB

Open AccessEditor’s ChoiceArticle

Comparisons of Loss Reduction Techniques Based on Pulsewidth Modulation and Model Predictive Control for Three-Phase Voltage Source Inverters

by Minh Hoang Nguyen, Sangshin Kwak and Seungdeog Choi

Machines 2023, 11(8), 829; https://doi.org/10.3390/machines11080829 - 14 Aug 2023

Cited by 3 | Viewed by 1813

Abstract

Due to the lack of comparative studies between discontinuous pulse-width modulation and model predictive control methods for reducing switching losses in two-level three-phase voltage source inverter, a comparative analysis of a generalized discontinuous pulse-width modulation and two model predictive control approaches for reducing [...] Read more.

Due to the lack of comparative studies between discontinuous pulse-width modulation and model predictive control methods for reducing switching losses in two-level three-phase voltage source inverter, a comparative analysis of a generalized discontinuous pulse-width modulation and two model predictive control approaches for reducing switching losses is studied in this paper. Both generalized discontinuous pulse-width modulation and two model predictive control approaches are described and conducted in the simulation and experiment. The output performance is obtained by these methods after conducting in various conditions, including switching frequency, output power, and load conditions. It is validated that the generalized discontinuous pulse-width modulation control scheme achieves a better control performance at steady-state, while two model predictive control schemes have better transient-state performance with a superior dynamic. Additionally, the generalized discontinuous pulse-width modulation approach achieves better reducing switching losses performance and has slightly higher efficiency than that of two model predictive control approaches. Full article

(This article belongs to the Section Electrical Machines and Drives)

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