Machines

22 pages, 11064 KiB

Open AccessEditor’s ChoiceArticle

A New Trajectory Tracking Control Method for Fully Electrically Driven Quadruped Robot

by Yulong You, Zhong Yang, Teng’an Zou, Yaoyu Sui, Changliang Xu, Chi Zhang, Hao Xu, Zhao Zhang and Jiaming Han

Machines 2022, 10(5), 292; https://doi.org/10.3390/machines10050292 - 21 Apr 2022

Cited by 10 | Viewed by 3414

Abstract

To improve the accuracy of tracking the trunk center-of-mass (CoM) trajectory and foot-end trajectory in a fully electrically driven quadruped robot, an efficient and practical new trajectory tracking control method is designed. The proposed trajectory tracking method is mainly divided into trunk balance [...] Read more.

To improve the accuracy of tracking the trunk center-of-mass (CoM) trajectory and foot-end trajectory in a fully electrically driven quadruped robot, an efficient and practical new trajectory tracking control method is designed. The proposed trajectory tracking method is mainly divided into trunk balance controller (TBC) and swing leg controller (SLC). In TBC, a quadruped robot dynamics model is developed to find the optimal foot-end force that follows the trunk CoM trajectory based on the model predictive control (MPC) principle. In SLC, the Bessel curve is planned as the desired trajectory at the foot-end, while the desired trajectory is tracked by a virtual spring-damping element driving the foot-end, meanwhile, the radial basis function neural network (RBFNN) is applied for supervisory control to improve the control performance for the system. The experimental results show that the control method can modify the robot’s foot-end trajectory tracking effect, so that the stability error can be eliminated and the robustness of the controller can be improved, meanwhile, the linear and circular trajectory for CoM can be tracked accurately and quickly. Full article

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

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17 pages, 4557 KiB

Open AccessEditor’s ChoiceArticle

Increasing Machining Accuracy Based on CNC Machine Tool Correction Data by Using Ad Hoc Modification

by Jiří Švéda, Štěpán Chládek, Tomáš Hornych, Tomáš Kozlok and Jan Smolík

Machines 2022, 10(5), 288; https://doi.org/10.3390/machines10050288 - 20 Apr 2022

Cited by 3 | Viewed by 3793

Abstract

The geometric accuracy of a workpiece represents one of the key parameters defining its quality, and it is affected by the appropriate selection of the machine tool, control system, NC program and cutting conditions. Up-to-date control systems contain advanced compensation functions, which increase [...] Read more.

The geometric accuracy of a workpiece represents one of the key parameters defining its quality, and it is affected by the appropriate selection of the machine tool, control system, NC program and cutting conditions. Up-to-date control systems contain advanced compensation functions, which increase the volumetric accuracy of the machine tools. Nevertheless, these functions use correction data measurements within the machine tool’s periodic maintenance plan. This paper introduces a method for ad hoc correction data modification. This modification is based on the difference between the real and nominal workpiece geometries, which are evaluated on a coordinate-measuring machine as a standard process in high-accuracy workpiece production. Correction data are compiled in the form of a three-dimensional structured mesh, where nodes of the mesh contain such correction values that interpolations within the mesh suppress workpiece geometric deviations. The correction mesh calculations are based on the assumption that the nodes are connected by imaginary springs and that they are initially in force equilibrium. Force disbalance is introduced by workpiece geometric deviations evaluated at arbitrary points. Then the new position of force-balanced nodes is calculated. Experimental results on a three-axis machining center have verified the proposed method, where geometric accuracy of the workpiece increased more than 85% without any negative effect on surface quality. The approach presented is efficient for increasing workpiece accuracy without the need for NC program modification. Full article

(This article belongs to the Section Advanced Manufacturing)

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27 pages, 10084 KiB

Open AccessEditor’s ChoiceArticle

A Saturation-Based Method for Primary Resonance Control of Flexible Manipulator

by Ruihai Geng, Yushu Bian, Liang Zhang and Yizhu Guo

Machines 2022, 10(4), 284; https://doi.org/10.3390/machines10040284 - 18 Apr 2022

Cited by 2 | Viewed by 2404

Abstract

When primary resonance occurs, even a small external disturbance can abruptly excite large amplitude vibration and deteriorate the working performance of a flexible manipulator. Most active control methods are effective for non-resonant vibration but not for primary resonance. In view of this, this [...] Read more.

When primary resonance occurs, even a small external disturbance can abruptly excite large amplitude vibration and deteriorate the working performance of a flexible manipulator. Most active control methods are effective for non-resonant vibration but not for primary resonance. In view of this, this paper puts forward a new nonlinear saturation-based control method to suppress the primary resonance of a flexible manipulator considering complicated rigid-flexible coupling and modal coupling. A vibration absorber with variable stiffness/damping is designed to establish an energy exchange channel for saturation. A novel idea of modal coupling enhancement is suggested to improve saturation performance by strengthening the coupling relationship between the mode of the vibration absorber and the controlled mode of the flexible manipulator. Through stability analysis on the primary resonance response of the flexible manipulator with the vibration absorber, the saturation mechanism is successfully established and the effectiveness of the saturation control algorithm is validated. On this basis, several important indexes are extracted and employed to optimize saturation control. Finally, a series of virtual prototyping simulations and experiments are conducted to verify the feasibility of the suggested saturation-based control method. This research will contribute to the primary resonance suppression of a flexible manipulator under a complex external excitation environment. Full article

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

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17 pages, 8142 KiB

Open AccessEditor’s ChoiceArticle

Rapid Calculation and Optimization of Vibration and Noise of Permanent-Magnet Synchronous Motors for EVs Based on Equivalent Structural Network

by Tengfei Song, Huijuan Liu, Binbin Bu and Zhenyang Zhang

Machines 2022, 10(4), 281; https://doi.org/10.3390/machines10040281 - 16 Apr 2022

Cited by 7 | Viewed by 3629

Abstract

Optimizing electromagnetic performance and vibration noise performance simultaneously is important when designing the drive motor for electric vehicles (EVs). This has not been fully explored, and there are only a few relevant studies. To achieve simultaneous optimization, this paper proposes an equivalent structural [...] Read more.

Optimizing electromagnetic performance and vibration noise performance simultaneously is important when designing the drive motor for electric vehicles (EVs). This has not been fully explored, and there are only a few relevant studies. To achieve simultaneous optimization, this paper proposes an equivalent structural network (ESN) of stator assembly to calculate the modal distribution and harmonic response transfer functions. Based on the ESN model, the motor’s electromagnetic vibration noise harmonic response, such as acceleration and equivalent radiated power level (ERPL), can be quickly calculated. The feasibility of the established ESN model is verified by structural-field finite-element method (FEM) and modal hammer tests. Based on the modern optimization algorithm and the ESN model, an improved multi-physics and multi-objective optimization design approach is proposed for an optimized design of a 30 kW interior permanent-magnet synchronous machine (IPMSM). The motor’s maximum output torque and ERPL were selected as optimization objectives, and then the ERPL and acceleration were recalculated using structural-field FEM to validate the accuracy of the optimal design. Finally, vibration acceleration tests were carried out on a manufactured prototype motor to verify the feasibility and validity of the proposed optimization design method. Full article

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

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14 pages, 2598 KiB

Open AccessEditor’s ChoiceArticle

From Novelty Detection to a Genetic Algorithm Optimized Classification for the Diagnosis of a SCADA-Equipped Complex Machine

by Luca Viale, Alessandro Paolo Daga, Alessandro Fasana and Luigi Garibaldi

Machines 2022, 10(4), 270; https://doi.org/10.3390/machines10040270 - 9 Apr 2022

Cited by 13 | Viewed by 2522

Abstract

In the field of Diagnostics, the fundamental task of detecting damage is basically a binary classification problem, which is addressed in many cases via Novelty Detection (ND): an observation is classified as novel if it differs significantly from reference, healthy data. ND is [...] Read more.

In the field of Diagnostics, the fundamental task of detecting damage is basically a binary classification problem, which is addressed in many cases via Novelty Detection (ND): an observation is classified as novel if it differs significantly from reference, healthy data. ND is practically implemented summarizing a multivariate dataset with univariate distance information called Novelty Index. As many different approaches are possible to produce NIs, in this analysis, the possibility of implementing a simple classifier in a reduced-dimensionality space of NIs is studied. In addition to a simple decision-tree-like classification method, the process for obtaining the NIs can result as a dimension reduction method and, in turn, the NIs can be used for other classification algorithms. In addition, a case study will be analyzed thanks to the data published by the Prognostics and Health Management Europe (PHME) society, on the occasion of the Data Challenge 2021. Full article

(This article belongs to the Special Issue 10th Anniversary of Machines—Feature Papers in Fault Diagnosis and Prognosis)

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27 pages, 3938 KiB

Open AccessEditor’s ChoiceArticle

Electrically Driven Lower Limb Exoskeleton Rehabilitation Robot Based on Anthropomorphic Design

by Moyao Gao, Zhanli Wang, Zaixiang Pang, Jianwei Sun, Jing Li, Shuang Li and Hansi Zhang

Machines 2022, 10(4), 266; https://doi.org/10.3390/machines10040266 - 7 Apr 2022

Cited by 35 | Viewed by 7761

Abstract

To help people with impairment of lower extremity movement regain the ability to stand and walk, and to enhance limb function, this study proposes an anthropomorphic design of an electrically driven, lower-limb exoskeleton rehabilitation robot. The angular range of the robot’s motion was [...] Read more.

To help people with impairment of lower extremity movement regain the ability to stand and walk, and to enhance limb function, this study proposes an anthropomorphic design of an electrically driven, lower-limb exoskeleton rehabilitation robot. The angular range of the robot’s motion was determined according to the characteristics of the targeted lower-limb joints; the robot was given an active–passive anthropomorphic design with 12 degrees of freedom. The multi-degree-of-freedom hip exoskeleton, bionic artificial knee exoskeleton and passive rigid-flexible coupling ankle exoskeleton can assist patients in rehabilitation exercises with better wear comfort and exercise flexibility. A kinetic model of the seven-rod lower-limb exoskeleton rehabilitation robot was built, and data analysis of the dynamically captured motion trajectory was conducted. These provided a theoretical basis for gait planning and the control system of the lower-limb exoskeleton rehabilitation robot. The results show that the lower-limb exoskeleton rehabilitation robot system possesses sound wearing comfort and movement flexibility, and the degree of freedom of movement of the exoskeleton robot matches well with that of human movement. The robot can thus provide effective assistance to patients’ standing and walking rehabilitation training. Full article

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

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19 pages, 4225 KiB

Open AccessEditor’s ChoiceArticle

An Environmental-Adaptability-Improved RatSLAM Method Based on a Biological Vision Model

by Chong Wu, Shumei Yu, Liang Chen and Rongchuan Sun

Machines 2022, 10(4), 259; https://doi.org/10.3390/machines10040259 - 4 Apr 2022

Cited by 8 | Viewed by 2714

Abstract

Inspired by rodents’ free navigation through a specific space, RatSLAM mimics the function of the rat hippocampus to establish an environmental model within which the agent localizes itself. However, RatSLAM suffers from the deficiencies of erroneous loop-closure detection, low reliability on the experience [...] Read more.

Inspired by rodents’ free navigation through a specific space, RatSLAM mimics the function of the rat hippocampus to establish an environmental model within which the agent localizes itself. However, RatSLAM suffers from the deficiencies of erroneous loop-closure detection, low reliability on the experience map, and weak adaptability to environmental changes, such as lighting variation. To enhance environmental adaptability, this paper proposes an improved algorithm based on the HSI (hue, saturation, intensity) color space, which is superior in handling the characteristics of image brightness and saturation from the perspective of a biological visual model. The proposed algorithm first converts the raw image data from the RGB (red, green, blue) space into the HSI color space using a geometry derivation method. Then, a homomorphic filter is adopted to act on the I (intensity) channel and weaken the influence of the light intensity. Finally, guided filtering is used to process the S (saturation) channel and improve the significance of image details. The experimental results reveal that the improved RatSLAM model is superior to the original method in terms of the accuracy of visual template matching and robustness. Full article

(This article belongs to the Special Issue Intelligent Mechatronics, Automation, Control Systems)

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19 pages, 5117 KiB

Open AccessEditor’s ChoiceArticle

Advanced High-Speed Lane Keeping System of Autonomous Vehicle with Sideslip Angle Estimation

by Hengyang Wang, Biao Liu and Junchao Qiao

Machines 2022, 10(4), 257; https://doi.org/10.3390/machines10040257 - 2 Apr 2022

Cited by 11 | Viewed by 2878

Abstract

An advanced LKS (lane keeping system) for use on curving roads is presented to maintain autonomous vehicle driving within the target lane, without unintentional lane departure. There are the following two main objectives in designing this system: one is performing perfect lane keeping [...] Read more.

An advanced LKS (lane keeping system) for use on curving roads is presented to maintain autonomous vehicle driving within the target lane, without unintentional lane departure. There are the following two main objectives in designing this system: one is performing perfect lane keeping and the other is ensuring the dynamic stability of the vehicle, especially when driving on a curving and low-friction road with time-varying high speed. In this paper, a combined vehicle model, consisting of a lane keeping model and a vehicle lateral dynamic model, is firstly introduced. Then, a novel adaptive-weight predictive controller is used to calculate the desired steering angle and the additional yaw moment which provide coordinated control forlane keeping and dynamic stability control. Meanwhile, a square-root cubature Kalman filter-based vehicle sideslip angle observer, with a strong tracking theory modification (ST-SRCKF), is established to estimate the sideslip angle during the driving process. Finally, HIL (hardware-in-the-loop) tests and field tests are constructed, and the results show the effectiveness of our proposed LKS controller and ST-SRCKF sideslip angle estimation. Full article

(This article belongs to the Section Vehicle Engineering)

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21 pages, 6926 KiB

Open AccessEditor’s ChoiceReview

Utilization of Additive Manufacturing in the Thermal Design of Electrical Machines: A Review

by Martin Sarap, Ants Kallaste, Payam Shams Ghahfarokhi, Hans Tiismus and Toomas Vaimann

Machines 2022, 10(4), 251; https://doi.org/10.3390/machines10040251 - 31 Mar 2022

Cited by 17 | Viewed by 7289

Abstract

Additive manufacturing (AM) is a key technology for advancing many fields, including electrical machines. It offers unparalleled design freedom together with low material waste and fast prototyping, which is why it has become to focus of many researchers. For electrical machines, AM allows [...] Read more.

Additive manufacturing (AM) is a key technology for advancing many fields, including electrical machines. It offers unparalleled design freedom together with low material waste and fast prototyping, which is why it has become to focus of many researchers. For electrical machines, AM allows the production of designs with optimized mechanical, electromagnetic and thermal parameters. This paper attempts to give the reader an overview of the existing research and thermal solutions which have been realized with the use of AM. These include novel heat sink and heat exchanger designs, solutions for cooling the machine windings directly, and additively manufactured hollow windings. Some solutions such as heat pipes, which have been produced with AM but not used to cool electrical machines, are also discussed, as these are used in conventional designs and will certainly be used for additively manufactured electrical machines in the future. Full article

(This article belongs to the Special Issue Future Trends in Advanced Design of Electrical Machines, Drives and Electric Vehicles Using Additive Manufacturing Approaches)

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15 pages, 1601 KiB

Open AccessEditor’s ChoiceArticle

The Existence of Autonomous Chaos in EDM Process

by Peng Wang, Zhuo Wang, Lihui Wang, Bo-Hu Li and Binxiu Wang

Machines 2022, 10(4), 252; https://doi.org/10.3390/machines10040252 - 31 Mar 2022

Cited by 1 | Viewed by 2093

Abstract

The dynamical evolution of electrical discharge machining (EDM) has drawn immense research interest. Previous research on mechanism analysis has discussed the deterministic nonlinearity of gap states at pulse-on discharging duration, while describing the pulse-off deionization process separately as a stochastic evolutionary process. In [...] Read more.

The dynamical evolution of electrical discharge machining (EDM) has drawn immense research interest. Previous research on mechanism analysis has discussed the deterministic nonlinearity of gap states at pulse-on discharging duration, while describing the pulse-off deionization process separately as a stochastic evolutionary process. In this case, the precise model describing a complete machining process, as well as the optimum performance parameters of EDM, can hardly be determined. The main purpose of this paper is to clarify whether the EDM system can maintain consistency in dynamic characteristics within a discharge interval. A nonlinear self-maintained equivalent model is first established, and two threshold conditions are obtained by the Shilnikov theory. The theoretical results prove that the EDM system could lead to chaos without external excitation. The time series of the deionization process recorded in the EDM experiments are then analyzed to further validate this theoretical conclusion. Qualitative chaotic analyses verify that the autonomous EDM process has chaotic characteristics. Quantitative methods are used to estimate the chaotic feature of the autonomous EDM process. By comparing the quantitative results of the autonomous EDM process with the non-autonomous EDM process, a deduction is further made that the EDM system will evolve towards steady chaos under an autonomous state. Full article

(This article belongs to the Section Advanced Manufacturing)

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21 pages, 5279 KiB

Open AccessEditor’s ChoiceArticle

Analytical Determination and Influence Analysis of Stiffness Matrix of Ball Bearing under Different Load Conditions

by Qingbo Niu, Yeteng Li, Yongsheng Zhu, Shiyuan Pei, Yanjing Yin and Dongfeng Wang

Machines 2022, 10(4), 238; https://doi.org/10.3390/machines10040238 - 28 Mar 2022

Cited by 4 | Viewed by 4653

Abstract

Bearing stiffness, as one of the most important service characteristics for ball bearing, plays a crucial role in the bearing design and rotor dynamic analysis. To rapidly and accurately calculate the stiffness matrix of ball bearing under the arbitrary load conditions, a 5-DOF [...] Read more.

Bearing stiffness, as one of the most important service characteristics for ball bearing, plays a crucial role in the bearing design and rotor dynamic analysis. To rapidly and accurately calculate the stiffness matrix of ball bearing under the arbitrary load conditions, a 5-DOF analytical model for bearing stiffness matrix analysis has been established by the ball–raceway contact analysis, implicit/explicit differential method, and matrix operations. The model has been validated comparing with the previous methods and experimental results. Based on this, the model has been used to investigate the influences of the load and operation conditions, the structural parameters variation on stiffness of ball bearing. The results show that property increasing axial preload can inhibit the attenuation of speed-varying stiffness, and the contact states between balls and raceways also have significant influence on the change in the stiffness of ball bearings. Besides, a larger curvature coefficient of inner raceway and a small curvature coefficient of outer raceway can effectively improve the stiffness of ball bearing at high speed. Therefore, the proposed method can be a useful tool in bearing optimize design and performance analysis of ball and rotor system under various load conditions. Full article

(This article belongs to the Special Issue Rolling Bearing and Rotor System Modeling and Simulation, Monitoring and Control, and Performance Diagnosis)

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15 pages, 7479 KiB

Open AccessEditor’s ChoiceArticle

The Modelling and Analysis of Micro-Milling Forces for Fabricating Thin-Walled Micro-Parts Considering Machining Dynamics

by Peng Wang, Qingshun Bai, Kai Cheng, Liang Zhao and Hui Ding

Machines 2022, 10(3), 217; https://doi.org/10.3390/machines10030217 - 20 Mar 2022

Cited by 12 | Viewed by 3042

Abstract

In the fabrication process of thin-walled micro-parts, both micro-cutting tools and thin-walled micro-parts have the characteristics of small size and low stiffness. Therefore, the regenerative chatter during the machining process cannot be ignored. The influence of the tool runout error and actual trochoidal [...] Read more.

In the fabrication process of thin-walled micro-parts, both micro-cutting tools and thin-walled micro-parts have the characteristics of small size and low stiffness. Therefore, the regenerative chatter during the machining process cannot be ignored. The influence of the tool runout error and actual trochoidal trajectories of the cutting edge on micro-milling forces should also be considered comprehensively. In this paper, the tool runout error in the micro-milling process is first analysed, and an instantaneous undeformed chip thickness model is established considering the runout error. On this basis, the dynamic deformation of the micro-cutting tool and thin-walled micro-part is studied, and an instantaneous, undeformed, chip-thickness model is proposed with the consideration of both the runout error and dynamic deformation. The dynamic parameters of the machining system are obtained using the receptance coupling method. Finally, thin-walled micro-part machining experiments are carried out, and the obtained results of micro-milling force simulation based on the proposed model are compared with the experimental results. The results indicate that the micro-milling force modelling, by taking the influence of machining dynamics into account, has better prediction accuracy, and the difference between the predicted resultant forces and the experimental results is less than 11%. Full article

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19 pages, 5887 KiB

Open AccessEditor’s ChoiceArticle

Partial Shaking Moment Balancing of Spherical Parallel Robots by a Combined Counterweight and Adjusting Kinematic Parameters Approach

by Hongfei Yu, Zhiqin Qian, Anil Borugadda, Wei Sun and Wenjun Zhang

Machines 2022, 10(3), 216; https://doi.org/10.3390/machines10030216 - 19 Mar 2022

Cited by 3 | Viewed by 2887

Abstract

Spherical parallel robots (SPR) are widely used in industries and robotic rehabilitation. Designing such systems for better balance properties is still a challenge. This paper presents a work to minimize the shaking moment for a fully force-balanced SPR by combining the counterweight (CW) [...] Read more.

Spherical parallel robots (SPR) are widely used in industries and robotic rehabilitation. Designing such systems for better balance properties is still a challenge. This paper presents a work to minimize the shaking moment for a fully force-balanced SPR by combining the counterweight (CW) and adjusting the kinematic parameters (AKP). An approximate model of the shaking moment of the SPR is proposed for computational efficiency (specifically allowing for a gradient-based optimization algorithm available in MATLAB) yet without the loss of much accuracy. The effectiveness of the proposed approach has been confirmed based on simulation, especially with the software system SPACAR due to its high reliability and easy availability. Specifically, the simulation result shows that compared with the unbalanced SPR, the shaking moment of the balanced SPR can decrease by more than 90%. It is worth mentioning that the AKP approach is an excellent example of mechatronics by combining the capability of re-planning the joint motion from the end-effector motion and adjusting the kinematic parameters to redistribute the mass of the whole robot for canceling the shaking force and shaking moment—inertia-induced force and moment to the ground. In short, the main contributions of this paper are: (1) a combined CW and AKP approach to the partial moment balancing of the SPR enhanced with a simplified mathematical model of the shaking moment of the SPR, and (2) a new design of the SPR which can be fully force balanced yet partially moment balanced. A note is taken that the simplified model is under the condition that the parameters of the link have certain geometric relations, which is a limitation of our approach. Full article

(This article belongs to the Special Issue Advances in Applied Mechatronics)

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134 pages, 7014 KiB

Open AccessEditor’s ChoiceReview

A Comprehensive Survey on Fault Tolerance in Multiphase AC Drives, Part 1: General Overview Considering Multiple Fault Types

by Alejandro G. Yepes, Oscar Lopez, Ignacio Gonzalez-Prieto, Mario J. Duran and Jesus Doval-Gandoy

Machines 2022, 10(3), 208; https://doi.org/10.3390/machines10030208 - 14 Mar 2022

Cited by 88 | Viewed by 9716

Abstract

Multiphase drives offer enhanced fault-tolerant capabilities compared with conventional three-phase ones. Their phase redundancy makes them able to continue running in the event of faults (e.g., open/short-circuits) in certain phases. Moreover, their greater number of degrees of freedom permits improving diagnosis and performance, [...] Read more.

Multiphase drives offer enhanced fault-tolerant capabilities compared with conventional three-phase ones. Their phase redundancy makes them able to continue running in the event of faults (e.g., open/short-circuits) in certain phases. Moreover, their greater number of degrees of freedom permits improving diagnosis and performance, not only under faults affecting individual phases, but also under those affecting the machine/drive as a whole. That is the case of failures in the dc link, resolver/encoder, control unit, cooling system, etc. Accordingly, multiphase drives are becoming remarkable contenders for applications where high reliability is required, such as electric vehicles and standalone/off-shore generation. Actually, the literature on the subject has grown exponentially in recent years. Various review papers have been published, but none of them currently cover the state-of-the-art in a comprehensive and up-to-date fashion. This two-part paper presents an overview concerning fault tolerance in multiphase drives. Hundreds of citations are classified and critically discussed. Although the emphasis is put on fault tolerance, fault detection/diagnosis is also considered to some extent, because of its importance in fault-tolerant drives. The most important recent advances, emerging trends and open challenges are also identified. Part 1 provides a comprehensive survey considering numerous kinds of faults, whereas Part 2 is focused on phase/switch open-circuit failures. Full article

(This article belongs to the Special Issue Feature Papers to Celebrate the First Impact Factor of Machines)

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14 pages, 5204 KiB

Open AccessEditor’s ChoiceArticle

Optimization Design and Performance Analysis of a Reverse-Salient Permanent Magnet Synchronous Motor

by Xiaokun Zhao, Baoquan Kou, Changchuang Huang and Lu Zhang

Machines 2022, 10(3), 204; https://doi.org/10.3390/machines10030204 - 11 Mar 2022

Cited by 12 | Viewed by 8982

Abstract

The reverse-salient permanent magnet synchronous motor (RSPMSM) is a competitive candidate for electric vehicles due to its high torque density and high efficiency. This paper proposes an optimized RSPMSM by adopting a segmented permanent magnet structure. First, the structure, electromagnetic torque, and current [...] Read more.

The reverse-salient permanent magnet synchronous motor (RSPMSM) is a competitive candidate for electric vehicles due to its high torque density and high efficiency. This paper proposes an optimized RSPMSM by adopting a segmented permanent magnet structure. First, the structure, electromagnetic torque, and current control laws of the RSPMSM are introduced in detail. Second, the optimization design method of the RSPMSM is proposed by taking the torque and constant-power speed range as optimized objectives, with the saliency ratio as a constraint. The optimized model of the RSPMSM is determined using the genetic algorithm (GA). Further performance analysis and comparisons are made between the initial motor and the optimized motor. Finally, a prototype is manufactured, and the performance of the RSPMSM is verified through the finite element method (FEM) and experiments. Full article

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

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25 pages, 75333 KiB

Open AccessEditor’s ChoiceArticle

Personalized Artificial Tibia Bone Structure Design and Processing Based on Laser Powder Bed Fusion

by Nan Yang, Youping Gong, Honghao Chen, Wenxin Li, Chuanping Zhou, Rougang Zhou and Huifeng Shao

Machines 2022, 10(3), 205; https://doi.org/10.3390/machines10030205 - 11 Mar 2022

Cited by 3 | Viewed by 2959

Abstract

Bone defects caused by bone diseases and bone trauma need to be implanted or replaced by surgery. Therefore, it is of great significance to design and prepare a tibial implant with good biocompatibility and excellent comprehensive mechanical properties. In this paper, with 316L [...] Read more.

Bone defects caused by bone diseases and bone trauma need to be implanted or replaced by surgery. Therefore, it is of great significance to design and prepare a tibial implant with good biocompatibility and excellent comprehensive mechanical properties. In this paper, with 316L stainless steel powder as the main material, a personalized artificial tibia design and processing method based on laser powder bed fusion is proposed. Firstly, the personalized model of the damaged part of the patient is reconstructed. Then, the porous structure of human tibia is manufactured by selective laser melting technology. To research the factors affecting the quality of selective laser melting porous structure, a laser heat source model, heat transfer model and molten pool model of laser powder bed fusion process were constructed; then, by changing the laser process parameters (laser power, laser beam diameter, scanning speed, powder layer thickness, etc.) to conduct multiple sets of simulation experiments, it is obtained that when the “laser power is 180 W, the laser scanning speed is 1000 mm/s, the laser beam diameter is 80 μm, the powder layer thickness is 50 μm”, the porous stainless steel parts with better quality can be obtained. Finally, the porous structure was fabricated by selective laser processing, and its properties were tested and analyzed. The experimental results show that the cell side length of cube is 1.2 mm, the elastic modulus of octahedral porous structure with pillar diameter of 0.35 mm is about 17.88 GPa, which match well with tibial bone tissue. Full article

(This article belongs to the Special Issue 3D/4D Bioprinting)

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12 pages, 4493 KiB

Open AccessEditor’s ChoiceArticle

Influence of Uneven Lighting on Quantitative Indicators of Surface Defects

by Ihor Konovalenko, Pavlo Maruschak, Halyna Kozbur, Janette Brezinová, Jakub Brezina, Bohdan Nazarevich and Yaroslav Shkira

Machines 2022, 10(3), 194; https://doi.org/10.3390/machines10030194 - 7 Mar 2022

Cited by 39 | Viewed by 3629

Abstract

The impact of the illumination level on the quantitative indicators of mechanical damage of the rolled strip is investigated. To do so, a physical model experiment was conducted in the laboratory. The obtained images of defects at light levels in the range of [...] Read more.

The impact of the illumination level on the quantitative indicators of mechanical damage of the rolled strip is investigated. To do so, a physical model experiment was conducted in the laboratory. The obtained images of defects at light levels in the range of 2–800 lx were recognized by a neural network model based on the U-net architecture with a decoder based on ResNet152. Two levels of illumination were identified, at which the total area of recognized defects increased: 50 lx and 300 lx. A quantitative assessment of the overall accuracy of defect recognition was conducted on the basis of comparison with data from images marked by an expert. The best recognition result (with Dice similarity coefficient DSC = 0.89) was obtained for the illumination of 300 lx. At lower light levels (less than 200 lx), some of the damage remained unrecognized. At high light levels (higher than 500 lx), a decrease in DSC was observed, mainly due to the fact that the surface objects are better visible and the recognized fragments become wider. In addition, more false-positives fragments were recognized. The obtained results are valuable for further adjustment of industrial systems for diagnosing technological defects on rolled metal strips. Full article

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

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11 pages, 4157 KiB

Open AccessEditor’s ChoiceArticle

Experimental Research on the Coupling Relationship between Fishtail Stiffness and Undulatory Frequency

by Yuanhao Zhang, Rongjie Kang, Donato Romano, Paolo Dario and Zhibin Song

Machines 2022, 10(3), 182; https://doi.org/10.3390/machines10030182 - 3 Mar 2022

Cited by 6 | Viewed by 2521

Abstract

Fish can swim in a variety of states. For example, they look flexible and perform low-frequency undulatory locomotion when cruising, but they seem very powerful and stiff and perform high-frequency undulatory when hunting. In the process of changing the motion state, the stiffness [...] Read more.

Fish can swim in a variety of states. For example, they look flexible and perform low-frequency undulatory locomotion when cruising, but they seem very powerful and stiff and perform high-frequency undulatory when hunting. In the process of changing the motion state, the stiffness of the fish body affects the swimming performance of the fish. In this article, we imitated the change of stiffness by superimposing rubber sheets and used experimental methods to test its swimming performance under different swing frequencies. A series of rubber fish tails were made according to the analysis of the swimming movement of real fish, providing different stiffness values and changing the curves of the body. In the prototype experiments, the base of the fish tail was fixed to a platform via a force sensor, which can oscillate at various speeds, so that the fish tail was able to swing and the thrust could be tested at different frequencies. According to the experimental results, we found that with the change of the swing frequency, there were different optimal stiffnesses that could make the thrust reach the maximum value, and with the increase of stiffness, the envelope interval of the swing curve gradually widened, the amplitude increased, and the hysteresis of the tail fin relative to the end decreased. Full article

(This article belongs to the Special Issue Advances in Underwater Robot Technology)

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18 pages, 5377 KiB

Open AccessEditor’s ChoiceArticle

A Comparative Study to Predict Bearing Degradation Using Discrete Wavelet Transform (DWT), Tabular Generative Adversarial Networks (TGAN) and Machine Learning Models

by Keval Bhavsar, Vinay Vakharia, Rakesh Chaudhari, Jay Vora, Danil Yurievich Pimenov and Khaled Giasin

Machines 2022, 10(3), 176; https://doi.org/10.3390/machines10030176 - 26 Feb 2022

Cited by 38 | Viewed by 5304

Abstract

Prognostics and health management (PHM) is a framework to identify damage prior to its occurrence which leads to the reduction of both maintenance costs and safety hazards. Based on the data collected in condition monitoring, the degradation of the part is predicted. Studies [...] Read more.

Prognostics and health management (PHM) is a framework to identify damage prior to its occurrence which leads to the reduction of both maintenance costs and safety hazards. Based on the data collected in condition monitoring, the degradation of the part is predicted. Studies show that most failures are caused by faults in rolling element bearing, which highlights that a bearing is one of the most important mechanical components of any machine. Thus, it becomes important to monitor bearing degradation to make sure that it is utilized properly. Generally, machine learning (ML) or deep learning (DL) techniques are utilized to predict bearing degradation using a data-driven approach, where signals are captured from the machine. There should be a large amount of data to apply either ML or DL techniques, but it is difficult to collect that amount of data directly from any machine. In this study, health assessment is carried out using the correlation coefficient to divide the bearing life into two degradation stages. The raw signal is processed using discrete wavelet transform (DWT), where mutual information (MI) is used to rank and select the base wavelet, after which tabular generative adversarial networks (TGAN) are used to generate the artificial coefficients. Statistical features are calculated from the real data (DWT coefficients) and the artificial data (generated from TGAN). The constructed feature vector is then used as an input to train machine learning models, namely ensemble bagged tree (EBT) and Gaussian process regression with the squared exponential kernel function (SEGPR), to estimate bearing degradation conditions. Both the machine learning models were validated on the publicly available experimental data of FEMTO bearing. Obtained results showed that the developed EBT and SEGPR models accurately predicted the bearing degradation conditions with the average lowest RMSE value of 0.0045 and MAE value of 0.0037. Full article

(This article belongs to the Special Issue Advances in Bearing Modeling, Fault Diagnosis, RUL Prediction)

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15 pages, 4928 KiB

Open AccessEditor’s ChoiceArticle

3D Reconstruction of High Reflective Welding Surface Based on Binocular Structured Light Stereo Vision

by Baizhen Li, Zhijie Xu, Feng Gao, Yanlong Cao and Quancheng Dong

Machines 2022, 10(2), 159; https://doi.org/10.3390/machines10020159 - 20 Feb 2022

Cited by 31 | Viewed by 5090

Abstract

The inspection of welding surface quality is an important task for welding work. With the development of product quality inspection technology, automated and machine vision-based inspection have been applied to more industrial application fields because of its non-contact, convenience, and high efficiency. However, [...] Read more.

The inspection of welding surface quality is an important task for welding work. With the development of product quality inspection technology, automated and machine vision-based inspection have been applied to more industrial application fields because of its non-contact, convenience, and high efficiency. However, challenging material and optical phenomena such as high reflective surface areas often present on welding seams tend to produce artifacts such as holes in the reconstructed model using current visual sensors, hence leading to insufficiency or even errors in the inspection result. This paper presents a 3D reconstruction technique for highly reflective welding surfaces based on binocular style structured light stereo vision. The method starts from capturing a fully lit image for identifying highly reflective regions on a welding surface using conventional computer vision models, including gray-scale, binarization, dilation, and erosion. Then, fringe projection profilometry is used to generate point clouds on the interested area. The mapping and alignment from 2D image to 3D point cloud is then established to highlight features that are vital for eliminating “holes”—large featureless areas—caused by high reflections such as the specular mirroring effect. A two-way slicing method is proposed to operate on the refined point cloud, following the concept of dimensionality reduction to project the sliced point cloud onto different image planes before a Smoothing Spline model is applied to fit the discrete point formed by projection. The 3D coordinate values of points in the “hole” region are estimated according to the fitted curves and appended to the original point cloud using iterative algorithms. Experiment results verify that the proposed method can accurately reconstruct a wide range of welding surfaces with significantly improved precision. Full article

(This article belongs to the Special Issue Precision Measurement and Machines)

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15 pages, 2484 KiB

Open AccessEditor’s ChoiceArticle

Predicting the Electrical Impedance of Rolling Bearings Using Machine Learning Methods

by Eckhard Kirchner, Christoph Bienefeld, Tobias Schirra and Alexander Moltschanov

Machines 2022, 10(2), 156; https://doi.org/10.3390/machines10020156 - 18 Feb 2022

Cited by 5 | Viewed by 2558

Abstract

The present paper describes a measurement setup and a related prediction of the electrical impedance of rolling bearings using machine learning algorithms. The impedance of the rolling bearing is expected to be key in determining the state of health of the bearing, which [...] Read more.

The present paper describes a measurement setup and a related prediction of the electrical impedance of rolling bearings using machine learning algorithms. The impedance of the rolling bearing is expected to be key in determining the state of health of the bearing, which is an essential component in almost all machines. In previous publications, the determination of the impedance of rolling bearings has already been advanced using analytical methods. Despite the improvements in accuracy achieved within the calculations, there are still discrepancies between the calculated and the measured impedance, leading to an approximately constant off-set value. This discrepancy motivates the machine learning approach introduced in this paper. It is shown that with the help of the data-driven methods the difference between analytical prediction and measurement is reduced to the order of up to 2% across the operational range analyzed so far. To introduce the context of the research shown, first the underlying physics of bearing impedance is presented. Subsequently different machine learning approaches are highlighted and compared with each other in terms of their prediction quality in the results part of this paper. As a further aspect, in addition to the prediction of the bearing impedance, it is investigated whether the rotational speed present at the bearing can be predicted from the frequency spectrum of the impedance using order analysis methods which is independent from the force prediction accuracy. The background to this is that, if the prediction quality is sufficiently high, the additional use of speed sensors could be omitted in future investigations. Full article

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

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20 pages, 17410 KiB

Open AccessEditor’s ChoiceArticle

Stability Analysis of Vaneless Space in High-Head Pump-Turbine under Turbine Mode: Computational Fluid Dynamics Simulation and Particle Imaging Velocimetry Measurement

by Wanquan Deng, Lianchen Xu, Zhen Li, Wen Tang, Xiaolong Wang, Linmin Shang, Demin Liu and Xiaobing Liu

Machines 2022, 10(2), 143; https://doi.org/10.3390/machines10020143 - 16 Feb 2022

Cited by 23 | Viewed by 3027

Abstract

When the Francis-type reversible pump-turbine runs under partial load, the pressure pulsation amplitude and frequency in vaneless space are high, posing a serious threat to the stability of unit operation. Water presents weak compressibility in a high-head pump-turbine, thereby affecting the amplitude–frequency characteristics [...] Read more.

When the Francis-type reversible pump-turbine runs under partial load, the pressure pulsation amplitude and frequency in vaneless space are high, posing a serious threat to the stability of unit operation. Water presents weak compressibility in a high-head pump-turbine, thereby affecting the amplitude–frequency characteristics of pressure pulsation. This study used numerical simulations in a model and prototype pump-turbine and particle image velocimetry (PIV) in a model pump-turbine to examine the internal flow field and pressure pulsation characteristics and determine the effect of the flow in the vaneless space on the amplitude–frequency characteristics of the pressure pulsation. The pressure pulsation amplitude–frequency characteristics were verified through prototype tests. The effects of the weak compressibility of the water on the propagation law of pressure pulsation throughout the flow passage of the prototype and model pump-turbine were roughly similar but exhibited certain differences. Considering the weak compressibility of water, the pressure pulsation fluctuations in each flow passage of the prototype and model pump-turbine exhibit varying degrees of improvement, which is more obvious at the prototype scale. Therefore, the pressure wave disturbance caused by the weak compressibility of the water has different effects on the prototype scale and model scale of the high-head Francis pump-turbine. Full article

(This article belongs to the Section Turbomachinery)

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15 pages, 4135 KiB

Open AccessEditor’s ChoiceArticle

Fundamental Design and Modelling of the Superconducting Magnet for the High-Speed Maglev: Mechanics, Electromagnetics, and Loss Analysis during Instability

by Zhihao Wu, Jianxun Jin, Boyang Shen, Luning Hao, Youguang Guo and Jianguo Zhu

Machines 2022, 10(2), 113; https://doi.org/10.3390/machines10020113 - 3 Feb 2022

Cited by 11 | Viewed by 3970

Abstract

The high-temperature superconductor (HTS) has been recognised as one of the most up-and-coming materials thanks to its superior electromagnetic performance (e.g., zero resistance). For a high-speed maglev, the HTS magnet can be the most crucial component because it is in charge of both [...] Read more.

The high-temperature superconductor (HTS) has been recognised as one of the most up-and-coming materials thanks to its superior electromagnetic performance (e.g., zero resistance). For a high-speed maglev, the HTS magnet can be the most crucial component because it is in charge of both the levitation and the propulsion of the maglev. Therefore, a fundamental study of HTS magnets for maglev is crucial. This article presents the fundamental design and modelling of the superconducting magnet for a high-speed maglev, including mechanics, electromagnetics, and loss analysis during instability. First, the measurements of the superconducting wire were performed. The HTS magnet was primarily designed and modelled to fulfil the basic electromagnetic requirements (e.g., magnetic field) in order to drive the maglev at a high speed. The modelling was verified by experimental tests on a scale-down HTS magnet. A more professional model using the H-formulation based on the finite element method (FEM) was built to further investigate some deeper physical phenomenon of the HTS magnet (e.g., current density and loss behaviours), particularly in situations where the high-speed maglev is in the normal steady state or encountering instability. Full article

(This article belongs to the Special Issue Feature Papers to Celebrate the First Impact Factor of Machines)

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15 pages, 3926 KiB

Open AccessEditor’s ChoiceArticle

Study on Mechanism of Roundness Improvement by the Internal Magnetic Abrasive Finishing Process Using Magnetic Machining Tool

by Jiangnan Liu and Yanhua Zou

Machines 2022, 10(2), 112; https://doi.org/10.3390/machines10020112 - 2 Feb 2022

Cited by 7 | Viewed by 2337

Abstract

An internal magnetic abrasive finishing process using a magnetic machining tool was proposed for finishing the internal surface of the thick tubes. It has been proved that this process is effective for finishing thick tubes, and it can improve the roundness while improving [...] Read more.

An internal magnetic abrasive finishing process using a magnetic machining tool was proposed for finishing the internal surface of the thick tubes. It has been proved that this process is effective for finishing thick tubes, and it can improve the roundness while improving the roughness. However, the mechanism of improving the roundness is not clear, so it is necessary to study it theoretically. In this research, firstly, the roundness curve expression was derived using the principle of roundness measurement by the assumed center method, and the expression of roundness curve expanded by Fourier series was obtained. The influencing factors of roundness improvement were then analyzed. Secondly, the experiments were carried out on SUS304 stainless steel tubes. By confirming the mechanism analysis results and the experimental results, it was concluded that the internal magnetic abrasive finishing process using the magnetic machining tool was effective for improving the roundness of the thick tubes whose thickness is from 10 mm to 30 mm. As the thickness of the tube increased, the improvement in roundness decreased. Full article

(This article belongs to the Special Issue High Precision Abrasive Machining: Machines, Processes and Systems)

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15 pages, 8002 KiB

Open AccessEditor’s ChoiceArticle

A Hybrid Mechanism-Based Robot for End-Traction Lower Limb Rehabilitation: Design, Analysis and Experimental Evaluation

by Lipeng Wang, Junjie Tian, Jiazheng Du, Siyuan Zheng, Jianye Niu, Zhengyan Zhang and Jiang Wu

Machines 2022, 10(2), 99; https://doi.org/10.3390/machines10020099 - 27 Jan 2022

Cited by 12 | Viewed by 3651

Abstract

Conventional lower-limb rehabilitation robots cannot provide in-time rehabilitation training for stroke patients in the acute stage due to their large size and mass as well as their complex wearing process. Aiming to solve the problems, first, a novel hybrid end-traction lower-limb rehabilitation robot [...] Read more.

Conventional lower-limb rehabilitation robots cannot provide in-time rehabilitation training for stroke patients in the acute stage due to their large size and mass as well as their complex wearing process. Aiming to solve the problems, first, a novel hybrid end-traction lower-limb rehabilitation robot (HE-LRR) was designed as the lower-limb rehabilitation requirement of patients in the acute stage, in this paper. The usage of (2-UPS + U)&(R + RPS)&(2-RR) hybrid mechanism and a mirror motion actuator had the advantages of compact structure, large working space and short wearing time to the HE-LRR. Then, the mobility of the HE-LRR was calculated and the motion property was analyzed based on screw theory. Meanwhile, the trajectory planning of the HE-LRR was carried out based on MOTOmed^® motion training. Finally, the motion capture and surface electromyography (sEMG) signal acquisition experiments in the MOTOmed motion training were performed. The foot trajectory experimental effect and the lower-limb muscle groups activation rules were studied ulteriorly. The experimental results showed that the HE-LRR achieved good kinematic accuracy and lower limb muscle groups training effect, illustrating that the HE-LRR possessed good application prospects for the lower-limb rehabilitation of patients in the acute stage. This research could also provide a theoretical basis for improving the standardization and compliance of lower-limb robot rehabilitation training. Full article

(This article belongs to the Special Issue Smart Machines: Applications and Advances in Human Motion Analysis)

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37 pages, 1941 KiB

Open AccessEditor’s ChoiceReview

Motion Planning for Mobile Manipulators—A Systematic Review

by Thushara Sandakalum and Marcelo H. Ang, Jr.

Machines 2022, 10(2), 97; https://doi.org/10.3390/machines10020097 - 27 Jan 2022

Cited by 79 | Viewed by 16362

Abstract

One of the fundamental fields of research is motion planning. Mobile manipulators present a unique set of challenges for the planning algorithms, as they are usually kinematically redundant and dynamically complex owing to the different dynamic behavior of the mobile base and the [...] Read more.

One of the fundamental fields of research is motion planning. Mobile manipulators present a unique set of challenges for the planning algorithms, as they are usually kinematically redundant and dynamically complex owing to the different dynamic behavior of the mobile base and the manipulator. The purpose of this article is to systematically review the different planning algorithms specifically used for mobile manipulator motion planning. Depending on how the two subsystems are treated during planning, sampling-based, optimization-based, search-based, and other planning algorithms are grouped into two broad categories. Then, planning algorithms are dissected and discussed based on common components. The problem of dealing with the kinematic redundancy in calculating the goal configuration is also analyzed. While planning separately for the mobile base and the manipulator provides convenience, the results are sub-optimal. Coordinating between the mobile base and manipulator while utilizing their unique capabilities provides better solution paths. Based on the analysis, challenges faced by the current planning algorithms and future research directions are presented. Full article

(This article belongs to the Special Issue Feature Papers to Celebrate the First Impact Factor of Machines)

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14 pages, 4754 KiB

Open AccessEditor’s ChoiceArticle

A Novel Fault Diagnosis Method Based on the KELM Optimized by Whale Optimization Algorithm

by Ruijun Liang, Yao Chen and Rupeng Zhu

Machines 2022, 10(2), 93; https://doi.org/10.3390/machines10020093 - 25 Jan 2022

Cited by 23 | Viewed by 2989

Abstract

To solve the problem that fault features are difficult to extract and the time-frequency features cannot fully represent the state information, a novel method is proposed in this paper based on the whale optimization algorithm (WOA) and the kernel extreme learning machine (KELM). [...] Read more.

To solve the problem that fault features are difficult to extract and the time-frequency features cannot fully represent the state information, a novel method is proposed in this paper based on the whale optimization algorithm (WOA) and the kernel extreme learning machine (KELM). First, the vibration signals are processed by the ensemble empirical mode decomposition and sample entropy to obtain the feature vectors. Based on this, a KELM model for fault diagnosis is established. Then, the penalty factor and the kernel parameters in the KELM are optimized by WOA to improve the stability and classification accuracy. Taking faults of a ball-screw pair on a linear feed table as a case, the experimental results indicate that the proposed method can effectively extract the fault features of the ball-screw pair, and it can achieve higher classification accuracy, faster convergence speed, and greater convergence precision than the existing fault diagnosis methods. Full article

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22 pages, 36854 KiB

Open AccessEditor’s ChoiceArticle

The Effect of Rotating Speeds on the Cavitation Characteristics in Hydraulic Torque Converter

by Meng Guo, Cheng Liu, Qingdong Yan, Wei Wei and Boo Cheong Khoo

Machines 2022, 10(2), 80; https://doi.org/10.3390/machines10020080 - 23 Jan 2022

Cited by 15 | Viewed by 4870

Abstract

Hydraulic torque converter is a kind of high speed rotating machine using viscosity hydraulic oil as working medium, and its internal flow field is very complex. Thereby cavitation can occur easily in the working process, resulting in severe degradation of torque converter performance, [...] Read more.

Hydraulic torque converter is a kind of high speed rotating machine using viscosity hydraulic oil as working medium, and its internal flow field is very complex. Thereby cavitation can occur easily in the working process, resulting in severe degradation of torque converter performance, noise, vibration and even failure. In order to reveal the effect of rotating speeds on the cavitation characteristics, a full flow passage geometry and a computational fluid dynamics (CFD) model with cavitation were developed to analyze the flow behavior in the torque converter. The results show that cavitation occurs when the speed difference between pump and turbine exceeds 1400 rpm for the basic model torque converter, which could be used as a useful indicator for the occurrence and degree of severity of flow cavitation. The increase of pump rotating speed or the decrease of speed ratio will intensify cavitation, which reduces the hydraulic transmission capacity and efficiency by over 20%, and seriously alters the shape, size, vapor volume fraction and region of cavitation bubbles. In extreme cases, more than 80% of the area on the suction side of the stator blade could be covered by cavitation bubbles. Moreover, the increase of pump rotating speed also changes the critical cavitation number and extends the cavitation range towards high speed ratio conditions not previously affected. These findings can provide guidance on how to choose the operating conditions of the hydraulic torque converter and how to improve its hydrodynamic performance and stability. Full article

(This article belongs to the Section Turbomachinery)

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16 pages, 4515 KiB

Open AccessEditor’s ChoiceArticle

Assist-As-Needed Control Strategy of Bilateral Upper Limb Rehabilitation Robot Based on GMM

by Maoqin Li, Jiaji Zhang, Guokun Zuo, Guang Feng and Xueliang Zhang

Machines 2022, 10(2), 76; https://doi.org/10.3390/machines10020076 - 21 Jan 2022

Cited by 22 | Viewed by 4110

Abstract

Robotic-assisted rehabilitation therapy has been shown to be effective in improving upper limb motor function and the daily behavior of patients with motor dysfunction. At present, the majority of upper limb rehabilitation robots can only move in the two-dimensional plane, and cannot adjust [...] Read more.

Robotic-assisted rehabilitation therapy has been shown to be effective in improving upper limb motor function and the daily behavior of patients with motor dysfunction. At present, the majority of upper limb rehabilitation robots can only move in the two-dimensional plane, and cannot adjust the assistance mode in real-time according to the patient’s rehabilitation needs. In this paper, according to the shortcomings of the current rehabilitation robot only moving in the two-dimensional plane, a type of bilateral mirror upper limb rehabilitation robot structure with the healthy side assisting the affected side is proposed. This can move in three-dimensional space. Additionally, an assist-as-needed (AAN) control strategy for upper limb rehabilitation training is proposed based on the bilateral upper limb rehabilitation robot. The control strategy adopts Gaussian Mixture Model (GMM) and impedance controller to maximize the patient’s rehabilitation effect. In the task’s design, there is no need to rely on the assistance of the therapist, only the patients who completed the task independently. GMM guides the rehabilitation robot to provide different assistance for the patients at different task stages and induces the patients to complete the rehabilitation training independently by judging the extent to which the patients can complete the task. Furthermore, in this paper, the effectiveness of the proposed control strategy was verified by three volunteers participating in a two-dimensional task. The experimental results show that the proposed AAN control strategy can effectively provide appropriate assistance according to the classification stage of the interaction between the patients and the rehabilitation robot, and thus, patients can better achieve the rehabilitation effect during the rehabilitation task as much as possible. Full article

(This article belongs to the Topic Motion Planning and Control for Robotics)

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53 pages, 6453 KiB

Open AccessEditor’s ChoiceReview

Marine Systems and Equipment Prognostics and Health Management: A Systematic Review from Health Condition Monitoring to Maintenance Strategy

by Peng Zhang, Zeyu Gao, Lele Cao, Fangyang Dong, Yongjiu Zou, Kai Wang, Yuewen Zhang and Peiting Sun

Machines 2022, 10(2), 72; https://doi.org/10.3390/machines10020072 - 19 Jan 2022

Cited by 57 | Viewed by 12886

Abstract

Prognostics and health management (PHM) is an essential means to optimize resource allocation and improve the intelligent operation and maintenance (O&M) efficiency of marine systems and equipment (MSAE). PHM generally consists of four technical processes, namely health condition motoring (HCM), fault diagnosis (FD), [...] Read more.

Prognostics and health management (PHM) is an essential means to optimize resource allocation and improve the intelligent operation and maintenance (O&M) efficiency of marine systems and equipment (MSAE). PHM generally consists of four technical processes, namely health condition motoring (HCM), fault diagnosis (FD), health prognosis (HP), and maintenance decision (MD). In recent years, a large amount of research has been implemented in each process. However, there is not any systematic review that covers the technical framework comprehensively. This article presents a review of the framework of PHM in the marine field to fill the gap. First, the essential HCM methods, which are widely observed in the academic literature, are introduced systematically. Then, the commonly used FD approaches and their applications in MSAE are summarized, and the implementation process of intelligent methods is systematically introduced. After that, the technologies of HP have been reviewed, including the construction of health indicator (HI), health stage (HS) division, and popular remaining useful life (RUL) prediction approaches. Afterwards, the evolution of maintenance strategy in the maritime field is reviewed. Finally, the challenges of implementing PHM for intelligent ships are put forward. Full article

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21 pages, 9622 KiB

Open AccessEditor’s ChoiceArticle

A Calculation Method for Tooth Wear Depth Based on the Finite Element Method That Considers the Dynamic Mesh Force

by Zao He, Yumei Hu, Xingyuan Zheng and Yuanyuan Yu

Machines 2022, 10(2), 69; https://doi.org/10.3390/machines10020069 - 18 Jan 2022

Cited by 19 | Viewed by 4178

Abstract

Gear wear is a progressive material removal process that gradually changes the tooth profile shape and dynamic mesh force, where the dynamic mesh force affects the tooth surface wear. To describe this process, a spur gear dynamic model that includes the mesh stiffness [...] Read more.

Gear wear is a progressive material removal process that gradually changes the tooth profile shape and dynamic mesh force, where the dynamic mesh force affects the tooth surface wear. To describe this process, a spur gear dynamic model that includes the mesh stiffness and unloaded static transmission error (STE) of the worn tooth profile is proposed for calculating the dynamic mesh force. Then, based on the finite element method (FEM), a dynamic contact analysis model that considers the dynamic mesh force is proposed for calculating the time-varying contact stress and relative sliding distance of the tooth surface mesh point. Finally, combined with the Archard wear model, a tooth wear depth calculation method that considers the worn tooth profile and the dynamic mesh force is proposed. In addition, the wear depth and dynamic characteristics under different wear times are studied. Full article

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

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16 pages, 9947 KiB

Open AccessEditor’s ChoiceArticle

Design of a 3D-Printed Hand Exoskeleton Based on Force-Myography Control for Assistance and Rehabilitation

by Daniele Esposito, Jessica Centracchio, Emilio Andreozzi, Sergio Savino, Gaetano D. Gargiulo, Ganesh R. Naik and Paolo Bifulco

Machines 2022, 10(1), 57; https://doi.org/10.3390/machines10010057 - 13 Jan 2022

Cited by 45 | Viewed by 10349

Abstract

Voluntary hand movements are usually impaired after a cerebral stroke, affecting millions of people per year worldwide. Recently, the use of hand exoskeletons for assistance and motor rehabilitation has become increasingly widespread. This study presents a novel hand exoskeleton, designed to be low [...] Read more.

Voluntary hand movements are usually impaired after a cerebral stroke, affecting millions of people per year worldwide. Recently, the use of hand exoskeletons for assistance and motor rehabilitation has become increasingly widespread. This study presents a novel hand exoskeleton, designed to be low cost, wearable, easily adaptable and suitable for home use. Most of the components of the exoskeleton are 3D printed, allowing for easy replication, customization and maintenance at a low cost. A strongly underactuated mechanical system allows one to synergically move the four fingers by means of a single actuator through a rigid transmission, while the thumb is kept in an adduction or abduction position. The exoskeleton’s ability to extend a typical hypertonic paretic hand of stroke patients was firstly tested using the SimScape Multibody simulation environment; this helped in the choice of a proper electric actuator. Force-myography was used instead of the standard electromyography to voluntarily control the exoskeleton with more simplicity. The user can activate the flexion/extension of the exoskeleton by a weak contraction of two antagonist muscles. A symmetrical master–slave motion strategy (i.e., the paretic hand motion is activated by the healthy hand) is also available for patients with severe muscle atrophy. An inexpensive microcontroller board was used to implement the electronic control of the exoskeleton and provide feedback to the user. The entire exoskeleton including batteries can be worn on the patient’s arm. The ability to provide a fluid and safe grip, like that of a healthy hand, was verified through kinematic analyses obtained by processing high-framerate videos. The trajectories described by the phalanges of the natural and the exoskeleton finger were compared by means of cross-correlation coefficients; a similarity of about 80% was found. The time required for both closing and opening of the hand exoskeleton was about 0.9 s. A rigid cylindric handlebar containing a load cell measured an average power grasp force of 94.61 N, enough to assist the user in performing most of the activities of daily living. The exoskeleton can be used as an aid and to promote motor function recovery during patient’s neurorehabilitation therapy. Full article

(This article belongs to the Special Issue Feature Papers to Celebrate the First Impact Factor of Machines)

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28 pages, 6057 KiB

Open AccessEditor’s ChoiceArticle

Identification of Vehicle System Dynamics from the Aspect of Interaction between the Steering and the Suspension Systems

by Danijela Miloradović, Jovanka Lukić, Jasna Glišović and Nenad Miloradović

Machines 2022, 10(1), 46; https://doi.org/10.3390/machines10010046 - 8 Jan 2022

Cited by 2 | Viewed by 2743

Abstract

Steering and suspension systems of a motor vehicle have very important mutual connections that have direct influence on a vehicle’s steerability, stability, comfort and life expectancy. These mechanical and functional couplings cause an intensive interaction between the two mentioned vehicle systems on a [...] Read more.

Steering and suspension systems of a motor vehicle have very important mutual connections that have direct influence on a vehicle’s steerability, stability, comfort and life expectancy. These mechanical and functional couplings cause an intensive interaction between the two mentioned vehicle systems on a geometrical, kinematical and dynamical level. This article presents a study on nonparametric identification of dynamic interaction between the steering and the suspension system of a passenger vehicle. A specific methodology for experimental research in on-road conditions was designed that was in line with the research objectives and the applied measuring system. Experimental data were acquired for a curvilinear drive, with different constant driving speeds and on different roads. A multiple input/multiple output model for identification of the vehicle dynamics system from the aspect of interaction between the steering and the suspension system was developed. The analysis of experimental data was realized with the selection of a corresponding identification model, decoupling of model inputs and conditioned spectral analysis. The results of the conditioned spectral analysis of experimentally obtained data records indicate the level of interaction between the observed input and output parameters of the steering and the suspension systems to be in the frequency range below 30 Hz. Full article

(This article belongs to the Section Vehicle Engineering)

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20 pages, 5846 KiB

Open AccessEditor’s ChoiceArticle

Analysis, Design and Experimental Research of a Novel Bilateral Patient Transfer Robot

by Lingfeng Sang, Hongbo Wang and Yu Tian

Machines 2022, 10(1), 33; https://doi.org/10.3390/machines10010033 - 4 Jan 2022

Cited by 4 | Viewed by 2785

Abstract

Patient transfer has always been a difficult problem in the hospital. For medical staff, there are problems including high risk of infection, heavy physical labor and low efficiency of transfer; for patients, there are problems including poor comfort and secondary injury. In this [...] Read more.

Patient transfer has always been a difficult problem in the hospital. For medical staff, there are problems including high risk of infection, heavy physical labor and low efficiency of transfer; for patients, there are problems including poor comfort and secondary injury. In this paper, a novel bilateral patient transfer robot is investigated and designed. The following tasks are conducted: (1) Based on the process of patient transfer, a transfer model, which consists of two degrees of freedom, is proposed, and the working principle of bilateral patient transfer robot is obtained and analyzed in detail. (2) Force analysis of the patient transfer robot is conducted. The corresponding relationship between the patient comfort and the insertion angle is proposed, and the optimal sizes of mechanical structure are obtained. (3) Based on the theoretical analysis, the mechanical structure and the control system of the robot are designed, and the prototype is manufactured. (4) Experimental research is conducted. The results show that the prototype can complete the required motion performance with a carrying capacity up to 150 kg and patient comfort is excellent. The results of this paper prove that this kind of patient transfer robot has good performance, it can also reduce the burden on medical staff. Full article

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

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16 pages, 5882 KiB

Open AccessEditor’s ChoiceArticle

Fatigue Analysis of Dozer Push Arms under Tilt Bulldozing Conditions

by Longye Pan, Xianglong Guan, Xingwei Luan, Yajun Huang, Ruwei Zhang, Jin-Hwan Choi and Xiangqian Zhu

Machines 2022, 10(1), 38; https://doi.org/10.3390/machines10010038 - 4 Jan 2022

Cited by 4 | Viewed by 7003

Abstract

Tilt bulldozing generates unbalanced loads on two push arms, which leads to the service lives of the two push arms being different. Because the push arms rotate in triaxial directions during tilt bulldozing, it is difficult to accurately analyze the fatigue life of [...] Read more.

Tilt bulldozing generates unbalanced loads on two push arms, which leads to the service lives of the two push arms being different. Because the push arms rotate in triaxial directions during tilt bulldozing, it is difficult to accurately analyze the fatigue life of the push arm with one specific boundary condition and loading history. Therefore, a fatigue analysis of the push arms under tilt bulldozing conditions is proposed based on co-simulation of RecurDyn-EDEM-AMESim in this paper. The control of tilt bulldozing conditions is realized automatically according to the tilt angle and blade depth. The dynamic loads of the push arms are accurately calculated in this virtual model. Subsequently, the stress–time histories are obtained to investigate the fatigue lives of push arms. Both the overall damage and the initiation positions of the cracks are predicted herein. It is determined that the fatigue lives of the right and left push arms are 7,317.84 h and 39,381.89 h, respectively. Thus, the life of the push arm on the blade’s tilted side is reduced by 81.42% compared to the other side. Additionally, experimental tests are conducted to verify the accuracy of the virtual model. Analysis results indicate that the strains of the push arms according to the virtual simulation are close to those measured in the experiments. Full article

(This article belongs to the Special Issue Dynamics and Diagnostics of Heavy-Duty Industrial Machines)

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25 pages, 1333 KiB

Open AccessEditor’s ChoiceReview

A Review of Thermal Monitoring Techniques for Radial Permanent Magnet Machines

by Tianze Meng and Pinjia Zhang

Machines 2022, 10(1), 18; https://doi.org/10.3390/machines10010018 - 24 Dec 2021

Cited by 20 | Viewed by 5101

Abstract

Permanent magnet machines are widely applied in motor drive systems. Therefore, condition monitoring of permanent magnet machines has great significance to assist maintenance. High temperatures are accountable for lots of typical malfunctions and faults, such as demagnetization of the permanent magnet (PM) and [...] Read more.

Permanent magnet machines are widely applied in motor drive systems. Therefore, condition monitoring of permanent magnet machines has great significance to assist maintenance. High temperatures are accountable for lots of typical malfunctions and faults, such as demagnetization of the permanent magnet (PM) and inter-turn short circuit of stator windings. Therefore, temperature monitoring of the PM and stator windings is essential for reliable operation. In this paper, an overview introducing and evaluating existing thermal monitoring methods is presented. First, the mechanism of thermal-caused failures for the PM and stator windings is introduced. Then, the design procedure and principles of existing temperature monitoring methods are introduced and summarized. Next, the evaluations and recommendations of application feasibility are demonstrated. Finally, the potential future challenges and opportunities for temperature monitoring of the PM and stator windings are discussed. Full article

(This article belongs to the Special Issue Feature Papers to Celebrate the First Impact Factor of Machines)

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19 pages, 5953 KiB

Open AccessEditor’s ChoiceArticle

Robust Lane Detection and Tracking Algorithm for Steering Assist Systems

by Mihail-Alexandru Andrei, Costin-Anton Boiangiu, Nicolae Tarbă and Mihai-Lucian Voncilă

Machines 2022, 10(1), 10; https://doi.org/10.3390/machines10010010 - 23 Dec 2021

Cited by 21 | Viewed by 5052

Abstract

Modern vehicles rely on a multitude of sensors and cameras to both understand the environment around them and assist the driver in different situations. Lane detection is an overall process as it can be used in safety systems such as the lane departure [...] Read more.

Modern vehicles rely on a multitude of sensors and cameras to both understand the environment around them and assist the driver in different situations. Lane detection is an overall process as it can be used in safety systems such as the lane departure warning system (LDWS). Lane detection may be used in steering assist systems, especially useful at night in the absence of light sources. Although developing such a system can be done simply by using global positioning system (GPS) maps, it is dependent on an internet connection or GPS signal, elements that may be absent in some locations. Because of this, such systems should also rely on computer vision algorithms. In this paper, we improve upon an existing lane detection method, by changing two distinct features, which in turn leads to better optimization and false lane marker rejection. We propose using a probabilistic Hough transform, instead of a regular one, as well as using a parallelogram region of interest (ROI), instead of a trapezoidal one. By using these two methods we obtain an increase in overall runtime of approximately 30%, as well as an increase in accuracy of up to 3%, compared to the original method. Full article

(This article belongs to the Section Vehicle Engineering)

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18 pages, 4607 KiB

Open AccessEditor’s ChoiceArticle

Optimizing the Sharpening Process of Hybrid-Bonded Diamond Grinding Wheels by Means of a Process Model

by Eckart Uhlmann and Arunan Muthulingam

Machines 2022, 10(1), 8; https://doi.org/10.3390/machines10010008 - 22 Dec 2021

Cited by 2 | Viewed by 3298

Abstract

The grinding wheel topography influences the cutting performance and thus the economic efficiency of a grinding process. In contrary to conventional grinding wheels, super abrasive grinding wheels should undergo an additional sharpening process after the initial profiling process to obtain a suitable microstructure [...] Read more.

The grinding wheel topography influences the cutting performance and thus the economic efficiency of a grinding process. In contrary to conventional grinding wheels, super abrasive grinding wheels should undergo an additional sharpening process after the initial profiling process to obtain a suitable microstructure of the grinding wheel. Due to the lack of scientific knowledge, the sharpening process is mostly performed manually in industrial practice. A CNC-controlled sharpening process can not only improve the reproducibility of grinding processes but also decrease the secondary processing time and thereby increase the economic efficiency significantly. To optimize the sharpening process, experimental investigations were carried out to identify the significant sharpening parameters influencing the grinding wheel topography. The sharpening block width l_Sb, the grain size of the sharpening block d_kSb and the area-related material removal in sharpening V’’_Sb were identified as the most significant parameters. Additional experiments were performed to further quantify the influence of the significant sharpening parameters. Based on that, a process model was developed to predict the required sharpening parameters for certain target topographies. By using the process model, constant work results and improved process reliability can be obtained. Full article

(This article belongs to the Special Issue Advances and Trends in Non-conventional, Abrasive and Precision Machining 2021)

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21 pages, 6560 KiB

Open AccessEditor’s ChoiceArticle

Study on Improvement of Lightning Damage Detection Model for Wind Turbine Blade

by Takuto Matsui, Kazuo Yamamoto and Jun Ogata

Machines 2022, 10(1), 9; https://doi.org/10.3390/machines10010009 - 22 Dec 2021

Cited by 8 | Viewed by 3712

Abstract

There have been many reports of damage to wind turbine blades caused by lightning strikes in Japan. In some of these cases, the blades struck by lightning continue to rotate, causing more serious secondary damage. To prevent such accidents, it is a requirement [...] Read more.

There have been many reports of damage to wind turbine blades caused by lightning strikes in Japan. In some of these cases, the blades struck by lightning continue to rotate, causing more serious secondary damage. To prevent such accidents, it is a requirement that a lightning detection system is installed on the wind turbine in areas where winter lightning occurs in Japan. This immediately stops the wind turbine if the system detects a lightning strike. Normally, these wind turbines are restarted after confirming soundness of the blade through visual inspection. However, it is often difficult to confirm the soundness of the blade visually for reasons such as bad weather. This process prolongs the time taken to restart, and it is one of the causes that reduces the availability of the wind turbines. In this research, we constructed a damage detection model for wind turbine blades using machine learning based on SCADA system data and, thereby, considered whether the technology automatically confirms the soundness of wind turbine blades. Full article

(This article belongs to the Special Issue Advances in Wind and Solar Energy Generation)

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21 pages, 10106 KiB

Open AccessEditor’s ChoiceArticle

Adjustable Speed Control and Damping Analysis of Torsional Vibrations in VSD Compressor Systems

by Mattia Rossi, Maria Stefania Carmeli and Marco Mauri

Machines 2021, 9(12), 374; https://doi.org/10.3390/machines9120374 - 20 Dec 2021

Cited by 5 | Viewed by 3362

Abstract

This paper proposes a model-based two-degree-of-freedom (2DOF) speed control for a medium voltage (MV) variable speed drive (VSD) connected to a centrifugal compressor (CC) train. Torsional mode excitations in the drive shaft due to converter switching behaviour are considered. An effective description of [...] Read more.

This paper proposes a model-based two-degree-of-freedom (2DOF) speed control for a medium voltage (MV) variable speed drive (VSD) connected to a centrifugal compressor (CC) train. Torsional mode excitations in the drive shaft due to converter switching behaviour are considered. An effective description of the harmonics transfer is proposed. The tuning strategy aims to optimize the tracking behaviour of the step and ramp command, taking care of critical speed excitations. The stability of the closed-loop dynamics against time delay and drive parameter variations are studied by means of Nyquist diagrams and time-domain simulations. A descriptive method for the process damping behaviour is proposed. The control strategy is evaluated through simulations as well as an experimental setup, based on a hardware in the loop (HIL) in a master–slave configuration. Full article

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

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54 pages, 1710 KiB

Open AccessEditor’s ChoiceReview

A Systematic Literature Review of Cutting Tool Wear Monitoring in Turning by Using Artificial Intelligence Techniques

by Lorenzo Colantonio, Lucas Equeter, Pierre Dehombreux and François Ducobu

Machines 2021, 9(12), 351; https://doi.org/10.3390/machines9120351 - 10 Dec 2021

Cited by 52 | Viewed by 9080

Abstract

In turning operations, the wear of cutting tools is inevitable. As workpieces produced with worn tools may fail to meet specifications, the machining industries focus on replacement policies that mitigate the risk of losses due to scrap. Several strategies, from empiric laws to [...] Read more.

In turning operations, the wear of cutting tools is inevitable. As workpieces produced with worn tools may fail to meet specifications, the machining industries focus on replacement policies that mitigate the risk of losses due to scrap. Several strategies, from empiric laws to more advanced statistical models, have been proposed in the literature. More recently, many monitoring systems based on Artificial Intelligence (AI) techniques have been developed. Due to the scope of different artificial intelligence approaches, having a holistic view of the state of the art on this subject is complex, in part due to a lack of recent comprehensive reviews. This literature review therefore presents 20 years of literature on this subject obtained following a Systematic Literature Review (SLR) methodology. This SLR aims to answer the following research question: “How is the AI used in the framework of monitoring/predicting the condition of tools in stable turning condition?” To answer this research question, the “Scopus” database was consulted in order to gather relevant publications published between 1 January 2000 and 1 January 2021. The systematic approach yielded 8426 articles among which 102 correspond to the inclusion and exclusion criteria which limit the application of AI to stable turning operation and online prediction. A bibliometric analysis performed on these articles highlighted the growing interest of this subject in the recent years. A more in-depth analysis of the articles is also presented, mainly focusing on six AI techniques that are highly represented in the literature: Artificial Neural Network (ANN), fuzzy logic, Support Vector Machine (SVM), Self-Organizing Map (SOM), Hidden Markov Model (HMM), and Convolutional Neural Network (CNN). For each technique, the trends in the inputs, pre-processing techniques, and outputs of the AI are presented. The trends highlight the early and continuous importance of ANN, and the emerging interest of CNN for tool condition monitoring. The lack of common benchmark database for evaluating models performance does not allow clear comparisons of technique performance. Full article

(This article belongs to the Special Issue Advances in Tool Life Prediction in Machining)

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26 pages, 7851 KiB

Open AccessEditor’s ChoiceArticle

Modeling, Design, and Implementation of an Underactuated Gripper with Capability of Grasping Thin Objects

by Long Kang, Sang-Hwa Kim and Byung-Ju Yi

Machines 2021, 9(12), 347; https://doi.org/10.3390/machines9120347 - 9 Dec 2021

Cited by 8 | Viewed by 7153

Abstract

Underactuated robotic grippers have the advantage of lower cost, simpler control, and higher safety over the fully actuated grippers. In this study, an underactuated robotic finger is presented. The design issues that should be considered for stable grasping are discussed in detail. This [...] Read more.

Underactuated robotic grippers have the advantage of lower cost, simpler control, and higher safety over the fully actuated grippers. In this study, an underactuated robotic finger is presented. The design issues that should be considered for stable grasping are discussed in detail. This robotic finger is applied to design a two-fingered underactuated gripper. Firstly, a new three-DOF linkage-driven robotic finger that combines a five-bar mechanism and a double parallelogram is presented. This special architecture allows us to put all of the required actuators into the palm. By adding a torsion spring and a mechanical stopper at a passive joint, this underactuated finger mechanism can be used to perform parallel grasping, shape-adaptive grasping, and environmental contact-based grasp. Secondly, the dynamic model of this robotic finger is developed to investigate how to select an appropriate torsion spring. The dynamic simulation is performed with a multi-body dynamic simulator to verify our proposed approach. Moreover, static grasp models of both two-point and three-point contact grasps are investigated. Finally, different types of grasping modes are verified experimentally with a two-fingered underactuated robotic gripper. Full article

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

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14 pages, 6355 KiB

Open AccessEditor’s ChoiceArticle

Torque Ripple Reduction of Switched Reluctance Motor with Non-Uniform Air-Gap and a Rotor Hole

by Grace Firsta Lukman and Jin-Woo Ahn

Machines 2021, 9(12), 348; https://doi.org/10.3390/machines9120348 - 9 Dec 2021

Cited by 15 | Viewed by 5530

Abstract

A switched reluctance motor has a very simple structure which becomes its key signature and leads to various advantages. However, because of its double saliency and switching principle, the motor is also known to have a relatively high torque ripple, and this hinders [...] Read more.

A switched reluctance motor has a very simple structure which becomes its key signature and leads to various advantages. However, because of its double saliency and switching principle, the motor is also known to have a relatively high torque ripple, and this hinders its use as a high-performance drive. In this paper, a method to reduce torque ripple while maintaining average torque is introduced. Two elements are used to achieve this, namely, a non-uniform air-gap on the rotor-pole face and one hole in each non-uniform region, which maintains the saturation level of the air-gap. This approach preserves the mechanical simplicity of the motor and is easy to implement. Simulations and experiments were performed to verify the effectiveness of the proposed design. Full article

(This article belongs to the Special Issue Design and Control of Electrical Machines)

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17 pages, 3638 KiB

Open AccessEditor’s ChoiceArticle

Experimentally Validated Extension of the Operating Range of an Electrically Driven Turbocharger for Fuel Cell Applications

by Markus Schoedel, Marco Menze and Joerg R. Seume

Machines 2021, 9(12), 331; https://doi.org/10.3390/machines9120331 - 2 Dec 2021

Cited by 6 | Viewed by 3458

Abstract

From an aerodynamic point of view, the electric turbocharger for the air supply of an automotive fuel cell faces difficult requirements: it must not only control the pressure level of the fuel cell, but it also has to operate with very high efficiency [...] Read more.

From an aerodynamic point of view, the electric turbocharger for the air supply of an automotive fuel cell faces difficult requirements: it must not only control the pressure level of the fuel cell, but it also has to operate with very high efficiency over a wide range. This paper explores features for the compressor and the turbine of an existing electric turbocharger, which are intended to meet the specific requirements of a fuel cell in an experimentally validated numerical study. Adjustable diffuser or nozzle vanes in the compressor and turbine achieve wider operating ranges but compromise efficiency, especially because of the necessary gaps between vanes and end walls. For the turbine, there are additional efficiency losses since the pivoting of the nozzle vanes leads to incidence and thus to flow separation at the leading edge of the nozzle vanes and the rotor blades. An increase in the mass flow and a slight efficiency improvement of the turbine with the low solidity nozzle vanes counteracts these losses. For the compressor, a reduction in the diffuser height and its influence over the operating range and power consumption yields an increase in surge margin as well as in maximum efficiency. Full article

(This article belongs to the Special Issue High Speed Air Compressor for a Fuel Cell System for Use in a Vehicle)

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16 pages, 6758 KiB

Open AccessEditor’s ChoiceArticle

Formation Control of Dual Auto Guided Vehicles Based on Compensation Method in 5G Networks

by Liuquan Wang, Qiang Liu, Chenxin Zang, Sanying Zhu, Chaoyang Gan and Yanqiang Liu

Machines 2021, 9(12), 318; https://doi.org/10.3390/machines9120318 - 26 Nov 2021

Cited by 8 | Viewed by 3228

Abstract

With commercial application of 5G networks, many researchers have started paying attention to real-time control in 5G networks. This paper focuses on dual auto guided vehicles collaborative transport scenarios and designs a formation control system in current commercial 5G networks. Firstly, the structure [...] Read more.

With commercial application of 5G networks, many researchers have started paying attention to real-time control in 5G networks. This paper focuses on dual auto guided vehicles collaborative transport scenarios and designs a formation control system in current commercial 5G networks. Firstly, the structure of the 5G network researched in this paper is introduced. Then the round-trip time of 5G networks is measured and analyzed. The result shows that although the 5G round-trip time has randomness, it is mainly concentrated in 19 ± 3 ms, and the jitter mainly in 0 ± 3 ms. The Kalman filter is applied to estimate the transmission delay and experiment result shows the effectiveness of the estimation. Furthermore, the total delay including transmission delay and execution delay in control system is discussed. After establishing the AGV kinematic and formation model, complete control system based on compensation method is proposed. Finally, an experiment is carried out. Compared to the result without formation control, maximum distance error is reduced by 82.61% on average, while maximum angle error 45.91% on average. The result shows the effectiveness of the control system in formation maintaining in 5G network. Full article

(This article belongs to the Section Vehicle Engineering)

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15 pages, 5862 KiB

Open AccessEditor’s ChoiceArticle

Test Evaluation Method for Lane Keeping Assistance System Using Dual Cameras

by Si-Ho Lee and Seon-Bong Lee

Machines 2021, 9(12), 310; https://doi.org/10.3390/machines9120310 - 25 Nov 2021

Cited by 1 | Viewed by 3115

Abstract

Recently, the number of vehicles equipped with the Lane Keeping Assistance System (LKAS) is increasing. Therefore, safety evaluation to validate the LKAS has become more important. However, the actual vehicle test for safety evaluation has disadvantages such as the need for professional manpower, [...] Read more.

Recently, the number of vehicles equipped with the Lane Keeping Assistance System (LKAS) is increasing. Therefore, safety evaluation to validate the LKAS has become more important. However, the actual vehicle test for safety evaluation has disadvantages such as the need for professional manpower, the use of expensive equipment, and environmental constraints. Therefore, we attempted to solve this problem using the dual cameras system with only inexpensive and accessible cameras. The optimal position of the dual cameras, image and focal length correction, and lane detection methods proposed in previous studies were used, and a theoretical equation for calculating the distance from the front wheel of the vehicle to the driving lane was proposed. For the actual vehicle testing, LKAS safety evaluation scenarios proposed in previous studies were used. According to the test results, the maximum error was 0.17 m, which indicated the reliability of the method because all errors in the tested scenarios exhibited similar trends and values. Therefore, through the use of the proposed theoretical equations in conjunction with inexpensive cameras, it is possible to reduce time, cost, and environmental problems in the development, vehicle application, and safety evaluation of LKAS components. Full article

(This article belongs to the Special Issue Advances in Vehicle Dynamics Control and Motion Planning for Autonomous/Semi-autonomous Vehicles)

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16 pages, 7450 KiB

Open AccessEditor’s ChoiceArticle

Obtainment of Residual Stress Distribution from Surface Deformation under Continuity Constraints for Thinned Silicon Wafers

by Haijun Liu, Tao Yang, Jiang Han, Xiaoqing Tian, Shan Chen and Lei Lu

Machines 2021, 9(11), 284; https://doi.org/10.3390/machines9110284 - 11 Nov 2021

Cited by 4 | Viewed by 3187

Abstract

Precision machining (e.g., fine grinding, polishing) induced residual stress is very small and often not constant across the wafer and it is difficult to be directly obtained by stress testing equipment or Stoney equation. The residual stress could be obtained theoretically based on [...] Read more.

Precision machining (e.g., fine grinding, polishing) induced residual stress is very small and often not constant across the wafer and it is difficult to be directly obtained by stress testing equipment or Stoney equation. The residual stress could be obtained theoretically based on the principle of superposition in which the entire wafer deformation is taken as the sum of all deformations induced by the residual stresses of different positions on the wafer surface. However, the solved residual stress is affected greatly by deformation measurement errors and fluctuates greatly across the wafer surface. To solve the problem, a regularization method with continuity constraints was proposed in this study. The mechanisms for the discontinuity of the residual stress distribution and the sensitivity of calculation results to the measurement errors were studied. The influences of the number of subareas of the silicon wafer were investigated and the continuity constraint term was constructed based on the positional relationship of different subareas. Stable and continuous residual stress distribution was successfully obtained after using the proposed regularization method. The method may also be applied to estimate the residual stress from surface deformation for thin substrate plates of other materials. Full article

(This article belongs to the Section Material Processing Technology)

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17 pages, 6493 KiB

Open AccessEditor’s ChoiceArticle

A Particle Swarm Optimisation with Linearly Decreasing Weight for Real-Time Traffic Signal Control

by Yanjun Shi, Yuhan Qi, Lingling Lv and Donglin Liang

Machines 2021, 9(11), 280; https://doi.org/10.3390/machines9110280 - 10 Nov 2021

Cited by 7 | Viewed by 2836

Abstract

Nowadays, traffic congestion has become a significant challenge in urban areas and densely populated cities. Real-time traffic signal control is an effective method to reduce traffic jams. This paper proposes a particle swarm optimisation with linearly decreasing weight (LDW-PSO) to tackle the signal [...] Read more.

Nowadays, traffic congestion has become a significant challenge in urban areas and densely populated cities. Real-time traffic signal control is an effective method to reduce traffic jams. This paper proposes a particle swarm optimisation with linearly decreasing weight (LDW-PSO) to tackle the signal intersection control problem, where a finite-interval model and an objective function are built to minimise spoilage time. The performance was evaluated in real-time simulation imitating a crowded intersection in Dalian city (in China) via the SUMO traffic simulator. The simulation results showed that the LDW-PSO outperformed the classical algorithms in this research, where queue length can be reduced by up to 20.4% and average waiting time can be reduced by up to 17.9%. Full article

(This article belongs to the Special Issue Connected and Automated Vehicles (CAVs): Technologies and Applications)

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19 pages, 1719 KiB

Open AccessEditor’s ChoiceArticle

Transformation towards a Smart Maintenance Factory: The Case of a Vessel Maintenance Depot

by Gwang Seok Kim and Young Hoon Lee

Machines 2021, 9(11), 267; https://doi.org/10.3390/machines9110267 - 2 Nov 2021

Cited by 4 | Viewed by 3720

Abstract

The conceptualization and framework of smart factories have been intensively studied in previous studies, and the extension to various business areas has been suggested as a future research direction. This paper proposes a method for extending the smart factory concept in the ship [...] Read more.

The conceptualization and framework of smart factories have been intensively studied in previous studies, and the extension to various business areas has been suggested as a future research direction. This paper proposes a method for extending the smart factory concept in the ship building phase to the ship servicing phase through actual examples. In order to expand the study, we identified the differences between manufacturing and maintenance. We proposed a smart transformation procedure, framework, and architecture of a smart maintenance factory. The transformation was a large-scale operation for the entire factory beyond simply applying a single process or specific technology. The transformations were presented through a vessel maintenance depot case and the effects of improvements were discussed. Full article

(This article belongs to the Special Issue Smart Manufacturing)

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26 pages, 1015 KiB

Open AccessEditor’s ChoiceReview

Fault Detection and Condition Monitoring of PMSGs in Offshore Wind Turbines

by Nuno M. A. Freire and Antonio J. Marques Cardoso

Machines 2021, 9(11), 260; https://doi.org/10.3390/machines9110260 - 30 Oct 2021

Cited by 17 | Viewed by 5406

Abstract

Research on fault detection (FD) and condition monitoring (CM) of rotating electrical generators for modern wind turbines has addressed a wide variety of technologies. Among these, permanent magnet synchronous generators (PMSGs) and the analysis of their electromagnetic signatures in the presence of faults [...] Read more.

Research on fault detection (FD) and condition monitoring (CM) of rotating electrical generators for modern wind turbines has addressed a wide variety of technologies. Among these, permanent magnet synchronous generators (PMSGs) and the analysis of their electromagnetic signatures in the presence of faults deserve emphasis in this paper. PMSGs are prominent in the offshore wind industry, and methods for FD and CM of PMSGs based on electromagnetic measurements are extensively discussed in academia. This paper is a concise review of FD and CM in wind turbines and PMSGs. Terminology and fundamentals of PMSG’s operation are introduced first, aiming to offer an easy read and good reference to a broad audience of engineers and data scientists. Experience and research challenges with stator winding failures are also discussed. Full article

(This article belongs to the Special Issue Feature Papers to Celebrate the First Impact Factor of Machines)

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