Machines

Personalized market demands make the job shop scheduling problem (JSSP) increasingly complex, and the need for scheduling methods that can solve scheduling strategies quickly and easily has become very urgent. In this study, we utilized the variety and simplicity of dispatching rules (DRs) and constructed a DR real-time selection system with self-feedback characteristics by combining simulation techniques with decision tree algorithms using makespan and machine utilization as scheduling objectives, which are well adapted to the JSSP of different scales. The DR real-time selection system includes a simulation module, a learning module, and an application module. The function of the simulation module is to collect scheduling data in which is embedded a novel mathematical model describing the JSSP; the function of the learning module is to construct a DR assignment model to assign DR combinations to the job shop system, and the function of the application module is to apply the assigned DR combinations. Finally, a series of job shop systems are simulated to compare the DR assignment model with the NSGA-II and PSO algorithms. The aim is to verify the superiority of the DR assignment model and the rationality of the DR real-time selection system. Full article

Platooning is generally known as a control method for driving a group of connected and automated vehicles in motorway context. Nevertheless, platoon control might also work on urban roads. One possible strategy to increase overall road traffic performance and to reduce congestion in urban traffic networks is to combine platooning with traffic signal control at intersections. The traffic flow can be maximized with coordinated scheduling of traffic signals together with platooning activities, resulting in decreased travel times and fuel consumption. This paper investigates several aspects of this combined control, such as the procedures for coordination and communication between platooning vehicles and traffic signals. Efficient algorithms are suggested to optimize platoon formation and dissolution at junctions and to change traffic signal phases depending on platoon arrival and departure times. The proposed solutions have been tested and verified with SUMO, a high-fidelity microscopic traffic simulator. Full article

This paper presents the new synthesis models of spatial linkages for designing measurement motion functions and ranges and identifying the actual dimension parameters. The spatial five-bar linkage is first introduced for the kinematic model of a double ball bar test of a two-axis rotary table. To design the ideal measurement motion and motion range of the double ball bar test, a novel saddle synthesis model of a spatial four-bar linkage RRSS is readily presented. Based on the output data measured from the double ball bar test, a new saddle synthesis model of a spatial five-bar linkage RRSPS is logically proposed for identifying their actual dimensions. Finally, three test cases and their results indicate that the new synthesis models presented in the paper can conveniently and efficiently calculate the measurement motion function and range and accurately identify the actual dimensions of the double ball bar test, which provides a suitable mathematical model for improving the accuracy of the double ball bar tests of a two-axis rotary table of machine tools. Full article

The teleoperation feature of a leader–follower robot is used to operate the robot in a working environment that is dangerous to the operator. This paper proposes a method for estimating the intended operation of the operator of the leader–follower robot and generating behaviors for the follower robot. By generating partially autonomous robot behavior, our proposed method decreases the burden on the operator and realizes a safe controller that is robust against misoperation or disturbances. Owing to the impact of misoperation on estimation and the potential for unintended movement of the follower robot, our proposed estimation method relies on historical values of intended operation. The proposed method was verified through simulation using real operation inputs to the leader system based on practical scenarios, including misoperation. Full article

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

In Industry 4.0., robots are regarded as one of the key components. In recent years, collaborative robots (cobots) have risen in relevance and have been included in the industry to perform tasks alongside humans. Robots have been used in many applications in manufacturing processes; for the scope of this paper, the emphasis on these applications is centered on welding and gluing. These applications need to be performed with specific speed, efficiency, and accuracy to attain optimal welding or bonding to the pieces. An operator cannot maintain such conditions consistently, with minimum variations, for an extended period; hence, robots are a more suitable option to perform those tasks. The robots used for these applications need to be instructed to follow a trajectory to either weld or apply the glue. This path must be programmed on the robot by an operator, and depending on the complexity of the trajectory, it can take up to extended periods of time to set all the required waypoints. There are specialized software environments that contribute to the automation of these tasks; however, the overall cost of the licenses is not affordable if the scale of the project only requires developing and programming trajectories a few times. This paper contains a proposal for an open-source Computer Aided Manufacturing (CAM) software to automatically generate the trajectories needed for the aforementioned welding and gluing applications. The procedure to develop the software starts by selecting the surface that will be welded or to which glue will be applied. The surface determines the model of the trajectory to be followed. Next, a processing system is fed with the individual points that make up the trajectory provided by their selection over the Computer Aided Drawing (CAD) model. This system then creates a program based on URScript^® that can be directly uploaded to and executed on the robot. A set of tests is presented to validate the applications and to demonstrate the versatility of the developed trajectory generation system. Full article

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

Periodic elastic metamaterials (EMMs) display the capability to forbid the transmission of elastic waves for certain frequency ranges, leading to band gaps. If topology optimization strategies are exploited to tune the band gaps of EMMs, the said band gaps cannot be modified in real-time. This limitation can be overcome by allowing for active materials in the design of EMMs. In this work, a hyperelastic piezoelectric composite was considered to assess the coupled effects of material and geometric nonlinearities on the behavior of sculptured microstructures featuring a three-dimensional periodicity. Specifically, it was assumed that the composite material is obtained by embedding piezo nanoparticles into a soft polymeric matrix. In this way, piezoelectricity and instability-induced pattern transformation could be fully exploited to actively tune the band gaps. A thermodynamically consistent multi-physics model for the active composite material is discussed and implemented in a general-purpose finite-element code. The reported results of the simulations showed how the band gaps are affected by the aforementioned nonlinearities and by a feature of the architected periodic cell linked to its topology. Full article

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

The arc sound signal is one of the most important aspects of information related to pattern identification regarding the penetration state of ship robotic GMAW; however, arc sound is inevitably affected by noise interference during the signal acquisition process. In this paper, an improved wavelet threshold denoising method is proposed to eliminate interference and purify the arc sound signal. The non-stationary random distribution characteristics of GMAW noise interference are also estimated by using the high-frequency detail coefficients in different domains after wavelet transformation, and a mode of measuring scale that is logarithmically negatively correlated with the wavelet decomposition scale is created to update the threshold. The gradient convergent threshold function is established using the natural logarithmic function structure and concave–convex gradient to enable the nonlinear adjustment of the asymptotic rate. Further, some property theorems related to the optimized threshold function are proposed and theoretically proven, and the effectiveness and adaptability of the improved method are verified via the denoising simulation of speech synthesis signals. The four traditional denoising methods and our improved version are applied in the pretreatment of the GMAW arc sound signal, respectively. Statistical analysis and short-time Fourier transform are used to extract eight-dimensional time and frequency domain feature parameters from the denoised signals with randomly time-varying characteristics, and the extracted joint feature parameters are used to establish a nonlinear mapping model of penetration state identification for ship robotic GMAW using the pattern classifiers of RBFNN, PNN and PSO-SVM. The simulation results yielded by visual penetration classification and the multi-dimensional evaluation index of the confusion matrix indicate that the improved denoising method proposed in this paper achieves a higher accuracy in the extraction of penetration state features and greater precision in the identification of pattern classification. Full article

This paper analyzes the performance of Kalman filter-based estimators for robust filtering and rotor asymmetry detection in wound rotor induction machines (WRIMs) using real-time data. Filter models were designed based on an extended model of WRIMs. The detection of rotor asymmetry was achieved by estimating the states of rotor resistance and speed using four filters. The sensitivity of the parameters under healthy and asymmetry conditions was thoroughly analyzed and categorized as low, medium, and high sensitivity parameters. Robust model-based estimators were designed to minimize the probability of false alarms. The performance analysis demonstrated that the dual unscented Kalman filter (DUKF) outperformed other Kalman filters such as the extended Kalman filter (EKF), dual extended Kalman filter (DEKF), and unscented Kalman filter (UKF) for state estimation of WRIM. Full article

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

In studies of dynamic stability and power quality, it is necessary to know the values of the mechanical parameters determining the transient response of wind turbines. Their exact values are not as decisive as the power curve, but an inaccurate estimate can distort or even invalidate the simulation results. From a review of the literature, it has been found that, despite their importance, the values of inertia, stiffness and damping are hardly available for any turbine model. Another detected problem is the lack of confidence in the data origin. This article aims to solve the issue of the scarcity and unreliability of data on inertia, and gathers the information found on the remaining mechanical parameters. Available blade inertia values in kg · m${}^2$ are presented. Special treatment has been given to those providing the mass distribution along the blade span, for which the provided values of inertia have been compared with those obtained numerically, showing good matching. With this, different reliable relations are obtained that allow for the calculation of the turbine rotor inertia, based on the mass and length of the blade. When the center of gravity is also available, a very correlated expression ($r^2=0.975$) is provided to obtain the inertia. The references to the stiffness and damping constant of the drive train, which are even more rare, will also be presented. In addition, the study includes a revision of gearboxes, generators and blade weight, according to their IEC-class and material. Full article

Available hydropneumatic suspension simulation test benches have insufficient loading accuracy and limited functionality rendering them unsuitable for performance testing of heavy vehicles with this type of suspension. Therefore, a multi-functional compound simulation test bench was designed that used an electro-hydraulic proportional control technique. A mathematical model was established to describe the hydraulic loading system, and the transfer function of the system was derived. The gain and phase margins confirmed the stability of the system. A simulation model was established in the Simulink environment and step and sine signals of different frequencies were applied separately to analyze the dynamic characteristics of the system. The results showed that the system responded slowly and exhibited phase lag and signal distortion. The dynamic characteristics of the system were improved by incorporating an adaptive fuzzy PID controller. Simulation results showed that the response of the system to the step signal stabilized at the preset value within 0.3 s with no oscillation or overshoot. The improved system performed well in replicating the random vibrations of heavy vehicles operating on Class B and C roads. This confirmed that the system can satisfy the loading requirements of heavy vehicle hydropneumatic suspensions and can be used as a simulation test bench for such suspensions. Full article

In electrical discharge machining (EDM), the tool electrode is one of the substantial components of the system, and it ensures the success or failure of the EDM process. The electrode’s role is to conduct electrical charges and erode the workpiece to the desired shape. Different electrode materials have different impacts on machining. Certain electrode materials remove metal quickly but wear out rapidly, while others degrade slowly but the material removal is too slow. The choice of the electrode has an influence on both the mechanical properties, such as metal removal rate (MRR), wear rate, surface finish, surface modification and machinability, and the electrical properties, such as sparking initiation, time lag, gap contamination and process stability. There are factors to consider when fabricating an electrode, which include the type of workpiece materials, the metallurgical alloying of the materials, the choice of fabrication techniques, the intended use of the electrode, and material cost. Considerable challenges in EDM electrode fabrication have been reported, which include excessive tool wear for green compact electrodes, high toughness for sintered electrodes, and poor rigidity for additively manufactured electrodes. To address these issues, researchers have explored different manufacturing methods, such as casting, conventional machining, electrodeposition, powder metallurgy and additive manufacturing. In this paper, the various techniques attempted and adopted in EDM electrode manufacturing are analyzed and discussed. This paper also sought to give insight into EDM, its various forms, the dielectric fluid’s properties, EDM electrode’s size and shape, the effects of the electrode on the EDM process, material removal, electrode wear, present technologies for electrode fabrication, and the limitations of these technologies. Finally, directions for future research are highlighted. Full article

The multi-random-effects gamma process has a better characterization effect for degraded data with individual differences. In this paper, a reliability evaluation method for gamma stochastic processes with multiple random effects is studied. The mathematical model of multiple random effects gamma process was established. The model parameters estimation method was established based on the Bayesian approach. The prior distribution acquisition method was discussed, and the parameters of the multiple randomeffects gamma process were estimated by the MCMC-Gibbs method. The correctness of the model and method was verified by numerical simulation, the influence of algorithm parameters on the algorithm solving process was studied. In the fourth part, the reliability of aviation hydraulic rotary joints was studied by using multiple random effects gamma processes. Full article

Due to advantages such as a high power-to-weight ratio, a simple structure, and low cost, pneumatic systems are widely applied in automation. However, precise position control of pneumatic actuators is challenging because of factors such as friction, compressibility, and external disturbances. This paper presents a backstepping sliding mode control (BSMC) strategy based on the extended state observer (ESO) for pneumatic cylinder position tracking. A nonlinear model of the pneumatic system is first established, then system states and disturbances are estimated by an ESO, next the BSMC approach is developed using backstepping method and sliding mode control theory, and the stability of the ESO and controller is analyzed using Lyapunov theory. Finally, simulations and experiments on a pneumatic testbed are performed to compare the effectiveness of the proposed approach with PID control. The results show that the proposed strategy improves tracking accuracy and robustness against disturbances, with a 77.04% reduction in root mean square error (RMSE). This research provides a promising control solution for automated pneumatic polishing robots. Full article

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