Search Results (12)

This study investigates the joint characteristics of a 60-layered copper foil stack using linear vibration ultrasonic welding for lithium-ion pouch cell applications. With increasing demand for high-capacity electric vehicle batteries, ensuring the reliability of multilayer electrode joints is essential. Experiments were conducted by varying vibrational amplitude, welding time, and clamping pressure. Weld quality was analyzed based on indentation profiles, joint strength, and failure modes. Results revealed that optimal welding energy (500–900 J) produced well-formed joints without surface cracks or tearing. Excessive welding energy (>900 J) led to material thinning and interfacial failure. The maximum T-peel peak load of 138.7 N was obtained at the 30th joining interface under 25 µm amplitude, 0.8 s welding time, and 1.5 bar clamping pressure. Interface-dependent optimum conditions were observed, reflecting thickness–direction variations in deformation and bonding within the 60-layer stack. Indentation length and depth correlated linearly with welding energy. Failure modes transitioned from no adhesion to tearing and button-pull types. The findings provide guidelines for optimizing welding parameters for high-quality multilayer foil joints in battery manufacturing. Full article

Drilling in aerospace one-up assembly demands high positional accuracy, strong clamping forces, and precise angular compensation to ensure quality in multi-layered stacks. Existing robotic solutions achieve these requirements but are costly, bulky, and unsuitable for flexible or collaborative environments. This work introduces the Advanced Collaborative Multifunctional End-Effector (ACME), a lightweight robotic drilling end-effector designed for integration with collaborative robots (cobots). ACME incorporates vacuum-assisted clamping capable of generating high forces, a passive self-normalization mechanism for angular alignment on double-curvature surfaces, and a compact 5-DoF positioning system for precise positioning and orientation. The system’s kinematics and dynamics were modeled and experimentally verified through frequency response function (FRF) testing, enabling precise behavior prediction. The tool is integrated within a cyber–physical system (CPS) featuring an interactive digital twin that, unlike passive monitoring systems, allows operators to configure workpieces, select drilling locations directly from rendered CAD, and supervise execution without programming expertise. Experiments demonstrated average positional errors of 0.19 mm and normality deviations of 0.29°, both within aerospace standards. The results confirm that ACME effectively extends cobot capabilities for aerospace-grade drilling while improving flexibility, safety, and operator accessibility. Full article

The significant potential loss of proton exchange membrane fuel cells (PEMFCs) at high current densities is primarily attributed to the high mass transfer resistance of the gas diffusion layer (GDL). The underlying mechanism of how structural parameters of the GDL under actual assembly conditions affect oxygen transport resistance remains unclear, particularly the quantitative relationship between the compression ratio (α) and tortuosity (γ). This study systematically evaluated the output performance and mass transfer overpotential of three commercially available GDLs with similar thickness and porosity under different compression ratios (5.4% to 27%) and four inlet humidity conditions (RH0% to RH100%). By accurately extracting and comparing mass transfer overpotentials, it was observed that the mass transfer overpotential initially decreased and then increased with the rising compression ratio, with an optimum observed at 21.6%. An empirical correlation between the compression ratio (α) and tortuosity (γ) was established as γ = 3.42α + 2.1. Based on this, a modified oxygen diffusion equation was proposed to accurately describe oxygen transport behavior within the GDL under compressed conditions. A modified oxygen diffusion equation was proposed to more accurately characterize the oxygen transport process within compressed GDLs. These findings establish a foundation for optimizing GDL design and stack assembly processes. Future work will build upon this study by incorporating multiphysics conditions such as stack clamping pressure, number of cells, intercell contact resistance, and assembly conditions (temperature and relative humidity), with the aim of elucidating the force–thermal–electrical–mass coupling mechanisms within the stack, thereby enhancing the overall performance and reliability of high-power-density proton exchange membrane fuel cell (PEMFC) stacks. Full article

Pre-stacked uncured metal–fiber-reinforced polymer (FRP) laminates, which are critical for aerospace components like double-curved fuselage panels, wing ribs, and engine nacelles, exhibit better deformation behavior than their fully cured counterparts. However, accurate process simulation requires precise material characterization and process optimization to achieve a defect-free structural design. This study focuses on two core material behaviors of uncured laminates—inter-ply friction at metal–prepreg interfaces and out-of-plane bending—and optimizes process parameters for their non-coherent deformation. Experimental tests included double-lap sliding tests (to quantify inter-ply friction) and clamped-beam bending tests (to characterize out-of-plane bending); a double-curved dome part was designed to assess the effects of the material constituent, fiber orientation, inter-ply friction, and clamping force, with validation via finite element modeling (FEM) in Abaqus software. The results indicate that the static–kinetic friction model effectively predicts inter-ply friction behavior, with numerical friction coefficient–displacement trends closely matching experimental data. Additionally, the flexural bending model showed that greater plastic deformation in metal layers increased bending force while reducing post-unloading spring-back depth. Furthermore, for non-coherent deformation, higher clamping forces improve FRP prepreg deformation and mitigate buckling, but excessive plastic deformation raises metal cracking risk. This work helps establish a combined experimental–numerical framework for the defect prediction and process optimization of complex lightweight components, which address the core needs of modern aerospace manufacturing. Full article

In view of the problems of low work efficiency and high operating costs caused by manual harvesting of Chinese cabbage in China, in this study, a Chinese cabbage harvester with agronomic integrity was designed. The harvester is mainly composed of a crawler chassis, a drawing device, a flexible clamping device, a cutting device, and a horizontal delivery device. Firstly, physical properties of Chinese cabbage such as diameter, plant height, weight, and drawing rate of Chinese cabbage were measured and analyzed to provide necessary basic data for the design of the harvester. Secondly, simulation tests were conducted on the Chinese cabbage harvesting process; a 3D model of Chinese cabbage using SolidWorks 2022 was established and filled with particles using the three-layer stacking method. At the same time, SolidWorks was applied to simplify the model of the Chinese cabbage harvester. The belt of the machine model was set as a flexible body through RecurDyn 2023 software and coupled with EDEM 2022 for simulation analysis. Based on single factor tests, the BBD model was applied to conduct multi-factor response surface analysis on the above factor levels. The optimal working conditions of the harvester were obtained as follows: the rotating speed of the cutting device was 207.85 r/min, the rotating speed of the flexible clamping conveyor belt was 165.51 r/min, the rotating speed of the drawing device was 102.38 r/min, and the machine walking speed was 1.37 km/h. The qualified rate of Chinese cabbage harvesting was the highest, achieving a maximum theoretical value of 97.91%. Field validation tests were conducted on the designed Chinese cabbage harvester. Based on the actual operating conditions of the Chinese cabbage harvester and the simulated operating parameters, the optimal parameter combination was finally determined as follows: rotating speed of the root cutting device was 200 r/min, rotating speed of the flexible clamping conveyor belt was 160 r/min, rotating speed of the drawing device was 100 r/min, and machine walking speed was 1.4 km/h, respectively. Through field verification tests, the highest qualified rate of Chinese cabbage harvesting reached 93.19%, showing a good harvesting effect, which approximates the simulated optimal qualified rate of 97.91%, meeting the mechanized harvesting demand of Chinese cabbage. This study provides reference to the further design and development of Chinese cabbage harvesters in the future. Full article

According to the latest literature, it is difficult to measure the multiple important physical parameters inside a proton battery stack accurately and simultaneously. The present bottleneck is external or single measurements, and the multiple important physical parameters (oxygen, clamping pressure, hydrogen, voltage, current, temperature, flow, and humidity) are interrelated, and have a significant impact on the performance, life, and safety of the proton battery stack. Therefore, this study used micro-electro-mechanical systems (MEMS) technology to develop a micro oxygen sensor and a micro clamping pressure sensor, which were integrated into the 6-in-1 microsensor developed by this research team. In order to improve the output and operability of microsensors, an incremental mask was redesigned to integrate the back end of the microsensor in combination with a flexible printed circuit. Consequently, a flexible 8-in-1 (oxygen, clamping pressure, hydrogen, voltage, current, temperature, flow, and humidity) microsensor was developed and embedded in a proton battery stack for real-time microscopic measurement. Multiple micro-electro-mechanical systems technologies were used many times in the process of developing the flexible 8-in-1 microsensor in this study, including physical vapor deposition (PVD), lithography, lift-off, and wet etching. The substrate was a 50 μm-thick polyimide (PI) film, characterized by good tensile strength, high temperature resistance, and chemical resistance. The microsensor electrode used Au as the main electrode and Ti as the adhesion layer. Full article

Ultra-thin sapphire wafer processing is receiving increasing attention in the LED substrate industry. In the cascade clamping method, the motion state of the wafer determines the uniformity of material removal, while the motion state of the wafer is related to its friction coefficient in the biplane processing system, but there is little relevant literature discussing the relationship between the motion state of wafer and friction coefficient. In this study, an analytical model of the motion state of sapphire wafers in the layer-stacked clamping process based on the frictional moment is established, the effect of each friction coefficient on its motion is discussed, the base plate of different materials and different roughness are experimentally studied, the layer-stacked clamping fixture is prepared in this way, and finally the failure form of the limiting tab is analyzed experimentally. The theoretical analysis shows that the sapphire wafer is mainly driven by the polishing plate, while the base plate is mainly driven by the holder, and the rotation speed of the two is not the same; the material of the base plate of the layer-stacked clamping fixture is stainless steel, the material of the limiter is glass fiber plate, and the main form of failure of the limiter is to be cut by the edge of the sapphire wafer and damage the material structure. Full article

In recent years, piezoelectric actuators, represented by inertial and inchworm actuators, have been widely applied because of their high accuracy and excellent responsiveness. Despite the development of various piezoelectric actuators, there remain some flaws in this technology. The sticking point is that the piezoelectric actuators based on the friction driving principle are prone to unwanted backward motion when outputting stepping motion. It is thus urgent to explore solutions from the perspectives of principle and structure. In this paper, a clamping-drive alternating operation piezoelectric actuator is proposed, the two feet of which are driven by two piezoelectric stacks, respectively. Due to double-foot alternate drive guide movement, backward movement is prevented in theory. By adopting the double-layer stator structure, integrated processing and assembly are facilitated. Meanwhile, a double flexible hinge mechanism is installed in the stator to prevent the drive foot from being overturned due to ineffectiveness and premature wear. In addition, the stator is equipped with the corresponding preload mechanism and clamping device. After the cycle action mechanism of one cycle and four steps is expounded, a model is established in this study to further demonstrate the principle. With the prototype produced, a series of experiments are performed. In addition, the amplitude of actuation of the stator is tested through amplitude experiment. The performance of the stator is evaluated by conducting experiments in the alternating step and single step actuation modes. Finally, the test results are analyzed to conclude that the actuator operating in either of these two modes can meet the practical needs of macro and micro actuation. Full article

During all the assembly stages of a polymer electrolyte membrane fuel cell (PEMFC) stack, gas diffusion layers (GDLs) endure clamping loads in the through-plane direction several times. Under such complicated assembly conditions, GDLs have to deform with the changes in structure, surface roughness, pore size, etc. A comprehensive understanding of the compressive performance of GDLs at different clamping phases is crucial to the assembly process improvement of PEMFCs. Two typical clamping compression was designed and performed to get close to the actual assembly conditions of PEMFCs. The results indicate that the initial clamping compression and the magnitude of the maximum clamping load have great impacts on the segmented compressive properties of GDLs. The nonlinear compressive performance of the GDL is mainly attributed to the unique microstructural information. The rough surface morphology contributes to the initial compressive characteristics where the big strain along with the small stress occurs, and the irreversible failures such as carbon fiber breakages and adhesive failures between fibers and binders account for the hysteresis between different compression stages. Importantly, it is found that the clamping compression hardly influences the small pore distribution below 175 μm but affects the large pore distribution over 200 μm. Full article

Double-sides polishing technology has the advantages of high flatness and parallelism, and high polishing efficiency. It is the preferred polishing method for the preparation of ultra-thin sapphire wafer. However, the clamping method is a fundamental problem which is currently difficult to solve. In this paper, a layer stacked clamping (LSC) method of ultra-thin sapphire wafer which was used on double-sides processing was proposed and the clamping mechanism of layer stacked clamping (LSC) was studied. Based on the rough surface contact model of fractal theory, combining the theory of van der Waals force and capillary force, the adhesion model of the rough surfaces was constructed, and the reliability of the model was verified through experiments. Research has found that after displacement between the two surfaces the main force of the adhesion force is capillary force. The capillary force decreases with the increasing of surface roughness, droplet volume, and contact angle. For an ultra-thin sapphire wafer with a diameter of 50.8 mm and a thickness of 0.17 mm, more than 1.4 N of normal adhesion force can be generated through the LSC method. Through the double-sides polishing experiment using the LSC method, an ultra-thin sapphire wafer with an average surface roughness (R_a) of 1.52 nm and a flatness (PV) of 0.968 μm was obtained. Full article

The compression of the gas diffusion layer (GDL) greatly affects the electrochemical performance of proton exchange membrane fuel cells (PEMFCs) by means of both the equivalent value and distribution of contact pressure, which depends on the packing manner of the fuel cell. This work develops an intelligent approach for improving the uniformity and equivalent magnitude of contact pressure on GDLs through optimizing the clamping forces and positions on end plates. A finite element (FE) model of a full-size single fuel cell is developed and correlated against a direct measurement of pressure between the GDL and a bipolar plate. Datasets generated by FE simulations based on the optimal Latin hypercube design are used as a driving force for the training of a radial basis function neural network, so-called the agent model. Once the agent model is validated, iterations for optimization of contact pressure on GDLs are carried out without using the complicated physical model anymore. Optimal design of clamping force and position combination is achieved in terms of better contact pressure, with the designed equivalent magnitude and more uniform distribution. Results indicate the proposed agent-based intelligent optimization approach is available for the packing design of fuel cells, stacks in particular, with significantly higher efficiency. Full article

In this study, an elastic-plastic stress analysis was carried out in woven steel fibers- thermoplastic clamped composite laminates. The stacking sequences were chosen as [0/0]₂, [15/-15]₂, [30/-30]₂ and [45/-45]₂ for woven steel fibers – thermoplastic composites plates. The layers were chosen for symmetric and antisymmetric cases. The finite element solution was performed by using the ANSYS software. Solid 186 element was utilized in the solution. Normal stress components at the clamped edges were found to be higher than that at the mid point of the laminated plates. Normal stresses are tensile at the mid point of the clamped edges and compressive at the mid point of the laminated plates. Then, the residual stress components were calculated in the critical points of the composite laminates. Full article