Search Results (28)

The retrofitting of existing stadiums with retractable roof systems presents a complex interdisciplinary challenge, requiring the reconciliation of aged structural capacity with modern performance demands. This paper investigates the engineering design and analysis of a new retractable roof system for the Ningbo (Yinzhou) Tennis Center, a facility originally completed in 2007 and now requiring an upgrade to host higher-tier WTA 500 events. The retrofit is further complicated by increased seismic design requirements and the need to preserve the existing structure. To address these constraints, this study proposes a novel, structurally independent roof system comprising 12 radially deployable units supported by an external single-layer spatial grid and lambda-shaped columns. A multidisciplinary approach integrates structural engineering, mechanical systems, and architectural technology. Key innovations include (1) the selection and detailed modeling of a rack-and-pinion drive mechanism, with a floating engagement design to accommodate dynamic load transfer; (2) a two-stage analytical framework employing both sub-assembly and integrated assembly finite element models to capture the unique mechanical behavior and coupling effects between the new and existing structures; (3) the strategic implementation of circumferential hoop cables to counteract uplift forces and redirect the internal force distribution in the supporting bifurcated columns; and (4) the validation of structural integrity through comprehensive static, stability, and seismic gap analyses, informed by wind tunnel testing. The results demonstrate that the proposed system satisfies all strength, stiffness, and stability criteria under multiple operational states (open, closed, and transitional) and meets the enhanced seismic fortification standards. This research provides a validated theoretical foundation and practical implementation guidelines for this specific stadium retrofit, demonstrating a viable pathway for extending the service life of aging sports infrastructure, with insights that may inform similar urban renewal projects under comparable conditions. Full article

Steer-by-wire (SBW) systems in wheel-steering vehicles enhance maneuverability by eliminating mechanical linkages. However, they are susceptible to delays between steering input and pinion response, which can compromise control precision and safety. To mitigate these delays, we developed a machine learning-based compensation method employing a hybrid architecture of convolutional neural networks (CNNs) and gated recurrent units (GRUs) to predict and adjust pinion behavior in real time. The model was trained using experimental data collected from a four-wheel steering test platform, including steering angle inputs, motor signals, and pinion position feedback. By learning the relationship between steering commands and rack force, the model enables dynamic delay correction under both nominal and fault conditions. The system is implemented on an NXP microcontroller and validated through experimental testing, and compared with other hybrid model configurations for performance evaluation. The results demonstrate that the CNN–GRU approach reduces the average steering delay to 3 ms, outperforming conventional PID tuning methods while maintaining high accuracy and system stability. Full article

This paper presents the results of a numerical study on the influence of the tooth root fillet manufacturing method on the bending strength of spur gears with straight teeth. A mathematical model describing the gear tooth geometry was developed, in which the transition curve at the tooth root was directly related to the applied machining process—either rack-type gear shaping or pinion-type gear shaping. Based on this model, a numerical procedure for calculating the bending stresses at the tooth root was formulated and verified using the finite element method (FEM). The results demonstrated high consistency between the proposed approach and FEM analysis, confirming the accuracy of the developed mathematical model and numerical methodology. The study also examined the effect of the tool fillet radius on the stress distribution in the root region. It was found that increasing the tool radius leads to a reduction in bending stresses, while the differences between the two machining methods gradually diminish. The proposed methodology offers a reliable numerical framework for assessing the strength of spur gears and can be effectively used in the design of lightweight, high-performance gear transmissions for aerospace and automotive applications. Full article

We present a case of unexpected proximal displacement of an intramedullary pin (IMP) during plate–rod repair of a femoral fracture caused by minimally invasive plate osteosynthesis (MIPO), requiring immediate revision. Implant retrieval analysis and ex vivo modelling were performed to characterise the technique failure mode. The case details are reported. Implant retrieval analysis consisted of stereo zoom microscopic examination of the retrieved IMP. Wear patterns formed by conflict with a 2.8 mm, two-fluted surgical drill bit and a 3.5 mm AO locking screw were replicated using a simple paper impression model. The mechanism of pin movement was replicated in a benchtop laminated polyurethane foam block model, and wear patterns produced during drilling and screw insertion were characterised using stereo zoom. The wear pattern visible on the retrieved IMP suggested axial displacement caused by a rack-and-pinion-like mechanism, enacted by contact with either the drill bit or locking screws during placement of the repair construct. Significant axial displacement of the IMP due to conflict with screws during construct placement is possible during the placement of plate–rod fixation. Surgeons should confirm implant positioning if implant conflict is recognised intra-operatively. Full article

Polymer worm gears are increasingly utilized in electric power steering (EPS) systems due to their favorable manufacturing features and performance. Ensuring consistent mechanical properties under various operating conditions is critical for steering reliability throughout a vehicle’s lifespan. This study investigates the durability of injection-molded polyamide 66 worm gears within a Pinion-EPS configuration, where torque from the assist motor is transmitted through a worm–worm gear set to the rack and ultimately to the vehicle wheels. Given the complexity of steering maneuvers and the absence of mechanical integrity in steer-by-wire systems, durability testing becomes essential to understand if the considered worm gear for a certain steering system application provides safety and the needed performance within a specified product service life. This paper compares multiple testing methodologies. Traditional approaches, such as maximum torque and rotational speed, prove insufficient for comprehensive durability assessment, especially considering the thermal sensitivity of polymer materials. The findings highlight the limitations of conventional testing methods and emphasize the need for application-specific testing methods that reflect real-world boundary conditions. This research contributes to the development of more accurate and reliable evaluation techniques for polymer gear components in modern EPS systems, with implications for both conventional and autonomous vehicle platforms. Full article

Wireless power transfer (WPT) technology offers a convenient, efficient, and environmentally robust power supply solution for rack-and-pinion modules. For WPT systems in such modules where the transmitter coil is a long rail, increasing the transmitter coil turns to enhance mutual inductance leads to issues like high cost, low efficiency, and installation difficulties. This paper introduces a relay resonator to strengthen system coupling and proposes a three-coil design scheme employing a single-turn long rail as the transmitter coil. The proposed all-detuned LCC-S-S topology exhibits constant output voltage (CV) and zero phase angle (ZPA) input characteristics while accounting for all cross-mutual inductances and coil resistances. The frequency detuning level of the relay resonator critically governs the system’s power transfer efficiency and directly determines the operational mode of the rectifier—either continuous conduction mode (CCM) or discontinuous conduction mode (DCM). To maximize system efficiency, the optimal detuning frequency of the relay coil is selected under CCM operation. Through optimized design of the three-coil parameters, the final prototype achieves an output power of 106.743 W and an efficiency of 90.865% when integrated with a 1200 mm single-turn long-rail transmitter coil. Full article

This study proposes a novel expandable spinal cage to maximize the effectiveness of spinal fusion surgery in the treatment of lumbar disk disorders and aims to verify its mechanical stability through finite element method (FEM) analysis and mechanical testing. To address the limitations of existing cages, which do not provide sufficient height and angle expansion and have constraints in independently adjusting height and angle with continuous fine-tuning, this study introduces a new linkage mechanism. This design enables precise spinal alignment restoration tailored to the individual anatomical characteristics of patients, even in minimally invasive surgical environments, distinguishing itself from traditional rack-and-pinion or wedge-based designs. The results of FEM analysis and static load testing demonstrated a high correlation between the predicted yield locations in FEM analysis and actual test results. Furthermore, the compression and compression–shear load tests confirmed that the proposed cage achieved an ultimate load exceeding the lowest fifth percentile of FDA-approved products, meeting clinical requirements. The proposed expandable spinal cage offers significant improvements over existing products and has the potential to evolve into a safer and more effective spinal fusion device through further dynamic fatigue testing and clinical studies to assess long-term durability and practical applicability. Full article

This paper proposes an underactuated dexterous hand with novel bidirectional self-locking joints (BSJs) that enable multiple fingertip motion trajectories. The BSJ design integrates a locking wheel, rack, finger side walls, and a self-holding electromagnetic actuator, combining rack-and-pinion transmission with friction self-locking principles. Building on the BSJ concept, an underactuated dexterous hand is developed. The study begins with an analysis of BSJ’s deviation angle, establishing the minimum deviation angle critical to its operation. A detailed mechanical model of a BSJ is formulated, and its parameters are quantitatively analyzed to determine a safety static friction coefficient (0.177). Five distinct finger motion modes are designed and kinematic analysis focuses on the index finger and the generation of 57 unique fingertip active motion trajectories. Experimental validation included single finger performance tests that confirmed the diversity of fingertip trajectories and the hand’s ability to withstand loading in both forward and reverse directions. Through envelope and precision grasping experiments, the dexterous hand demonstrated its adaptability and ability to grasp objects of various sizes and shapes, such as strawberries, apples, student ID cards, and water bottles. This capability underscores its potential for a wide range of applications, from prosthetic hands for rehabilitation, where precision and adaptability are key, to robotic hands in industrial automation, offering flexibility in diverse tasks. Full article

In Japan, the aging and decreasing number of agricultural workers is a significant problem. For wine grape harvesting, especially for large farming areas, there is physical strain to farmers. In order to solve this problem, this study focuses on developing an automated harvesting robot for wine grapes. The harvesting robot needs high dust, water, and mud resistance because grapevines are grown in hard conditions. Therefore, a three-axis linear robot was developed using a rack and pinion mechanism in this study, which can be used in outdoor conditions with low cost. Three brushless DC motors were utilized to drive the three-axis linear robot. The motors were controlled using a control area network (CAN) bus to simplify the hardware system. The accuracy of the robot positioning was evaluated at the automated harvesting condition. The experiment results show that the accuracy is approximately 5 mm, 9 mm, and 9 mm in the x-axis (horizontal), y-axis (vertical), and z-axis (depth), respectively. In order to improve the accuracy, we constructed an error model of the robot and conducted a calibration of the robot. The accuracy was improved to around 2 mm of all three axes after calibration. The experimental results show that the accuracy of the robot is high enough for automated harvesting of the wine grapes. Full article

The energy efficiency in metal cutting is, sometimes, very low. Recent studies show that the energy consumed for detaching chips represents only about 15% of the total energy involved in material machining. The available solutions for energy optimization in cutting processes mentioned are the improvement of manufacturing equipment, the optimization of processes, and appropriate production scheduling. Already-performed research shows that to increase energy efficiency, the cutting force must be reduced, for example, by reducing the depth of the cut and by increasing the feed rate. However, this is applicable when the cutting force is quasi-constant during the process, which is not the case for gear teeth cutting when the cutting force significantly varies. The present paper proposes a new solution for energy efficiency increase in gear teeth cutting, namely, the smoothing of the cutting force variation during the machining process, by keeping the area of the detached chip section quasi-constant during the cutting process. This can be reached by replacing the constant rolling feed, currently used in gear teeth cutting, with a rolling feed that varies after an appropriate law. An algorithm dedicated to implementing this solution has been developed. It uses graphical modeling in CATIA to find the variation in the detached chip area. Original MatLab R2018a applications were developed (i) to identify the analytical form of the law that approximates this variation and (ii) to find the variation law of the feed during the rolling motion, if imposing a constant area of the detached chip. The algorithm was successfully applied in the cases of toothing with a rack tool (by slotting) and with a pinion cutter (by slotting and turning). A technical solution for method implementation in practice is also presented. Full article

Due to long-term operation under low-speed and heavy-load conditions, large module gears and racks are inevitably subject to tooth surface wear. To investigate the changes in gear tooth bending strength, the Three Gorges ship lift was taken as the research object and a simulation test bench was established. An analytical method, a finite element method, and an experimental method were utilized to analyze the bending stress of gears under normal and various uniform wear conditions. The obtained results revealed that with the increase in wear degree and load, the bending stress of single-tooth meshing was significantly higher than that of double-tooth meshing, and the single-tooth meshing time also increased, which indicates that gear wear accelerated the process of performance degradation. Furthermore, the relative errors obtained by the three calculation methods were all at a low level. This investigation aims to provide a solid theoretical and experimental basis for the dynamic analysis of large module gear and rack transmission. Full article

Energy is the primary concern of the modern era and the requirement of energy is being increased day by day; energy resources are not sufficiently available for sustainable development. It is crucial to generate affordable and pollution-free sources of energy to meet this required demand. Walking is a common daily activity for humans; the kinetic energy from walking is converted into mechanical energy. Moreover, this energy is converted into electrical power using a rack-and-pinion mechanism which is simply a non-conventional method of producing electric current. In this research study, a simple and low-cost rack-and-pinion mechanism with a flywheel is introduced to enhance the performance and efficiency of energy conversion from kinetic energy to mechanical energy and subsequently into electrical energy. The results showed that the proposed footstep floor tile generated an average power of 3 watts for a 0.5 s duration with a peak load of 60 kg. The electrical energy produced per step was noted as 1.8 Joules. A percentage of 75% of the total potential energy theoretically accessible was transmitted by the energy-harvesting paver, and 50% of it was successfully converted into electricity. The generated energy is stored in a backup battery bank system and can be used to charge smart devices, providing a cost-effective and pollution-free solution. Full article

People with upper limb disabilities or high quadriplegia have extremely high requirements for the maneuverability and functionality of power wheelchairs. Normal wheelchairs cannot meet travel tasks, while smart customized wheelchairs are expensive and cannot be popularized. Therefore, a novel extension control instrument for power wheelchairs with low cost, strong scalability, and convenient usage is proposed, which can realize the control of the wheelchair by sensing a change of head posture. The device is divided into a head motion sensing unit (HMSU) and a wheelchair assistance control unit (WACU). The mapping relationship between the head attitude and the subject’s motion intention is established. The inertial measurement module in the HMSU collects the head attitude data and uses the Kalman filtering method to obtain the accurate Euler angle. The WACU is fixed on the original controller of the wheelchair. The joystick is inserted into the extended control mechanism and controlled, instead of the hand, through a 2-degree-of-freedom servo system combined with the pinion and rack push rod structure, thus controlling the movement of the wheelchair. In proceeding, the system can also detect the distance of objects in the environment in real time through the three-direction (front, left, right) ultrasonic ranging sensors installed on the WACU, with a certain obstacle avoidance function. The prototype experiments prove that the extension control instrument developed in this paper based on the Kalman filter can quickly and accurately identify head motion and accurately control the movement of the wheelchair. It is easy to operate and has strong universality, which presents a new low-cost solution for the travel of patients with disabilities. Full article

To improve collision safety in robot–human collaborative applications, increasing attention has been paid to rotational variable stiffness actuators. A new rotational variable stiffness actuator, which works in two stages, is proposed for hybrid passive–active stiffness regulation. The passive stage is based on the motions of springs driven by the rack-and-pinion systems, elastically converting the shaft’s rotation into the inner shell rotation fixed to the internal gear of the active stage. The active stage is designed to achieve the movement of the pivot point located on the roller actuated by the adjustment motor, providing the output angle of the output shaft. The two pairs of rack-and-pinion systems of the passive stage and the two pairs of planetary gears of the active stage are designed for side-by-side placement, improving the stability and balance of the stiffness regulation process. Two symmetrical cam-slider mechanisms acting as leverage pivots ensure the synchronous movements of the two rollers. The variable stiffness actuator is designed and validated by simulations and experiments. Strength analysis and stiffness analysis are presented. The designed actuator can obtain the range of stiffness adjustment of 35–3286 N·mm/deg. The range of the angle difference between the input and output shafts is ±48°. Full article

This paper presents the design of a compliant rack and pinion mechanism with the support of a compliant rolling contact joint (CRCJ). The flexible strips are mounted to connect the rack and pinion to accelerate the mechanism. Two types of rack and pinion mechanism are proposed: rack and pinion mechanism and double rack and pinion actuator. The 3D model is created with finite element analysis (FEM) for structural analysis to observe the maximum strength and the deformation of the flexible strip. A 3D-printed model is proposed by using a fused deposition method (FDM) by printing layer by layer for experimental and demonstration purposes. In this study, we propose a set of examples to convert a traditional rigid body mechanism to complete a complaint mechanism to accumulate the actual function and also to increase the high possibilities of mounting. Full article