Search Results (18)

Rockfall hazard assessment and mitigation design relies heavily on three-dimensional trajectory modeling, in which the coefficient of restitution (COR) is a governing parameter controlling rebound, energy dissipation, and runout distance. In practice, COR values are commonly selected from generalized tables based on slope material type, introducing significant epistemic uncertainty and limiting predictive accuracy. This study presents a comparative evaluation of large-scale field rockfall experiments and 3-D numerical simulations conducted at a former aggregate quarry in Boise, Idaho, to assess the performance of tabulated restitution coefficients. Concrete blocks of controlled shape (spheres, cubes, and rectangular prisms) and mass (17–68 kg) were instrumented with inertial sensors and released from two slope configurations. High-resolution UAV-based LiDAR was used to reconstruct slope geometry, while dynamic cone penetrometer and friction tests were performed to characterize spatial variability in slope material stiffness. These data were incorporated into RocFall3 to simulate block trajectories using spatially varying COR values. Initial models assuming zero rotational velocity and tabulated COR ranges failed to reproduce observed runout distances, dispersion patterns, and modes of motion, particularly for non-spherical blocks. Incorporating field-measured initial rotational velocities significantly improved agreement between modeled and observed trajectories, by correcting the unrealistic sliding mode of motion previously observed. However, quantitative discrepancies in deposition and dispersion persisted, highlighting limitations associated with simplified slope geometry and the loss of small-scale surface features during LiDAR surface reconstruction. The results demonstrate that restitution behavior is strongly shape-dependent and that realistic initial conditions are essential for physically meaningful simulations. The findings underscore the need for site-specific, material-informed approaches to COR estimation and for improved integration of high-fidelity field data into physics-based rockfall models. Full article

Runout is a common failure of brake discs. The detection of this fault usually depends on the driver, as there is a vibration in the car and on the brake pedal. As Advanced Driver Assistant Systems are implemented and autonomous driving modes are available, braking is carried out by the car instead. Brake disc runout can cause longer braking distance, so it is essential to recognize and repair it. NVH measurements have been validated to be one of the solutions to detect the fault immediately without disassembling the brake unit. In this article, the previous vibration measurements are extended with other methods that can also be used for fault detection. Brake fluid pressure measurement and integration of the disc rotation angle sensor enable the detection of faults without additional sensors. The aim of the research is to design a measurement method that can be compared with previously validated measurements. Full article

The precise measurement of crankshaft torsional vibration is critical for diesel engine reliability, yet it is often compromised by systematic errors from toothed disc runout. To address this challenge, this paper elucidates the dual mechanism of these errors, which manifest as micro-level voltage fluctuations in signal and macro-level time-domain deviations. Based on this understanding, a composite compensation method is proposed. First, a dual-line approximation method is presented for preprocessing the raw sensor signals, aiming to eliminate the distortion in rotational speed calculations caused by anomalous voltages. Second, a synchronous sampling scheme based on the differential measurement principle is developed. This scheme utilizes a symmetrically arranged dual-sensor structure to suppress runout errors and is combined with a time-domain feature reconstruction technique to restore the true rotational speed signal. Validation on a custom-built universal joint torsional vibration test rig demonstrates that the proposed method can effectively eliminate systematic deviations arising from toothed disc runout, thereby significantly enhancing the accuracy of torsional vibration measurements. The measurement method presented in this paper offers a valuable reference for the high-precision measurement of engine torsional vibration characteristics. Full article

The radial magnetic bearing system is an open-loop, unstable, strong nonlinear system with a high rotor speed, predisposition to jitter, and poor interference immunity. The system is subjected to the main interference generated by gravity, and rotor imbalance and sensor runout seriously affect the system’s rotor position control performance. A plug-in repetitive control method based on equivalent-input-disturbance (EID) is presented to address the issue of decreased control accuracy of the magnetic bearing system caused by disturbances from gravity, rotor imbalance, and sensor runout. First, a linearized model of the magnetic bearing rotor containing parameter fluctuations due to the eddy current effect and temperature rise effect is established, and a plug-in repetitive controller (PRC) is designed to enhance the rejection effect of periodic disturbances. Next, an EID system is introduced, and a Luenberger observer is used to estimate the state variables and disturbances of the system. The estimates of the EID are then used for feedforward compensation to address the issue of large overshoot in the system. Finally, simulations are conducted for comparison with the PID control method and PRC control method. The plug-in repetitive controller method assessed in this paper improves control performance by an average of 87.9% and 57.7% and reduces the amount of over-shooting by an average of 66.5% under various classes of disturbances, which proves the efficiency of the control method combining a plug-in repetitive controller with the EID theory. Full article

In this work we propose proof-of-concept methods to detect malfunctions of the braking system in passenger vehicles. In particular, we investigate the problem of detecting deformations of the brake disc based on data recorded by acceleration sensors mounted on the suspension of the vehicle. Our core hypothesis is that these signals contain vibrations caused by brake disc deformation. Since faults of this kind are typically monitored by the driver of the vehicle, the development of automatic fault-detection systems becomes more important with the rise of autonomous driving. In addition, the new brake boosters separate the brake pedal from the hydraulic system which results in less significant effects on the brake pedal force. Our paper offers two important contributions. Firstly, we provide a detailed description of our novel measurement scheme, the type and placement of the used sensors, signal acquisition and data characteristics. Then, in the second part of our paper we detail mathematically justified signal representations and different algorithms to distinguish between deformed and normal brake discs. For the proper understanding of the phenomenon, different brake discs were used with measured runout values. Since, in addition to brake disc deformation, the vibrations recorded by our accelerometers are nonlinearly dependent on a number of factors (such as the velocity, suspension, tire pressure, etc.), data-driven models are considered. Through experiments, we show that the proposed methods can be used to recognize faults in the braking system caused by brake disc deformation. Full article

Ceramic-copper substrates, as high-power, load-bearing components, are widely used in new energy vehicles, electric locomotives, high-energy lasers, integrated circuits, and other fields. The service length will depend on the substrate’s copper-coated surface quality, which frequently achieved by utilising an abrasive strip polishing procedure on the substrate’s copper-coated surface. Precision diamond fly-cutting processing machine tools were made because of the low processing accuracy and inability to match the production line’s efficiency. An analysis of the fly-cutting machining principle and the structural makeup of the ceramic-copper substrate is the first step in creating a roughness prediction model based on a tool tip trajectory. This model demonstrates that a shift in the tool tip trajectory due to spindle runout error directly impacts the machined surface’s roughness. The device’s structural optimisation design is derived from the above analyses and implemented using finite element software. Modal and harmonic response analysis validated the machine’s gantry symmetrical structural layout, a parametric variable optimisation design optimised the machine tool’s overall dimensions, and simulation validated the fly-cutterring’s constituent parts. Enhancing the machine tool’s stability and motion accuracy requires using the LK-G5000 laser sensor to measure the guideway’s straightness. The result verified the machine tool’s design index, with the Z- and Y-axes’ straightness being better than 2.42 $\mathsf{\mu }$m$/800$ mm and 2.32 $\mathsf{\mu }$m$/200$ mm, respectively. Ultimately, the device’s machining accuracy was confirmed. Experiments with flying-cut machining on a 190 × 140 mm ceramic-copper substrate yielded a roughness of Sa9.058 nm. According to the experimental results, the developed machine tool can fulfil the design specifications. Full article

The AMB-rotor system is complex and has strong coupling characteristics, which allows multi-harmonic disturbances to enter the system through different ways to produce vibrations with rich spectrum components, which has a great influence on the improvement of micro-vibration accuracy of the rotor system. To further achieve active control of the micro-vibration in the AMB-rotor system, firstly, the mechanism of multi-source disturbance is analyzed according to the working principle of the AMB-rotor system, and the mathematical and physical relationship between the mechanism of disturbance generation and the inducement is deeply studied. Then, the structure of a novel adaptive notch filter, the method of adaptive frequency estimation and analysis of harmonic current suppression in the AMB system are presented. Finally, simulation and experimental research using an MSCMG system demonstrate the feasibility of the proposed method regarding the elimination of harmonic control current. Full article

As the main components of mechanical products and important transmission components of mechanical motion, shaft workpieces (SW) need to undergo high-speed motion while also withstanding high torque motion, which has high processing requirements. At the same time, the processing quality of the workpieces determines the success of the entire processing process, and the quality-inspection methods and the accuracy of the technology directly affect the evaluation of the product. This paper designs an intelligent detection system for the surface shape error (SSE) of SW that combines multiple sensors. Based on the principle of sensor use and specific experimental status, the overall scheme of the detection system is designed, followed by research on the spatial positioning algorithm and surface measurement algorithm of the workpiece to be tested. We then compensate and correct the errors with the algorithm. The effectiveness of the system is verified by measuring the surface size of the workpiece. Finally, the radial circular runout error is taken as an example to verify the detection system. The results show that the measurement error is less than 5%, and the accuracy of the system is high. Full article

The traditional tool center point (TCP) calibration method requires the operator to use their experience to set the actual position of the tool center point. To address this lengthy workflow and low accuracy, while improving accuracy and efficiency for time-saving and non-contact calibration, this paper proposes an enhanced automatic TCP calibration method based on a laser displacement sensor and implemented on a cooperative robot with six degrees of freedom. During the calibration process, the robot arm will move a certain distance along the X and Y axes and collect the information when the tool passes through the laser during the process to calculate the runout of the tool, and then continue to move a certain distance along the X and Y axes for the second height calibration. After the runout angle is calculated and calibrated by triangulation, the runout calibration is completed and the third X and Y axis displacement is performed to find out the exact position of the tool on the X and Y axes. Finally, the tool is moved to a position higher than the laser, and the laser is triggered by moving downward to obtain information to complete the whole experimental process and receive the calibrated tool center position. The whole calibration method is, firstly, verified in the virtual simulation environment and then implemented on the actual cooperative robot. The results of the proposed TCP calibration method for the case of using a pin tool can achieve a positioning deviation of 0.074 and 0.125 mm for the robot moving speeds of 20 and 40 mm/s, respectively. The orientation deviation in the x-axis are 0.089 and −0.184 degrees for the robot moving speeds of 20 and 40 mm/s, respectively. The positioning repeatability of ±0.083 mm for the moving speed of 20 mm/s is lower than ±0.101 mm for the speed of 40 mm/s. It shows that lower moving speed can obtain higher accuracy and better repeatability. This result meets the requirements of TCP calibration but also achieves the purpose of being simple, economical, and time-saving, and it takes only 60 s to complete the whole calibration process. Full article

Maintenance of adequate thermal properties is critical for correct operation of a gas foil bearing. In this work, the authors present the results of the experimentally conducted thermal characterization of a prototype installation of the bearing. A novel method of temperature identification, based on integrated thermocouples readings, has been employed to determine the thermal properties of the specialized sensing top foil mounted in the tested bearing. Two measurement campaigns have been subsequently completed, applying freely-suspended and two-node support configurations, to gather complementary knowledge regarding the bearing’s operation. Apart from the rotational speed and temperature field measurements, the authors have also studied the friction torque and the shaft’s journal trajectories based on its radial displacements. The temporal courses for the above-mentioned quantities have enabled inference on the effects present during run-up, run-out and stable state operation at a constant speed. As confirmed, the applied distribution of the integrated sensors allows for temperature readings on the entire outer surface of the foil, and therefore, provides useful data for the bearing characterization. The work is concluded with presentation of the recommended directions regarding future improvements of the proposed measurement technique and more comprehensive study of the bearing’s characteristics. Full article

To realize the hyperstatic performance index of a magnetically suspended flywheel and simultaneously suppress the vibration force caused by mass imbalance and sensor runout, a compound control method based on a repetitive controller and displacement force compensation of the synchronous force is proposed. First, the mechanism of different interference vibration forces is analyzed by establishing a model of the magnetically suspended flywheel. The analysis shows that the x–y direction is symmetric, and the flywheel structure has symmetry. Second, considering the symmetry of the x- and y-directions, the x-direction is taken as an example for analysis, the parameter design and stability analysis are carried out, and the range of parameters of the compound repetitive control method is obtained. Finally, a flywheel with different speeds is simulated. It was found that the vibration force of each frequency can be suppressed by the compound control method, and the inhibition rate of the vibration force can reach as much as 95%. The results show that the unbalanced vibration and vibration force caused by the sensor runout can be effectively suppressed by using the compound repetitive control method. Full article

With its standardized and unified interface, the quick-change fixture is an important part for maintaining high efficiency without compensation of precision in the metal-turning process because it can conveniently realize high-precision repeated clamping and multi-station conversion without complex positioning and adjustment steps. However, the existing quick-change fixture products and related research cannot fully meet the needs of repeatability and applicability raised from ultra-precision, single-point diamond turning with ultra-high accuracy and ultra-small depth of cut. In this paper, we develop a quick-change fixture for ultra-precision diamond turning, in which the end-toothed disc acts as the positioning element. Specifically, the main parameters of two key components of the end-toothed disc and slotted disc spring are calculated analytically to ensure the positioning accuracy of the designed fixture used in the rotation condition, which is further ensured by controlling the machining tolerance of the tooth profile of the end-toothed disc. Additionally, finite element simulations are performed to investigate the static and modal states of the quick-change fixture, which demonstrate a maximum deformation of about 0.9 μm and a minimum natural frequency of 5655.9 Hz for the designed fixture. Two high-precision sensors are used to detect the radial jump and end run-out values after repeated clamping actions, which are employed to verify the repetitive positioning accuracy of the fixture. Subsequent finite-element simulation of the clamping of small-diameter copper bar, as well as the diamond turning experiment, jointly demonstrate that the designed fixture can achieve a precision of 1 μm. Current work provides an effective quick-change fixture to reduce the deformation of a weak-stiffness workpiece caused by clamping deformation in ultra-precision diamond cutting. Full article

Standards for the fatigue testing of wearable sensing technologies are lacking. The majority of published fatigue tests for wearable sensors are performed on proof-of-concept stretch sensors fabricated from a variety of materials. Due to their flexibility and stretchability, polymers are often used in the fabrication of wearable sensors. Other materials, including textiles, carbon nanotubes, graphene, and conductive metals or inks, may be used in conjunction with polymers to fabricate wearable sensors. Depending on the combination of the materials used, the fatigue behaviors of wearable sensors can vary. Additionally, fatigue testing methodologies for the sensors also vary, with most tests focusing only on the low-cycle fatigue (LCF) regime, and few sensors are cycled until failure or runout are achieved. Fatigue life predictions of wearable sensors are also lacking. These issues make direct comparisons of wearable sensors difficult. To facilitate direct comparisons of wearable sensors and to move proof-of-concept sensors from “bench to bedside”, fatigue testing standards should be established. Further, both high-cycle fatigue (HCF) and failure data are needed to determine the appropriateness in the use, modification, development, and validation of fatigue life prediction models and to further the understanding of how cracks initiate and propagate in wearable sensing technologies. Full article

In addition to providing an extremely clean environment for primary loop of high-temperature gas-cooled reactor (HTR), the primary helium circulator (PHC) using electromagnetic levitation technology also provides an effective means for vibration control. Besides synchronous vibration produced by mass imbalance and sensor runout, double-frequency vibration produced by unbalanced magnetic pull (UMP) is serious in PHC engineering prototype (PHC-EP). In this paper, we firstly analyzed the mechanism of UMP and the multi-frequency vibration characteristics in combination with the PHC-EP. Then we put forward a distributed iterative learning control (ILC) algorithm and a parallel control scheme to suppress the periodic vibrations. Finally, we verified the methods by carrying out experimental researches on the active magnetic bearing (AMB) bench of PHC-EP. The results show that the methods put forward in this paper have significant control effect on the double-frequency vibration generated by UMP of the PHC-EP and provide theoretical and practical references for the PHC safe operation in HTR. Full article

In the milling process, cutting forces contain key information about the machining process status in terms of workpiece quality and tool condition. On-line cutting force measurement is key for machining condition monitoring and machined surface quality assurance. This paper presents a novel instrumented working table with integrated polyvinylidene fluoride (PVDF) thin-film sensors, thus enabling the dynamic milling force measurement with compact structures. To achieve this, PVDF thin-film sensors are integrated into the working table to sense forces in different directions and the dedicated cutting force decoupling model is derived. A prototype instrumented working table is developed and validated. The validation demonstrates that profiles of the forces measured from the developed instrumented working table prototype and the dynamometer match well. Furthermore, the milling experiment results convey that the instrumented working table prototype could also identify the tool runout due to tool manufacturing or assembly errors, and the force signal spectrum analysis indicates that the developed working table can capture the tool passing frequency correctly, therefore, is suitable for the milling force measurement. Full article