Search Results (20)

In this work, we describe the mechanical design, analysis, and tests of an innovative automatic high-speed industrial postal canceling machine. The main novelties of this machine are automatic feeding of heterogeneous letters in a very compact design, high speed of letter processing (>22,000 letters per hour), and letter jamming detection. This is the first time that such an industrial and automatic machine is being constructed in a reduced desktop size and is able to handle heterogeneous types of letters at a high-speed rate. The cancel machine includes a linear feeding belt for the letter feeding, assisted by a vacuum letter gripper and a set of conveyor belts that guide the letter to the impression. The machine has low energy consumption and is easy to maintain with multiple safety limit switches. The design is fully compliant with the new European machine regulations. We show the details of the mechanical design, and we present several performance and speed tests, demonstrating that the machine achieves more than 99.8% of canceling rate with different sizes and thicknesses of letters, padded and mixed-size, while having a letter canceling speed of more than 22,000 letters per hour. Full article

The fourth Industrial Revolution is driving the maritime and port logistics industry toward greater operational efficiency and reduced human intervention through automatic mooring systems. This study developed and applied a lab-based evaluation procedure to assess the performance and stability of vacuum suction pads in such systems. Test conditions were based on Cavotec’s specifications, with evaluation criteria tailored to the pads’ required performance. Relevant standards were reviewed to establish a vacuum pressure leakage criterion of 5% or less. Results showed that the pads maintained pressure reductions below this threshold, confirming their suitability for automatic mooring, though dynamic factors like heave and tides remain untested. Full article

Chronic Kidney Disease (CKD) is a disorder that affects over 10% of the global population, and that would benefit from innovative methodologies that would provide early detection. Since it has been reported that there are high levels of urease in CKD patients’ saliva, this sample is a promising non-invasive alternative to blood for CKD detection and monitoring. This work introduces a novel 3D µPAD for quantifying urease activity in saliva in a range of 0.041–0.750 U/mL, with limits of detection and quantification of 0.012 and 0.041 U/mL, respectively. The device uses the urease in the sample to convert urea into ammonia, causing a colorimetric change in the bromothymol blue. The accuracy of the developed device was evaluated by comparing the measurements of several saliva samples (#13) obtained with the μPAD and with a commercially available kit. Stability studies were also performed to assess its functionality as a point-of-care methodology, and the device was stable for 4 months when stored in a vacuum. After the sample placement, it could be scanned within 40 min without providing significantly different results. The developed device quantifies urease activity in saliva within 30 min, providing a simple, portable, lab-free alternative to existing methodologies. Full article

This study presents the development and process integration of an alternative demoulding system for high-pressure die casting. The system is aimed at the removal of large structural castings, which are becoming increasingly popular in the industry under the terms mega- and gigacasting. The development differs from conventional systems in the fact that it completely avoids ejectors and realises the demoulding via the principle of vacuum suction cups. Preliminary tests were carried out in which various established materials for vacuum cups were initially identified and the suitability of the selected cup concept was investigated by varying influencing variables from the high-pressure die casting. These tests showed that a suction pad material combination of an elastomer with a thermal barrier and an aramid felt on the surface provides the best results under the given process boundary conditions. Based on this, a multi-segmented vacuum mask with contour adaptation to the casting to be removed was developed. This vacuum mask is used to build up the holding force between the casting and the removal device. The necessary removal force is applied via pneumatic cylinders. The functional capability of the concept and the system integration was verified by experiments on a real die-casting mould for test specimens. The shrinkage and demoulding process can be successfully modelled in the simulation and the real measured demoulding force is only approx. 15% higher than in the simulation. During demoulding in the high-pressure die-casting process, vacuums of up to 88.7% were achieved at temperatures up to 395 °C. Full article

This paper investigates the structure and phase composition of Al–TiB₂ metal matrix composites prepared from the Al–Ti–B system powder using self-propagating high-temperature synthesis (SHS) in semi-industrial conditions (the amount of the initial powder mixture was 1000 g). The samples produced in semi-industrial conditions do not differ from the laboratory samples, and consist of the aluminum matrix and TiB₂ ceramic particles. The temperature rise leads to the growth in the average size of TiB₂ particles from 0.4 to 0.6 µm as compared to the laboratory samples. SHS-produced composites are milled to the average particle size of 42.3 µm. The powder particles are fragmented, their structure is inherited from the SHS-produced Al–TiB₂ metal matrix composite. The obtained powder can be used as the main raw material and additive in selective laser sintering, vacuum sintering, and hot pressing products. It is worth noting that these products can find their own application in the automotive industry: brake pads, drums, rail discs, etc. Full article

A ship’s automatic mooring system relies on vacuum suction pads with rubber seals to withstand external loads, such as mooring forces. This paper focused on the design requirements and performance testing of vacuum suction pads to develop a high-performance automatic mooring system and evaluated the performance of vacuum suction pads through real-scale testing. The mooring capacity of the target ship, the training ship HANBADA, was estimated based on the port and fishing port design standards of the Ministry of Oceans and Fisheries. Under the most extreme ocean conditions (beafort 6), the estimated longitudinal (surge) and lateral (sway) mooring forces acting on HANBADA were 17.7 and 248 kN, respectively. In the real-scale performance test, stable suction was achieved under both dry and water spraying conditions, with the suction force ranging from 180 to 200 kN, under sway conditions. The vacuum ratio remained satisfactory, indicating stable suction. However, under surge conditions, the vacuum ratio decreased slightly to 0.99. Furthermore, the rubber seals returned to their initial shape after load removal, demonstrating their effectiveness in the automatic mooring system. This study provides valuable insights into the design requirements and performance testing of vacuum suction pads, establishing their suitability for developing high-performance automatic mooring systems. Full article

This paper is devoted to the problem of wear resistance in square Si3N4 ceramic cutting inserts, which exhibit high hardness and strength, in combination with brittleness, and are subject to increased mechanical and thermal loads in machining super alloys for aviation purposes (e.g., a nickel-based alloy of Inconel 718 type). Microtextures were proposed to reduce the intensity of the contact loads on the pad between the cutting edge and the workpiece. The simulation of the mechanical and thermal loads demonstrated the superior ability of the faces with the preformed microgrooves (125 µm in width) compared to microwells (ø100 µm). The tense state was 4.97 times less, and deformations were 2.96 times fewer. The microtextures hamper the development of thermal fields at 900 °C. Two types of microtextures (210 µm-wide microgrooves and microwells 80 µm in diameter) were produced on the rake faces of the cutting inserts via an innovative and integrated approach (the electrical discharge machining of dielectrics using a multifunctional electro-conductive assisted and wear-resistant TiN coating and TiO₂ powder mixed suspension). The TiN coating was deposited via magnetron vacuum plasma sputtering (95%N₂/5%Ar). The failure criterion in turning was 400 µm. An increase of 30% in tool wear resistance was demonstrated. Full article

In this work, a new microfluidic paper-based analytical device (µPAD) was developed for on-hand creatinine quantification in urine samples. When compared to conventional methods, this innovative paper device is more accessible and portable, it provides low-cost analysis (cost of consumables of 40 cents), and it is applicable to non-invasive biological fluids. Furthermore, the paper-based approach is used within an environmentally friendly assembly with no need for wax printing and small amounts of reagents resulting in low waste production and easy disposal by incineration. Its assembly method includes cutting paper discs arranged into several reading units within a plastic pouch, enabling effective creatinine quantification with accuracy based on a vertical flow approach. The method is based on the colourimetric reaction between creatinine and alkaline picric acid, where the solution colour changes from yellow to orange/red. Under optimal conditions, the developed method allowed creatinine quantification in the dynamic range of 2.20–35.0 mg/dL, with a limit of detection (LOD) of 0.66 mg/dL and a limit of quantification (LOQ) of 2.20 mg/dL. The colour intensity developed was processed in ImageJ software, based on digital image scanning, performed in 20 min (up to 4 h) after the sample insertion. The device is stable for up to one week when stored in a vacuum at 4 °C. The method was validated by comparing the results with a batch-wise procedure, where there were no statistically significant differences between both methods. Full article

In order to investigate the self-healing behavior of asphalt binder at the molecule scale, the self-healing models of neat and aged asphalt binder with different damage degrees were established by introducing a vacuum pad between two layers filled with asphalt molecules. With this model, the self-healing process was simulated at various healing conditions to reveal the effects of oxidative aging, damage degree and healing temperature on the self-healing property. In addition, self-healing efficiency was evaluated using the indexes representative of the characteristics of different self-healing stages. Our results show that the oxidative aging weakened the stacked structure of the asphalt binder and increased the healing activation energy barrier. The increasing damage degree extended the distance for particles to travel, thus prolonging the time required for the crack interfaces contacting with each other. The elevated temperature improved the molecular mobility by supplying more energy to the molecular system. Furthermore, the self-healing process was evaluated quantitatively by the density variation at the crack closing stage and the diffusion coefficient at the intrinsic healing stage. The duration of each stage was influenced by the oxidative aging, damage degree and healing temperature. The findings in this paper are helpful to reveal and evaluate the self-healing property of asphalt binder. Full article

Most microsensors are composed of devices and covers. Due to the complicated structure of the cover and various other requirements, it difficult to use wafer-level packaging with such microsensors. In particular, for monolithic microsensors combined with read-out ICs, the available process margins are further reduced due to the thermal and mechanical effects applied to IC wafers during the packaging process. This research proposes a low-temperature, wafer-level vacuum packaging technology based on Cu-Sn bonding and nano-multilayer getter materials for use with microbolometers. In Cu-Sn bonding, the Cu/Cu₃Sn/Cu microstructure required to ensure reliability can be obtained by optimizing the bonding temperature, pressure, and time. The Zr-Ti-Ru based nanomultilayer getter coating inside the cap wafer with high step height has been improved by self-aligned shadow masking. The device pad, composed of bonded wafer, was opened by wafer grinding, and the thermoelectrical properties were evaluated at the wafer-level. The bonding strength and vacuum level were characterized by a shear test and thermoelectrical test using microbolometer test pixels. The vacuum level of the packaged samples showed very narrow distribution near 50 mTorr. This wafer-level packaging platform could be very useful for sensor development whereby high reliability and excellent mechanical/optical performance are both required. Due to its reliability and the low material cost and bonding temperature, this wafer-based packaging approach is suitable for commercial applications. Full article

To improve plasma and chemical resistance on various vacuum components used for semiconductor manufacturing equipment, various ceramic coating techniques have been applied. Among these methods for ceramic coating, the well-known atmospheric plasma spray (APS) is advantageous for providing thick film (100 µm or more) deposition. However, there are problems associated with the phase transition of the coating film and poor film quality due to formation of voids. To solve these problems, the aerosol deposition (AD) method has been developed. This method provides nice ceramic film quality. However, the coating rate is quite slow and has difficulty producing thick films (>30 µm). To overcome these limitations, microwave plasma-assisted aerosol deposition (μ-PAD) is applied at low vacuum conditions without the AD nozzle. This method uses a microwave plasma source during the AD process. After enduring a long-term durability test, as a trial run, μ-PAD has been applied on the actual process site. With the Al₂O₃ powder, μ-PAD shows a coating rate that is 12 times higher than the AD method. In addition, the formation of a thicker film (96 µm) deposition has been demonstrated. On the other hand, the coating film hardness, porosity, adhesion, and withstand voltage characteristics were confirmed to be less than the AD method. Full article

Compared with the traditional mooring system, the automated vacuum mooring system can meet the development needs of large-scale ship automation, port automation, and environmental protection. This review describes the latest research focuses, progress, applications, and future perspectives regarding the automated vacuum mooring system. First, the components, working principles, advantages, limits, and risks of the automated vacuum mooring system are discussed. Secondly, typical application cases of automated vacuum mooring systems are introduced, looking at two aspects of the ship-based system and shore-based system. Then, the routine maintenance of the automated vacuum mooring system is introduced. Finally, a discussion on the challenges and future perspectives of the automated vacuum mooring system is provided in this review. The advantages of an automated vacuum mooring system make it a potentially highly effective and economical option for a wider range of ship mooring than a traditional mooring system. Full article

This paper reports a MEMS capacitive pressure sensor (CPS) based on the operating principle of touch mode. The CPS was designed and fabricated using wafer-level self-packaged MEMS processes. The variable capacitance sensing structure was vacuum-sealed in a cavity using the Si–glass anodic bonding technique, and the embedded Al feedthrough lines at the Si–glass interface were used to realize the electrical connections between the parallel plate electrodes and the electrode pads through Al vias. The optimal design of the CPS structure was performed to trade-off the performance and reliability using finite element simulation. The CPS based on a circular-shaped diaphragm with a radius of 2000 µm and a thickness of 40 µm exhibits good comprehensive performance with a sensitivity of 52.3 pF/MPa and a nonlinearity of 2.7%FS in the pressure range of 100–500 kPa when the ambient temperature is less than 50 °C. Full article

A combination of the venturi module and the vortex cup was proposed to solve vortex instability and to enhance grip capacity. Mounting a venturi suction pad inside the vortex cup improved vacuum generation efficiency. When the vortex cup properly maintained the non-contact air gap and generated an equivalent vacuum to achieve a sealing effect around the open gap of the suction pad, the combined head improved grip capacity and stabilized the non-contact environment. Furthermore, the flow patterns around the venturi chamber and the swirl inside the vortex cup were analyzed based on the design elements of each module. In a module that integrated some of the venturi’s features internally, increased air consumption of the vortex cup was required than that of the venturi. However, it supported a wide range of non-contact grips. The coupled model effectively protected the vacuum suction features of the venturi suction pad in all non-contact environments in that range. Full article

In this work, the design of a microfluidic paper-based analytical device (μPAD) for the quantification of nitrate in urine samples was described. Nitrate monitoring is highly relevant due to its association to some diseases and health conditions. The nitrate determination was achieved by combining the selectivity of the nitrate reductase enzymatic reaction with the colorimetric detection of nitrite by the well-known Griess reagent. For the optimization of the nitrate determination μPAD, several variables associated with the design and construction of the device were studied. Furthermore, the interference of the urine matrix was evaluated, and stability studies were performed, under different conditions. The developed μPAD enabled us to obtain a limit of detection of 0.04 mM, a limit of quantification of 0.14 mM and a dynamic concentration range of 0.14–1.0 mM. The designed μPAD proved to be stable for 24 h when stored at room temperature in air or vacuum atmosphere, and 60 days when stored in vacuum at −20 °C. The accuracy of the nitrate μPAD measurements was confirmed by analyzing four certified samples (prepared in synthetic urine) and performing recovery studies using urine samples. Full article