2009 Vol.22(4)
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2009, 23(4).
Abstract:
The six-component force/torque sensor has become one kind of the most important sensors with the ability of measuring all the external forces and torques. A novel hyperstatic six-component force/torque sensor based on the Stewart platform structure, which can be used for the force measurement of the robot wrist, is proposed, and its structural optimal design, finite element analysis and calibration experimentation is presented. The characteristic of the sensor structure is analyzed in comparison with the traditional Stewart platform-based sensor. The mathematical expression of the sensor’s force mapping matrix is introduced. The condition number and generalized amplifying coefficient defined by singular values of force Jacobian matrix are used to evaluate the performances of isotropy and sensitivity of the sensor respectively. The optimal design of the sensor structure is performed with the objective of achieving high measurement sensitivity and good isotropy. The sensor prototype is fabricated, and the static and dynamic characteristics of the sensor are analyzed with finite element analysis software package ANSYS. The calibration device is manufactured, and the data acquisition and processing system is developed. The theoretical and experimental study of the static calibration of the sensor prototype is carried out. The results of simulation analysis and calibration experimentation prove the feasibility of the hyperstatic sensor structure, and the contents of this paper possess theoretical significance and engineering value for the further research and practical application of the six-component force sensor.
The six-component force/torque sensor has become one kind of the most important sensors with the ability of measuring all the external forces and torques. A novel hyperstatic six-component force/torque sensor based on the Stewart platform structure, which can be used for the force measurement of the robot wrist, is proposed, and its structural optimal design, finite element analysis and calibration experimentation is presented. The characteristic of the sensor structure is analyzed in comparison with the traditional Stewart platform-based sensor. The mathematical expression of the sensor’s force mapping matrix is introduced. The condition number and generalized amplifying coefficient defined by singular values of force Jacobian matrix are used to evaluate the performances of isotropy and sensitivity of the sensor respectively. The optimal design of the sensor structure is performed with the objective of achieving high measurement sensitivity and good isotropy. The sensor prototype is fabricated, and the static and dynamic characteristics of the sensor are analyzed with finite element analysis software package ANSYS. The calibration device is manufactured, and the data acquisition and processing system is developed. The theoretical and experimental study of the static calibration of the sensor prototype is carried out. The results of simulation analysis and calibration experimentation prove the feasibility of the hyperstatic sensor structure, and the contents of this paper possess theoretical significance and engineering value for the further research and practical application of the six-component force sensor.
2009, 23(4).
Abstract:
Mechanical properties of structural materials are particularly important for design, performance realization and reliability analysis of microelectromechanical systems (MEMS). Furthermore，accurate database of mechanical properties at the micro scale can provide indispensable reference for establishing MEMS standard. Electroplated nickel film is one of the most favored structural materials used in MEMS, thus its mechanical properties has been studied for many years. However, the measured values show large scatter in Young’s modulus of nickel film. Young’s modulus and yield stress of electroplated nickel film are measured by using a micro-tensile testing instrument. The tensile load applied on the specimen is measured by a load cell with accuracy 0.25 mN directly, without additional friction. Through measuring the axial stiffness coefficient of the tensile instrument in situ, the tensile strain of the specimen is obtained by using two-serial spring model. The electroplated nickel films were fabricated from sulfamate baths, and the gauge section is 500 μm long and 10 μm wide nominally, and thickness range between 25 μm and 50 μm. The obtained Young’s modulus from tensile testing is 83±6 GPa for nickel specimens electroplated at current density of 20 mA/cm2 and it increases to 124±5 GPa as current density is decreased to 10 mA/cm2. The phenomena are interpreted in terms of porosity of microstructure. The higher current density produced microstucture with low density and high volume fraction of pores, and the microstructure of high porosity corresponds to a lower modulus. The measured values of Young’s modulus are consistent with those of calculated from the exponential empirical formula between Young’s modulus and porosity. The micro-tensile testing instrument can also be used for mechanical measurement of other MEMS films.
Mechanical properties of structural materials are particularly important for design, performance realization and reliability analysis of microelectromechanical systems (MEMS). Furthermore，accurate database of mechanical properties at the micro scale can provide indispensable reference for establishing MEMS standard. Electroplated nickel film is one of the most favored structural materials used in MEMS, thus its mechanical properties has been studied for many years. However, the measured values show large scatter in Young’s modulus of nickel film. Young’s modulus and yield stress of electroplated nickel film are measured by using a micro-tensile testing instrument. The tensile load applied on the specimen is measured by a load cell with accuracy 0.25 mN directly, without additional friction. Through measuring the axial stiffness coefficient of the tensile instrument in situ, the tensile strain of the specimen is obtained by using two-serial spring model. The electroplated nickel films were fabricated from sulfamate baths, and the gauge section is 500 μm long and 10 μm wide nominally, and thickness range between 25 μm and 50 μm. The obtained Young’s modulus from tensile testing is 83±6 GPa for nickel specimens electroplated at current density of 20 mA/cm2 and it increases to 124±5 GPa as current density is decreased to 10 mA/cm2. The phenomena are interpreted in terms of porosity of microstructure. The higher current density produced microstucture with low density and high volume fraction of pores, and the microstructure of high porosity corresponds to a lower modulus. The measured values of Young’s modulus are consistent with those of calculated from the exponential empirical formula between Young’s modulus and porosity. The micro-tensile testing instrument can also be used for mechanical measurement of other MEMS films.
2009, 23(4).
Abstract:
The previous experiments of wire drawing with ultrasonic vibration were mostly carried out on self-made machine or drawing test machine and the drawing speed didn’t conform to practical production. In order to promote the practical application of the technology, the ultrasonic vibration system was designed and manufactured by using the classical dynamics method. The dynamic characteristic of the ultrasonic vibration system was analyzed. The performance parameters of the system were measured on the resistance analyzer. The oxygen-free brass wire drawing with ultrasonic vibration at the approximate speed of practice was carried out on the LH-200/17 drawing machine. By comparing the wire drawing through ultrasonic vibration and the conventional wire drawing, the experimental results show that the drawing process with ultrasound was steady at the high drawing speed of 1 126 mm/s, while the broken wire often occurs at the speed of 980 mm/s during the conventional wire drawing; the ultrasonic vibration reduced the drawing force by 7 %; and the ultrasound also reduced the uneven deformation of the wire and greatly improved the surface quality of the wire. The research results provide theoretical and experimental support for the practice and application of the wire drawing by ultrasonic vibration.
The previous experiments of wire drawing with ultrasonic vibration were mostly carried out on self-made machine or drawing test machine and the drawing speed didn’t conform to practical production. In order to promote the practical application of the technology, the ultrasonic vibration system was designed and manufactured by using the classical dynamics method. The dynamic characteristic of the ultrasonic vibration system was analyzed. The performance parameters of the system were measured on the resistance analyzer. The oxygen-free brass wire drawing with ultrasonic vibration at the approximate speed of practice was carried out on the LH-200/17 drawing machine. By comparing the wire drawing through ultrasonic vibration and the conventional wire drawing, the experimental results show that the drawing process with ultrasound was steady at the high drawing speed of 1 126 mm/s, while the broken wire often occurs at the speed of 980 mm/s during the conventional wire drawing; the ultrasonic vibration reduced the drawing force by 7 %; and the ultrasound also reduced the uneven deformation of the wire and greatly improved the surface quality of the wire. The research results provide theoretical and experimental support for the practice and application of the wire drawing by ultrasonic vibration.
2009, 23(4).
Abstract:
Casing treatment is a widely employed technique to increase the stall margins of turbomachineries. In the last several decades, many researches on casing treatment have been carried out. However, the mechanism of its expanding stall margins is still not very clear. Till now, most casing teatment schemes are designed for axial compressors, while the investigations on casing treatments in centrifugal compressors are rarely reported. Moreover, current investigation methods mainly focus on experiments, and perfect theoretical analysis is not yet feasible. In order to study the effectiveness and further the mechanism of casing treatments in centrifugal compressors, in this paper, a computationally based investigation of the impact of the self-recirculating casing treatment on the performance of a radial compressor is carried out. The results indicate that, by casing bleed and injection, the casing treatment with inclined blades in the cavity expands the stall margin most. At low mass flows, the reversed flow through the cavity with inclined blades develops the counter swirl flow in front of the impeller inlet, which is considered to benefit increasing the pressure rise from the injection port to the bleed port and thereby augment the recirculating flow. At 120% design speed, the stall margin is larger than that at the design speed. However, the cost of extending the stall margin is the reduction of isentropic efficiency. A mended casing treatment by shifting the bleed port upstream is also studied. It is demonstrated that, relative to the original casing treatment, this mend can improve the efficiency evidently notwithstanding a little narrowing of the flow range.
Casing treatment is a widely employed technique to increase the stall margins of turbomachineries. In the last several decades, many researches on casing treatment have been carried out. However, the mechanism of its expanding stall margins is still not very clear. Till now, most casing teatment schemes are designed for axial compressors, while the investigations on casing treatments in centrifugal compressors are rarely reported. Moreover, current investigation methods mainly focus on experiments, and perfect theoretical analysis is not yet feasible. In order to study the effectiveness and further the mechanism of casing treatments in centrifugal compressors, in this paper, a computationally based investigation of the impact of the self-recirculating casing treatment on the performance of a radial compressor is carried out. The results indicate that, by casing bleed and injection, the casing treatment with inclined blades in the cavity expands the stall margin most. At low mass flows, the reversed flow through the cavity with inclined blades develops the counter swirl flow in front of the impeller inlet, which is considered to benefit increasing the pressure rise from the injection port to the bleed port and thereby augment the recirculating flow. At 120% design speed, the stall margin is larger than that at the design speed. However, the cost of extending the stall margin is the reduction of isentropic efficiency. A mended casing treatment by shifting the bleed port upstream is also studied. It is demonstrated that, relative to the original casing treatment, this mend can improve the efficiency evidently notwithstanding a little narrowing of the flow range.
2009, 23(4).
Abstract:
Dynamic optimization of electromechanical coupling system is a significant engineering problem in the field of mechatronics. The performance improvement of electromechanical equipment depends on the system design parameters. Aiming at the spindle unit of refitted machine tool for solid rocket, the vibration acceleration of tool is taken as objective function, and the electromechanical system design parameters are appointed as design variables. Dynamic optimization model is set up by adopting Lagrange-Maxwell equations, Park transform and electromechanical system energy equations. In the procedure of seeking high efficient optimization method, exponential function is adopted to be the weight function of particle swarm optimization algorithm. Exponential inertia weight particle swarm algorithm(EPSA), is formed and applied to solve the dynamic optimization problem of electromechanical system. The probability density function of EPSA is presented and used to perform convergence analysis. After calculation, the optimized design parameters of the spindle unit are obtained in limited time period. The vibration acceleration of the tool has been decreased greatly by the optimized design parameters. The research job in the paper reveals that the problem of dynamic optimization of electromechanical system can be solved by the method of combining system dynamic analysis with reformed swarm particle optimization. Such kind of method can be applied in the design of robots, NC machine, and other electromechanical equipments.
Dynamic optimization of electromechanical coupling system is a significant engineering problem in the field of mechatronics. The performance improvement of electromechanical equipment depends on the system design parameters. Aiming at the spindle unit of refitted machine tool for solid rocket, the vibration acceleration of tool is taken as objective function, and the electromechanical system design parameters are appointed as design variables. Dynamic optimization model is set up by adopting Lagrange-Maxwell equations, Park transform and electromechanical system energy equations. In the procedure of seeking high efficient optimization method, exponential function is adopted to be the weight function of particle swarm optimization algorithm. Exponential inertia weight particle swarm algorithm(EPSA), is formed and applied to solve the dynamic optimization problem of electromechanical system. The probability density function of EPSA is presented and used to perform convergence analysis. After calculation, the optimized design parameters of the spindle unit are obtained in limited time period. The vibration acceleration of the tool has been decreased greatly by the optimized design parameters. The research job in the paper reveals that the problem of dynamic optimization of electromechanical system can be solved by the method of combining system dynamic analysis with reformed swarm particle optimization. Such kind of method can be applied in the design of robots, NC machine, and other electromechanical equipments.
2009, 23(4).
Abstract:
Road friction coefficient is a key factor for the stability control of the vehicle dynamics in the critical conditions. Obviously the vehicle dynamics stability control systems, including the anti-lock brake system(ABS), the traction control system(TCS), and the active yaw control(AYC) system, need the accurate tire and road friction information. However, the simplified method based on the linear tire and vehicle model could not obtain the accurate road friction coefficient for the complicated maneuver of the vehicle. Because the active braking control mode of AYC is different from that of ABS, the road friction coefficient cannot be estimated only with the dynamics states of the tire. With the related dynamics states measured by the sensors of AYC, a comprehensive strategy of the road friction estimation for the active yaw control is brought forward with the sensor fusion technique. Firstly, the variations of the dynamics characteristics of vehicle and tire, and the stability control mode in the steering process are considered, and then the proper road friction estimation methods are brought forward according to the vehicle maneuver process. In the steering maneuver without braking, the comprehensive road friction from the four wheels may be estimated based on the multi-sensor signal fusion method. The estimated values of the road friction reflect the road friction characteristic. When the active brake involved, the road friction coefficient of the braked wheel may be estimated based on the brake pressure and tire forces, the estimated values reflect the road friction between the braked wheel and the road. So the optimal control of the wheel slip rate may be obtained according to the road friction coefficient. The methods proposed in the paper are integrated into the real time controller of AYC, which is matched onto the test vehicle. The ground tests validate the accuracy of the proposed method under the complicated maneuver conditions.
Road friction coefficient is a key factor for the stability control of the vehicle dynamics in the critical conditions. Obviously the vehicle dynamics stability control systems, including the anti-lock brake system(ABS), the traction control system(TCS), and the active yaw control(AYC) system, need the accurate tire and road friction information. However, the simplified method based on the linear tire and vehicle model could not obtain the accurate road friction coefficient for the complicated maneuver of the vehicle. Because the active braking control mode of AYC is different from that of ABS, the road friction coefficient cannot be estimated only with the dynamics states of the tire. With the related dynamics states measured by the sensors of AYC, a comprehensive strategy of the road friction estimation for the active yaw control is brought forward with the sensor fusion technique. Firstly, the variations of the dynamics characteristics of vehicle and tire, and the stability control mode in the steering process are considered, and then the proper road friction estimation methods are brought forward according to the vehicle maneuver process. In the steering maneuver without braking, the comprehensive road friction from the four wheels may be estimated based on the multi-sensor signal fusion method. The estimated values of the road friction reflect the road friction characteristic. When the active brake involved, the road friction coefficient of the braked wheel may be estimated based on the brake pressure and tire forces, the estimated values reflect the road friction between the braked wheel and the road. So the optimal control of the wheel slip rate may be obtained according to the road friction coefficient. The methods proposed in the paper are integrated into the real time controller of AYC, which is matched onto the test vehicle. The ground tests validate the accuracy of the proposed method under the complicated maneuver conditions.
2009, 23(4).
Abstract:
A servo press is a new type of mechanical press that is driven by programmable motors and offers superior performance such as low noise, excellent efficiency and high precision for metal forming operations. Similar to multi-link mechanical presses, a servo mechanical press tends to grow in size as the tonnage increases that calls for larger, heavy duty servo motors, which could be expensive and may not even be available. In this paper, a new concept of servo mechanical press with redundant actuation is proposed firstly using two servo motors driving one input shaft, i.e. one-point-two-motor mode that makes it possible to produce a larger press with available servomotors. Then the punching mechanism design is detailed. The performance indices are set up including mechanical advantage reciprocal and link force ratios. A bounded feasible solution space is constructed for dimensional synthesis based on non-dimensional link lengths and assembly conditions. The performance atlases are depicted over the bounded feasible solution space that lead to a visual solution of the punching mechanism with global optimization. Finally, case studies are given to illustrate the design method with visual global optimization, and a prototype with 200 t punching force is being developed in our laboratory to demonstrate efficacy of the new concept for servo mechanical press. The presented research provides a feasible solution to the development of heavy-duty servo mechanical presses and finds potential applications in the development of other types of heavy equipments with electric drive.
A servo press is a new type of mechanical press that is driven by programmable motors and offers superior performance such as low noise, excellent efficiency and high precision for metal forming operations. Similar to multi-link mechanical presses, a servo mechanical press tends to grow in size as the tonnage increases that calls for larger, heavy duty servo motors, which could be expensive and may not even be available. In this paper, a new concept of servo mechanical press with redundant actuation is proposed firstly using two servo motors driving one input shaft, i.e. one-point-two-motor mode that makes it possible to produce a larger press with available servomotors. Then the punching mechanism design is detailed. The performance indices are set up including mechanical advantage reciprocal and link force ratios. A bounded feasible solution space is constructed for dimensional synthesis based on non-dimensional link lengths and assembly conditions. The performance atlases are depicted over the bounded feasible solution space that lead to a visual solution of the punching mechanism with global optimization. Finally, case studies are given to illustrate the design method with visual global optimization, and a prototype with 200 t punching force is being developed in our laboratory to demonstrate efficacy of the new concept for servo mechanical press. The presented research provides a feasible solution to the development of heavy-duty servo mechanical presses and finds potential applications in the development of other types of heavy equipments with electric drive.
2009, 23(4).
Abstract:
The on-line diameter measurement of larger axis workpieces is hard to achieve high precision detection, because of the bad environment of locale, the problem to amend the measuring error by non-uniform temperature field, and the difficulty to collimate and locate by usual method. By improving the measurement accuracy of larger axis accessories, it is useful to raise axis and hole’s industry produce level. Because of the influence of complex environment in locale and some influential factors which are hard excluded from the large diameter measurement with multi-rolling-wheels method, the measurement results may not support or even contradict each other. To the situation, this paper puts forward a mutual support deviation distinguish data fusion method, including mutual support deviation detection and weight data fusion. The mutual support deviation detection part can effectively remove or weaken the unexpected impact on the measurement results and the weight data fusion part can get more accurate estimate result to the detected data. So the method can further improve the reliability of measurement results and increase the accuracy of the measurement system. By using the weight data fusion based on the mutual support (DFMS) to the simulation and experiment data, both simulation results and experiment results show that the method can effectively distinguish the data influenced by unexpected impact and improve the stability and reliability of measurement results. The new provided mutual support deviation distinguish method can be used to single sensor measurement and multi-sensor measurement, and can be used as a reference in the data distinguish of other area. The DFMS is helpful to realize the diameter measurement expanded uncertainty in 5×10–6D or even higher when the measured axis workpiece’s diameter is 1–5 m ( ).
The on-line diameter measurement of larger axis workpieces is hard to achieve high precision detection, because of the bad environment of locale, the problem to amend the measuring error by non-uniform temperature field, and the difficulty to collimate and locate by usual method. By improving the measurement accuracy of larger axis accessories, it is useful to raise axis and hole’s industry produce level. Because of the influence of complex environment in locale and some influential factors which are hard excluded from the large diameter measurement with multi-rolling-wheels method, the measurement results may not support or even contradict each other. To the situation, this paper puts forward a mutual support deviation distinguish data fusion method, including mutual support deviation detection and weight data fusion. The mutual support deviation detection part can effectively remove or weaken the unexpected impact on the measurement results and the weight data fusion part can get more accurate estimate result to the detected data. So the method can further improve the reliability of measurement results and increase the accuracy of the measurement system. By using the weight data fusion based on the mutual support (DFMS) to the simulation and experiment data, both simulation results and experiment results show that the method can effectively distinguish the data influenced by unexpected impact and improve the stability and reliability of measurement results. The new provided mutual support deviation distinguish method can be used to single sensor measurement and multi-sensor measurement, and can be used as a reference in the data distinguish of other area. The DFMS is helpful to realize the diameter measurement expanded uncertainty in 5×10–6D or even higher when the measured axis workpiece’s diameter is 1–5 m ( ).
2009, 23(4).
Abstract:
The dynamics analysis plays an important role for the control, simulation and optimization of the parallel manipulators. Normally, the Stewart type manipulators have a platform and several legs. The inverse dynamics can be solved efficiently by taking the advantage of such structural characteristics. However, for the forward dynamics analysis, this structural decomposition still faces challenges from both modeling and computation. In this paper, an efficient approach is proposed for the forward dynamics of the 6-PUS manipulator based on the platform-legs composite simulation. By composite method, the dynamics modeling of the parallel manipulator is separated into the forward dynamics of the platform and the kineto-statics of the legs. The global simulation model can be constructed by connecting the predefined platform model and leg models according to the manipulator’s topology. Thus, the global simulation can be decomposed into the independent calculations of purely algebraic equations and ordinary differential equations (ODEs), the computational cost can be reduced and the stability of the simulation can be improved. For the purpose of solving the manipulator’s forward dynamics accurately, the algebraic-loop problem is discussed and a closed form algorithm is proposed. A numerical example of the 6-PUS manipulator is given to demonstrate the effectiveness of the proposed approach. The example results show that the modeling efficiency can be improved and the simulation stability can be ensured for decomposing the system equations into purely algebraic equations and ODEs
The dynamics analysis plays an important role for the control, simulation and optimization of the parallel manipulators. Normally, the Stewart type manipulators have a platform and several legs. The inverse dynamics can be solved efficiently by taking the advantage of such structural characteristics. However, for the forward dynamics analysis, this structural decomposition still faces challenges from both modeling and computation. In this paper, an efficient approach is proposed for the forward dynamics of the 6-PUS manipulator based on the platform-legs composite simulation. By composite method, the dynamics modeling of the parallel manipulator is separated into the forward dynamics of the platform and the kineto-statics of the legs. The global simulation model can be constructed by connecting the predefined platform model and leg models according to the manipulator’s topology. Thus, the global simulation can be decomposed into the independent calculations of purely algebraic equations and ordinary differential equations (ODEs), the computational cost can be reduced and the stability of the simulation can be improved. For the purpose of solving the manipulator’s forward dynamics accurately, the algebraic-loop problem is discussed and a closed form algorithm is proposed. A numerical example of the 6-PUS manipulator is given to demonstrate the effectiveness of the proposed approach. The example results show that the modeling efficiency can be improved and the simulation stability can be ensured for decomposing the system equations into purely algebraic equations and ODEs
2009, 23(4).
Abstract:
Compared with other kinds of airbags, curtain airbag(CAB) has more complex structures and larger coverage area. The product development process depends on many module tests, sled tests and full size vehicle tests. Computer aided engineering(CAE) technology can replace tests to a great extent, also save test costs and product development time. This paper introduces the way of setting up simulation models and application of static deployment tests and free motion headform(FMH) tests to verify simulation models. In the CAB simulation, uniform pressure airbag models and computational fluid dynamics(CFD) models are all used. The uniform pressure airbag models are not able to simulate the pressure difference among different parts inside the cushion during inflating process. CFD-based CAB models are used to help the curtain airbag optimization design. Based on effective CAE simulation, the optimization analyses related to diffuser tube parameters, inflator mass flow rate and cushion folding patterns are discussed and performed in different cases. The optimization result shows that the proposed techniques are helpful to the parametric optimization design of side curtain airbag module in curtain airbag development process.
Compared with other kinds of airbags, curtain airbag(CAB) has more complex structures and larger coverage area. The product development process depends on many module tests, sled tests and full size vehicle tests. Computer aided engineering(CAE) technology can replace tests to a great extent, also save test costs and product development time. This paper introduces the way of setting up simulation models and application of static deployment tests and free motion headform(FMH) tests to verify simulation models. In the CAB simulation, uniform pressure airbag models and computational fluid dynamics(CFD) models are all used. The uniform pressure airbag models are not able to simulate the pressure difference among different parts inside the cushion during inflating process. CFD-based CAB models are used to help the curtain airbag optimization design. Based on effective CAE simulation, the optimization analyses related to diffuser tube parameters, inflator mass flow rate and cushion folding patterns are discussed and performed in different cases. The optimization result shows that the proposed techniques are helpful to the parametric optimization design of side curtain airbag module in curtain airbag development process.
2009, 23(4).
Abstract:
A design approach is presented in this paper for underactuation in robotic finger mechanisms. The characters of underactuated finger mechanisms are introduced as based on linkage and spring systems. The feature of self-adaptive enveloping grasp by underactuated finger mechanisms is discussed with feasible in grasping unknown objects. The design problem of robotic fingers is analyzed by looking at many aspects for an optimal functionality. Design problems and requirements for underactuated mechanisms are formulated as related to human-like robotic fingers. In particular, characteristics of finger mechanisms are analyzed and optimality criteria are summarized with the aim to formulate a general design algorithm. A general multi-objective optimization design approach is applied as based on a suitable optimization problem by using suitable expressions of optimality criteria. An example is illustrated as an improvement of finger mechanism in Laboratory of Robotics and Mechatronics (LARM) Hand. Results of design outputs and grasp simulations are reported with the aim to show the practical feasibility of the proposed concepts and computations.
A design approach is presented in this paper for underactuation in robotic finger mechanisms. The characters of underactuated finger mechanisms are introduced as based on linkage and spring systems. The feature of self-adaptive enveloping grasp by underactuated finger mechanisms is discussed with feasible in grasping unknown objects. The design problem of robotic fingers is analyzed by looking at many aspects for an optimal functionality. Design problems and requirements for underactuated mechanisms are formulated as related to human-like robotic fingers. In particular, characteristics of finger mechanisms are analyzed and optimality criteria are summarized with the aim to formulate a general design algorithm. A general multi-objective optimization design approach is applied as based on a suitable optimization problem by using suitable expressions of optimality criteria. An example is illustrated as an improvement of finger mechanism in Laboratory of Robotics and Mechatronics (LARM) Hand. Results of design outputs and grasp simulations are reported with the aim to show the practical feasibility of the proposed concepts and computations.
2009, 23(4).
Abstract:
Computer aided process planning(CAPP) is an important content of computer integrated manufacturing, and intelligentizing is the orientation of development of CAPP. Process planning has characters of empirical and time-consuming to finalize, and the same technical aim always can be achieved by different process schemes, so intelligentizing of process decision making always be a difficult point of CAPP and computer integrated manufacturing (CIM). For the purpose of intelligent aided process decision making and reuse of process resource, this paper proposed a decision making method based on rough sets(RS) and regular distance computing. The main contents and methods of process planning decision making are analyzed under agile response manufacturing environment, the concept of process knowledge granule is represented, and the methods of process knowledge granule partitioning and granularity analysis are put forward. Based on the theory of RS and combined the method of process attributes importance identification, the paper brought forward a computing model for process scheme regulation distance under the same attribute conditions, and conflict resolution strategy was introduced to acquire process scheme fit for actual situation of enterprise’s manufacturing resources, so as to realize process resources’ conflict resolution and quick excavate and reuse of enterprises’ existing process knowledge, to advance measures of process decision making and improve the rationality and capability of agile response of process planning.
Computer aided process planning(CAPP) is an important content of computer integrated manufacturing, and intelligentizing is the orientation of development of CAPP. Process planning has characters of empirical and time-consuming to finalize, and the same technical aim always can be achieved by different process schemes, so intelligentizing of process decision making always be a difficult point of CAPP and computer integrated manufacturing (CIM). For the purpose of intelligent aided process decision making and reuse of process resource, this paper proposed a decision making method based on rough sets(RS) and regular distance computing. The main contents and methods of process planning decision making are analyzed under agile response manufacturing environment, the concept of process knowledge granule is represented, and the methods of process knowledge granule partitioning and granularity analysis are put forward. Based on the theory of RS and combined the method of process attributes importance identification, the paper brought forward a computing model for process scheme regulation distance under the same attribute conditions, and conflict resolution strategy was introduced to acquire process scheme fit for actual situation of enterprise’s manufacturing resources, so as to realize process resources’ conflict resolution and quick excavate and reuse of enterprises’ existing process knowledge, to advance measures of process decision making and improve the rationality and capability of agile response of process planning.
2009, 23(4).
Abstract:
Force feedback dataglove is an important interface of human-machine interaction between manipulator and virtual assembly system, which is in charge of the bidirectional transmission of movement and force information between computer and operator. The exoskeleton force feedback dataglove is designed taking the pneumatic artificial muscle as actuator, meanwhile, its structure and work principle are introduced, and the force control problem is analyzed and researched by experiment. The mathematic model of grasping rigid object for finger is established. Considering the friction of tendon-sheath system and finger deformation, the closed-loop force control for a single joint, a single finger and multi-fingers are studied respectively by the feedforward proportional-integral(PI) control method with variable arguments. On the premise of the force smoothness, the control error of the force exerted on the finger joint is in the range of ±0.25 N, which meets the requirement of force feedback. By experimental analysis, the reason of force fluctuation is that the finger joint has a small amplitude quiver, and the consistent change tendency of the force between proximal interphalangeal(PIP) joint and distal interphalangeal(DIP) joint results from their angle coupling relationship.
Force feedback dataglove is an important interface of human-machine interaction between manipulator and virtual assembly system, which is in charge of the bidirectional transmission of movement and force information between computer and operator. The exoskeleton force feedback dataglove is designed taking the pneumatic artificial muscle as actuator, meanwhile, its structure and work principle are introduced, and the force control problem is analyzed and researched by experiment. The mathematic model of grasping rigid object for finger is established. Considering the friction of tendon-sheath system and finger deformation, the closed-loop force control for a single joint, a single finger and multi-fingers are studied respectively by the feedforward proportional-integral(PI) control method with variable arguments. On the premise of the force smoothness, the control error of the force exerted on the finger joint is in the range of ±0.25 N, which meets the requirement of force feedback. By experimental analysis, the reason of force fluctuation is that the finger joint has a small amplitude quiver, and the consistent change tendency of the force between proximal interphalangeal(PIP) joint and distal interphalangeal(DIP) joint results from their angle coupling relationship.
2009, 23(4).
Abstract:
Reliability model of a mechanical product system will be newly reconstructed and maintenance cost will increase because failed parts can be replaced with new components during service, which should be accounted for in system design. In this paper, a reliability model and reliability-based design optimization methodology for maintenance are presented. First, based on the time-to-failure density function of the part of the system, the age distributions of all parts of the system during service are investigated, a reliability model of the mechanical system for maintenance is developed. Then, reliability simulations of the systems with Weibull probability density functions are performed, the system minimum reliability and steady reliability for maintenance are defined based on reliability simulation during the life cycle of the system. Thirdly, a maintenance cost model is developed based on replacement rates of the parts, a reliability-based design optimization model for maintenance is presented, in which total life cycle cost is considered as design objective and system reliability as design constrain. Finally, the reliability-based design optimization methodology for maintenance is used to design of a link ring for the chain conveyor, which shows that optimal design with the lowest maintenance cost can be obtained, and minimum reliability and steady reliability of the system can satisfy requirement of system reliability during service of the chain conveyor.
Reliability model of a mechanical product system will be newly reconstructed and maintenance cost will increase because failed parts can be replaced with new components during service, which should be accounted for in system design. In this paper, a reliability model and reliability-based design optimization methodology for maintenance are presented. First, based on the time-to-failure density function of the part of the system, the age distributions of all parts of the system during service are investigated, a reliability model of the mechanical system for maintenance is developed. Then, reliability simulations of the systems with Weibull probability density functions are performed, the system minimum reliability and steady reliability for maintenance are defined based on reliability simulation during the life cycle of the system. Thirdly, a maintenance cost model is developed based on replacement rates of the parts, a reliability-based design optimization model for maintenance is presented, in which total life cycle cost is considered as design objective and system reliability as design constrain. Finally, the reliability-based design optimization methodology for maintenance is used to design of a link ring for the chain conveyor, which shows that optimal design with the lowest maintenance cost can be obtained, and minimum reliability and steady reliability of the system can satisfy requirement of system reliability during service of the chain conveyor.
2009, 23(4).
Abstract:
Stochastic resonance(SR) enhances the nonlinear system behavior with the assistance of noise, including the sensitivity and selectivity of the response to the exterior stimulus. The energy-transfer mechanism makes the weak information revealed in the output spectrum, while the time-waveform is distorted. The distortion analysis was made both from the particle’s dynamics and signal processing. The factors causing the deviation in the output are presented and the function of the recovery system is proposed. By the investigation of the particle’s motion track in the bistable system and the suggested recovery system, the influences of noise and system parameters on the recovery course were discussed. Moreover, the pulse distortion appearing the recovery waveform caused by the particle’s transitions at the bistable potential’ inflexions was explained. Due to different characteristics, cascaded-bistable SR or mono-stable SR was introduced to process different types of signals. The final recovery signal is just the suggested recovery system’s response to the SR output. Meanwhile, the recovery system is optional, as parameter-tuned or parameter-fixed. Since the method requires no average processing, it is applicable to a single sample with limited length. The numerical simulations reveal that the SR recovery method can recover the waveform containing weak information submerged in noise effectively. The engineering application to the vibration analysis of metal cutting chose the combination of mono-stable SR and the parameter-fixed recovery system. Because the optimal SR state is not required strongly, the system parameters are tuned in a wider range than the traditional SR processing methods.
Stochastic resonance(SR) enhances the nonlinear system behavior with the assistance of noise, including the sensitivity and selectivity of the response to the exterior stimulus. The energy-transfer mechanism makes the weak information revealed in the output spectrum, while the time-waveform is distorted. The distortion analysis was made both from the particle’s dynamics and signal processing. The factors causing the deviation in the output are presented and the function of the recovery system is proposed. By the investigation of the particle’s motion track in the bistable system and the suggested recovery system, the influences of noise and system parameters on the recovery course were discussed. Moreover, the pulse distortion appearing the recovery waveform caused by the particle’s transitions at the bistable potential’ inflexions was explained. Due to different characteristics, cascaded-bistable SR or mono-stable SR was introduced to process different types of signals. The final recovery signal is just the suggested recovery system’s response to the SR output. Meanwhile, the recovery system is optional, as parameter-tuned or parameter-fixed. Since the method requires no average processing, it is applicable to a single sample with limited length. The numerical simulations reveal that the SR recovery method can recover the waveform containing weak information submerged in noise effectively. The engineering application to the vibration analysis of metal cutting chose the combination of mono-stable SR and the parameter-fixed recovery system. Because the optimal SR state is not required strongly, the system parameters are tuned in a wider range than the traditional SR processing methods.
2009, 23(4).
Abstract:
Zn–Al coatings can provide protection to exposed steel parts in most environments. For this reason, the investigation of Zn–Al coatings become very popular in recent years. In order to study the microstructures and properties of mechanically deposited Zn–Al coating, zinc powders and aluminum powders were used to deposit Zn–Al coating by mechanical plating. The microstructures, phase constitutes and compositions of the coating were observed and analyzed with optical microscopy (OM), scanning electron microscopy(SEM), X-ray diffraction(XRD) and X-ray energy-dispersive spectroscopy(EDS). The results of observation show that the coating consists of almost spherically shaped zinc particles point contacting with each other; the coatings are composed of zinc particles, aluminum particles, interstice, and tin; extra fine zinc powders and some smaller interspersed inclusions are positioned in the interstices. Porosity and thickness of the coating were tested by ferroxyl test and magnetic method. The corrosion resistance of coatings was studied by neutral salt spraying test(NSS) , immersion test and electrochemical polarization. It is found that the thickness of the coating dose lacks uniformity, with an uneven thickness distribution and an average variation of approximately 2–5μm; the coating can afford cathodic protection to the steel substrate; the corrosion resistance of Zn–Al coatings is better than that of the mechanically plated zinc coatings with same thickness. These conclusions can be applied to improve anti-corrosion performance by mechanically deposit Zn–Al coatings.
Zn–Al coatings can provide protection to exposed steel parts in most environments. For this reason, the investigation of Zn–Al coatings become very popular in recent years. In order to study the microstructures and properties of mechanically deposited Zn–Al coating, zinc powders and aluminum powders were used to deposit Zn–Al coating by mechanical plating. The microstructures, phase constitutes and compositions of the coating were observed and analyzed with optical microscopy (OM), scanning electron microscopy(SEM), X-ray diffraction(XRD) and X-ray energy-dispersive spectroscopy(EDS). The results of observation show that the coating consists of almost spherically shaped zinc particles point contacting with each other; the coatings are composed of zinc particles, aluminum particles, interstice, and tin; extra fine zinc powders and some smaller interspersed inclusions are positioned in the interstices. Porosity and thickness of the coating were tested by ferroxyl test and magnetic method. The corrosion resistance of coatings was studied by neutral salt spraying test(NSS) , immersion test and electrochemical polarization. It is found that the thickness of the coating dose lacks uniformity, with an uneven thickness distribution and an average variation of approximately 2–5μm; the coating can afford cathodic protection to the steel substrate; the corrosion resistance of Zn–Al coatings is better than that of the mechanically plated zinc coatings with same thickness. These conclusions can be applied to improve anti-corrosion performance by mechanically deposit Zn–Al coatings.
2009, 23(4).
Abstract:
Hollow cylinders are widely used in spacecraft, rockets, weapons, metallurgy, materials, and mechanical manufacturing industries, and so on, hydraulic bulging roll cylinder and hydraulic press work all belong to hollow cylinders. However, up till now, the solution of the cylinder subjected to the pressures in the three-dimensional space is still at the stage of the analytical solution to the normal pressure or the approximate solution to the variable pressure by numerical method. The analytical solution to the variable pressure of the cylinder has not yet made any breakthrough in theory and can not meet accurate theoretical analysis and calculation requirements of the cylindrical in Engineering. In view of their importance, the precision calculation and theoretical analysis are required to investigate on engineering. A stress function which meets both the biharmonic equations and boundary conditions is constructed in the three-dimensional space. Furthermore, the analytic solution of a hollow cylinder subjected to exponential function distributed variable pressure on its inner and outer surfaces is deduced. By controlling the pressure subject to exponential function distributed variable pressure in the hydraulic bulging roller without any rolling load, using a static tester to record the strain supported hydraulic bulging roll, and comparing with the theoretical calculation, the experimental test result has a higher degree of agreement with the theoretical calculation. Simultaneously, the famous Lamè solution can be deduced when given the unlimited length of cylinder along the axis. The analytic solution paves the way for the mathematic building and solution of hollow cylinder with randomly uneven pressure.
Hollow cylinders are widely used in spacecraft, rockets, weapons, metallurgy, materials, and mechanical manufacturing industries, and so on, hydraulic bulging roll cylinder and hydraulic press work all belong to hollow cylinders. However, up till now, the solution of the cylinder subjected to the pressures in the three-dimensional space is still at the stage of the analytical solution to the normal pressure or the approximate solution to the variable pressure by numerical method. The analytical solution to the variable pressure of the cylinder has not yet made any breakthrough in theory and can not meet accurate theoretical analysis and calculation requirements of the cylindrical in Engineering. In view of their importance, the precision calculation and theoretical analysis are required to investigate on engineering. A stress function which meets both the biharmonic equations and boundary conditions is constructed in the three-dimensional space. Furthermore, the analytic solution of a hollow cylinder subjected to exponential function distributed variable pressure on its inner and outer surfaces is deduced. By controlling the pressure subject to exponential function distributed variable pressure in the hydraulic bulging roller without any rolling load, using a static tester to record the strain supported hydraulic bulging roll, and comparing with the theoretical calculation, the experimental test result has a higher degree of agreement with the theoretical calculation. Simultaneously, the famous Lamè solution can be deduced when given the unlimited length of cylinder along the axis. The analytic solution paves the way for the mathematic building and solution of hollow cylinder with randomly uneven pressure.
2009, 23(4).
Abstract:
The condition of rotor system must be assessed in order to develop condition-based maintenance for rotating machinery. It is determined by multiple variables such as unbalance degree, misalignment degree, the amount of bending deformation of the shaft, occurrence of shaft crack of rotor system and so on. The estimation of the degrees of unbalance and misalignment in flexible coupling-rotor system is discussed. The model-based approach is employed to solve this problem. The models of the equivalent external loads for unbalance and misalignment are derived and analyzed. Then, the degrees of unbalance and misalignment are estimated by analyzing the components of the equivalent external loads of which the frequencies are equal to the 1 and 2 times running frequency respectively. The equivalent external loads are calculated according to the dynamic equation of the original rotor system and the differences between the dynamical responses in normal case and the vibrations when the degree of unbalance or misalignment or both changes. The denoise method based on bandpass filter is used to decrease the effect of noise on the estimation accuracy. The numerical examples are given to show that the proposed approach can estimate the degrees of unbalance and misalignment of the flexible coupling-rotor system accurately.
The condition of rotor system must be assessed in order to develop condition-based maintenance for rotating machinery. It is determined by multiple variables such as unbalance degree, misalignment degree, the amount of bending deformation of the shaft, occurrence of shaft crack of rotor system and so on. The estimation of the degrees of unbalance and misalignment in flexible coupling-rotor system is discussed. The model-based approach is employed to solve this problem. The models of the equivalent external loads for unbalance and misalignment are derived and analyzed. Then, the degrees of unbalance and misalignment are estimated by analyzing the components of the equivalent external loads of which the frequencies are equal to the 1 and 2 times running frequency respectively. The equivalent external loads are calculated according to the dynamic equation of the original rotor system and the differences between the dynamical responses in normal case and the vibrations when the degree of unbalance or misalignment or both changes. The denoise method based on bandpass filter is used to decrease the effect of noise on the estimation accuracy. The numerical examples are given to show that the proposed approach can estimate the degrees of unbalance and misalignment of the flexible coupling-rotor system accurately.
2009, 23(4).
Abstract:
New armament systems are subjected to the method for dealing with multi-stage system reliability-growth statistical problems of diverse population in order to improve reliability before starting mass production. Aiming at the test process which is high expense and small sample-size in the development of complex system, the specific methods are studied on how to process the statistical information of Bayesian reliability growth regarding diverse populations. Firstly, according to the characteristics of reliability growth during product development, the Bayesian method is used to integrate the testing information of multi-stage and the order relations of distribution parameters. And then a Gamma-Beta prior distribution is proposed based on non-homogeneous Poisson process(NHPP) corresponding to the reliability growth process. The posterior distribution of reliability parameters is obtained regarding different stages of product, and the reliability parameters are evaluated based on the posterior distribution. Finally, Bayesian approach proposed in this paper for multi-stage reliability growth test is applied to the test process which is small sample-size in the astronautics filed. The results of a numerical example show that the presented model can make use of the diverse information synthetically, and pave the way for the application of the Bayesian model for multi-stage reliability growth test evaluation with small sample-size. The method is useful for evaluating multi-stage system reliability and making reliability growth plan rationally.
New armament systems are subjected to the method for dealing with multi-stage system reliability-growth statistical problems of diverse population in order to improve reliability before starting mass production. Aiming at the test process which is high expense and small sample-size in the development of complex system, the specific methods are studied on how to process the statistical information of Bayesian reliability growth regarding diverse populations. Firstly, according to the characteristics of reliability growth during product development, the Bayesian method is used to integrate the testing information of multi-stage and the order relations of distribution parameters. And then a Gamma-Beta prior distribution is proposed based on non-homogeneous Poisson process(NHPP) corresponding to the reliability growth process. The posterior distribution of reliability parameters is obtained regarding different stages of product, and the reliability parameters are evaluated based on the posterior distribution. Finally, Bayesian approach proposed in this paper for multi-stage reliability growth test is applied to the test process which is small sample-size in the astronautics filed. The results of a numerical example show that the presented model can make use of the diverse information synthetically, and pave the way for the application of the Bayesian model for multi-stage reliability growth test evaluation with small sample-size. The method is useful for evaluating multi-stage system reliability and making reliability growth plan rationally.
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