2013 Vol.26(5)
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2013, 27(5).
Abstract:
Laboratory experiments were conducted for falling U-chain, but explicit analytic form of the general equations of motion was not presented. Several modeling methods were developed for fish robots. However, they just focused on the whole fishs locomotion which does little favor to understand the detailed swimming behavior of fish. In view of this, Udwadia-Kalaba theory is used to model these two multi-body systems and obtain explicit analytic equations of motion. For falling U-chain, the mass matrix is non-singular. Second-order constraints are used to get the constraint force and equations of motion and the numerical simulation is conducted. Simulation results show that the chain tip falls faster than the freely falling body. For fish robot, two-joint Carangiform fish robot is focused on. Quasi-steady wing theory is used to approximately calculate fluid lift force acting on the caudal fin. Based on the obtained explicit analytic equations of motion (the mass matrix is singular), propulsive characteristics of each part of the fish robot are obtained. Through these two cases of U chain and fish robot, how to use Udwadia-Kalaba equation to obtain the dynamical model is shown in detail and the modeling methodology for multi-body systems is presented clearly. It is also shown that Udwadia-Kalaba theory is applicable to systems whether or not their mass matrices are singular. In the whole process of applying Udwadia-Kalaba equation, Lagrangian multipliers and quasi-coordinates are not used. Udwadia-Kalaba theory is creatively applied to dynamical modeling of falling U-chain and fish robot problems and explicit analytic equations of motion are obtained.
Laboratory experiments were conducted for falling U-chain, but explicit analytic form of the general equations of motion was not presented. Several modeling methods were developed for fish robots. However, they just focused on the whole fishs locomotion which does little favor to understand the detailed swimming behavior of fish. In view of this, Udwadia-Kalaba theory is used to model these two multi-body systems and obtain explicit analytic equations of motion. For falling U-chain, the mass matrix is non-singular. Second-order constraints are used to get the constraint force and equations of motion and the numerical simulation is conducted. Simulation results show that the chain tip falls faster than the freely falling body. For fish robot, two-joint Carangiform fish robot is focused on. Quasi-steady wing theory is used to approximately calculate fluid lift force acting on the caudal fin. Based on the obtained explicit analytic equations of motion (the mass matrix is singular), propulsive characteristics of each part of the fish robot are obtained. Through these two cases of U chain and fish robot, how to use Udwadia-Kalaba equation to obtain the dynamical model is shown in detail and the modeling methodology for multi-body systems is presented clearly. It is also shown that Udwadia-Kalaba theory is applicable to systems whether or not their mass matrices are singular. In the whole process of applying Udwadia-Kalaba equation, Lagrangian multipliers and quasi-coordinates are not used. Udwadia-Kalaba theory is creatively applied to dynamical modeling of falling U-chain and fish robot problems and explicit analytic equations of motion are obtained.
Fracture Assessment for Electron Beam Welded Damage Tolerant Ti-6Al-4V Alloy by the FITNET Procedure
2013, 27(5).
Abstract:
Fracture assessment of the cracked structures is essential to avoiding fracture failure. A number of fracture assessment procedures have been proposed for various steel structures. However, the studies about the application of available procedures for titanium alloy structures are scarcely reported. Fracture assessment for the electron beam(EB) welded thick-walled damage tolerant Ti-6Al-4V(TC4-DT) alloy is performed by the fitness-for-service(FFS) FITNET procedure. Uniaxial tensile tests and fracture assessment tests of the base metal and weld metal are carried out to obtain the input information of assessment. The standard options and advanced options of FITNET FFS procedure are used to the fracture assessment of the present material. Moreover, the predicted maximum loads of compact tensile specimen using FITNET FFS procedure are verified with the experimental data of fracture assessment tests. As a result, it is shown that the mechanical properties of weld metal are inhomogeneous along the weld depth. The mismatch ratio M is less than 10% at the weld top and middle, whereas more than 10% at the weld bottom. Failure assessment lines of standard options are close to that of advanced option, which means that the standard options are suitable for fracture assessment of the present welds. The accurate estimation of the maximum loads has been obtained by fracture assessment of standard options with error less than 6%. Furthermore, there are no potential advantages of applying higher options or mismatch options. Thus, the present welded joints can be treated as homogeneous material during the fracture assessment, and standard option 1 can be used to achieve accurate enough results. This research provides the engineering treatment methods for the fracture assessment of titanium alloy and its EB welds.
Fracture assessment of the cracked structures is essential to avoiding fracture failure. A number of fracture assessment procedures have been proposed for various steel structures. However, the studies about the application of available procedures for titanium alloy structures are scarcely reported. Fracture assessment for the electron beam(EB) welded thick-walled damage tolerant Ti-6Al-4V(TC4-DT) alloy is performed by the fitness-for-service(FFS) FITNET procedure. Uniaxial tensile tests and fracture assessment tests of the base metal and weld metal are carried out to obtain the input information of assessment. The standard options and advanced options of FITNET FFS procedure are used to the fracture assessment of the present material. Moreover, the predicted maximum loads of compact tensile specimen using FITNET FFS procedure are verified with the experimental data of fracture assessment tests. As a result, it is shown that the mechanical properties of weld metal are inhomogeneous along the weld depth. The mismatch ratio M is less than 10% at the weld top and middle, whereas more than 10% at the weld bottom. Failure assessment lines of standard options are close to that of advanced option, which means that the standard options are suitable for fracture assessment of the present welds. The accurate estimation of the maximum loads has been obtained by fracture assessment of standard options with error less than 6%. Furthermore, there are no potential advantages of applying higher options or mismatch options. Thus, the present welded joints can be treated as homogeneous material during the fracture assessment, and standard option 1 can be used to achieve accurate enough results. This research provides the engineering treatment methods for the fracture assessment of titanium alloy and its EB welds.
2013, 27(5).
Abstract:
The influences of machining and misalignment errors play a very critical role in the performance of the anti-backlash double-roller enveloping hourglass worm gear(ADEHWG). However, a corresponding efficient method for eliminating or reducing these errors on the tooth profile of the ADEHWG is seldom reported. The gear engagement equation and tooth profile equation for considering six different errors that could arise from the machining and gear misalignment are derived from the theories of differential geometry and gear meshing. Also, the tooth contact analysis(TCA) is used to systematically investigate the influence of the machining and misalignment errors on the contact curves and the tooth profile by means of numerical analysis and three-dimensional solid modeling. The research results show that vertical angular misalignment of the worm wheel() has the strongest influences while the tooth angle error() has the weakest influences on the contact curves and the tooth profile. A novel efficient approach is proposed and used to minimize the effect of the errors in manufacturing by changing the radius of the grinding wheel and the approaching point of contact. The results from the TCA and the experiment demonstrate that this tooth profile design modification method can indeed reduce the machining and misalignment errors. This modification design method is helpful in understanding the manufacturing technology of the ADEHWG.
The influences of machining and misalignment errors play a very critical role in the performance of the anti-backlash double-roller enveloping hourglass worm gear(ADEHWG). However, a corresponding efficient method for eliminating or reducing these errors on the tooth profile of the ADEHWG is seldom reported. The gear engagement equation and tooth profile equation for considering six different errors that could arise from the machining and gear misalignment are derived from the theories of differential geometry and gear meshing. Also, the tooth contact analysis(TCA) is used to systematically investigate the influence of the machining and misalignment errors on the contact curves and the tooth profile by means of numerical analysis and three-dimensional solid modeling. The research results show that vertical angular misalignment of the worm wheel() has the strongest influences while the tooth angle error() has the weakest influences on the contact curves and the tooth profile. A novel efficient approach is proposed and used to minimize the effect of the errors in manufacturing by changing the radius of the grinding wheel and the approaching point of contact. The results from the TCA and the experiment demonstrate that this tooth profile design modification method can indeed reduce the machining and misalignment errors. This modification design method is helpful in understanding the manufacturing technology of the ADEHWG.
2013, 27(5).
Abstract:
The research of reliability design for impact vibration of hydraulic pressure pipeline systems is still in the primary stage, and the research of quantitative reliability of hydraulic components and system is still incomplete. On the condition of having obtained the numerical characteristics of basic random parameters, several techniques and methods including the probability statistical theory, hydraulic technique and stochastic perturbation method are employed to carry out the reliability design for impact vibration of the hydraulic pressure system. Considering the instantaneous pressure pulse of hydraulic impact in pipeline, the reliability analysis model of hydraulic pipeline system is established, and the reliability-based optimization design method is presented. The proposed method can reflect the inherent reliability of hydraulic pipe system exactly, and the desired result is obtained. The reliability design of hydraulic pipeline system is achieved by computer programs and the reliability design information of hydraulic pipeline system is obtained. This research proposes a reliability design method, which can solve the problem of the reliability-based optimization design for the hydraulic pressure system with impact vibration practically and effectively, and enhance the quantitative research on the reliability design of hydraulic pipeline system. The proposed method has generality for the reliability optimization design of hydraulic pipeline system.
The research of reliability design for impact vibration of hydraulic pressure pipeline systems is still in the primary stage, and the research of quantitative reliability of hydraulic components and system is still incomplete. On the condition of having obtained the numerical characteristics of basic random parameters, several techniques and methods including the probability statistical theory, hydraulic technique and stochastic perturbation method are employed to carry out the reliability design for impact vibration of the hydraulic pressure system. Considering the instantaneous pressure pulse of hydraulic impact in pipeline, the reliability analysis model of hydraulic pipeline system is established, and the reliability-based optimization design method is presented. The proposed method can reflect the inherent reliability of hydraulic pipe system exactly, and the desired result is obtained. The reliability design of hydraulic pipeline system is achieved by computer programs and the reliability design information of hydraulic pipeline system is obtained. This research proposes a reliability design method, which can solve the problem of the reliability-based optimization design for the hydraulic pressure system with impact vibration practically and effectively, and enhance the quantitative research on the reliability design of hydraulic pipeline system. The proposed method has generality for the reliability optimization design of hydraulic pipeline system.
2013, 27(5).
Abstract:
The present research on involute spline cold roll-beating forming is mainly about the principles and motion relations of cold roll-beating, the theory of roller design, and the stress and strain field analysis of cold roll-beating, etc. However, the research on law of metal flow in the forming process of involute spline cold roll-beating is rare. According to the principle of involute spline cold roll-beating, the contact model between the rollers and the spline shaft blank in the process of cold roll-beating forming is established, and the theoretical analysis of metal flow in the cold roll-beating deforming region is proceeded. A finite element model of the spline cold roll-beating process is established, the formation mechanism of the involute spline tooth profile in cold roll-beating forming process is studied, and the node flow tracks of the deformation area are analyzed. The experimental research on the metal flow of cold roll-beating spline is conducted, and the metallographic structure variation, grain characteristics and metal flow line of the different tooth profile area are analyzed. The experimental results show that the particle flow directions of the deformable bodies in cold roll-beating deformation area are determined by the minimum moving resistance. There are five types of metal flow rules of the deforming region in the process of cold roll-beating forming. The characteristics of involute spline cold roll-beating forming are given, and the forming mechanism of involute spline cold roll-beating is revealed. This paper researches the law of metal flow in the forming process of involute spline cold roll-beating, which provides theoretical supports for solving the tooth profile forming quality problem.
The present research on involute spline cold roll-beating forming is mainly about the principles and motion relations of cold roll-beating, the theory of roller design, and the stress and strain field analysis of cold roll-beating, etc. However, the research on law of metal flow in the forming process of involute spline cold roll-beating is rare. According to the principle of involute spline cold roll-beating, the contact model between the rollers and the spline shaft blank in the process of cold roll-beating forming is established, and the theoretical analysis of metal flow in the cold roll-beating deforming region is proceeded. A finite element model of the spline cold roll-beating process is established, the formation mechanism of the involute spline tooth profile in cold roll-beating forming process is studied, and the node flow tracks of the deformation area are analyzed. The experimental research on the metal flow of cold roll-beating spline is conducted, and the metallographic structure variation, grain characteristics and metal flow line of the different tooth profile area are analyzed. The experimental results show that the particle flow directions of the deformable bodies in cold roll-beating deformation area are determined by the minimum moving resistance. There are five types of metal flow rules of the deforming region in the process of cold roll-beating forming. The characteristics of involute spline cold roll-beating forming are given, and the forming mechanism of involute spline cold roll-beating is revealed. This paper researches the law of metal flow in the forming process of involute spline cold roll-beating, which provides theoretical supports for solving the tooth profile forming quality problem.
2013, 27(5).
Abstract:
Existing rotary ultrasonic motors operating in extreme environments cannot meet the requirements of good environmental adaptability and compact structure at same time, and existing ultrasonic motors with Langevin transducers show better environmental adaptability, but size of these motors are usually big due to the radial arrangement of the Langevin transducers. A novel dual driving face rotary ultrasonic motor is proposed, and its working principle is experimentally verified. The working principle of the novel ultrasonic motor is firstly proposed. The 5th in-plane flexural vibration travelling wave, excited by the Langevin transducers around the stator ring, is used to drive the rotors. Then the finite element method is used in the determination of dimensions of the prototype motor, and the confirmation of its working principle. After that, a laser Doppler vibrometer system is used for measuring the resonance frequency and vibration amplitude of the stator. At last, output characteristics of the prototype motor are measured, environmental adaptability is tested and performance for driving a metal ball is also investigated. At room temperature and 200 V(zero to peak) driving voltage, the motors no-load speed is 80 r/min, the stalling torque is 0.35 Nm and the maximum output power is 0.85 W. The response time of this motor is 0.96 ms at the room temperature, and it decreases or increases little in cold environment. A metal ball driven by the motor can rotate at 210 r/min with the driving voltage 300 V(zero to peak). Results indicate that the prototype motor has a large output torque and good environmental adaptability. A rotary ultrasonic motor owning compact structure and good environmental adaptability is proposed, and lays the foundations of ultrasonic motors applications in extreme environments.
Existing rotary ultrasonic motors operating in extreme environments cannot meet the requirements of good environmental adaptability and compact structure at same time, and existing ultrasonic motors with Langevin transducers show better environmental adaptability, but size of these motors are usually big due to the radial arrangement of the Langevin transducers. A novel dual driving face rotary ultrasonic motor is proposed, and its working principle is experimentally verified. The working principle of the novel ultrasonic motor is firstly proposed. The 5th in-plane flexural vibration travelling wave, excited by the Langevin transducers around the stator ring, is used to drive the rotors. Then the finite element method is used in the determination of dimensions of the prototype motor, and the confirmation of its working principle. After that, a laser Doppler vibrometer system is used for measuring the resonance frequency and vibration amplitude of the stator. At last, output characteristics of the prototype motor are measured, environmental adaptability is tested and performance for driving a metal ball is also investigated. At room temperature and 200 V(zero to peak) driving voltage, the motors no-load speed is 80 r/min, the stalling torque is 0.35 Nm and the maximum output power is 0.85 W. The response time of this motor is 0.96 ms at the room temperature, and it decreases or increases little in cold environment. A metal ball driven by the motor can rotate at 210 r/min with the driving voltage 300 V(zero to peak). Results indicate that the prototype motor has a large output torque and good environmental adaptability. A rotary ultrasonic motor owning compact structure and good environmental adaptability is proposed, and lays the foundations of ultrasonic motors applications in extreme environments.
2013, 27(5).
Abstract:
The problem of spacecraft attitude regulation based on the reaction of arm motion has attracted extensive attentions from both engineering and academic fields. Most of the solutions of the manipulators motion tracking problem just achieve asymptotical stabilization performance, so that these controllers cannot realize precise attitude regulation because of the existence of non-holonomic constraints. Thus, sliding mode control algorithms are adopted to stabilize the tracking error with zero transient process. Due to the switching effects of the variable structure controller, once the tracking error reaches the designed hyper-plane, it will be restricted to this plane permanently even with the existence of external disturbances. Thus, precise attitude regulation can be achieved. Furthermore, taking the non-zero initial tracking errors and chattering phenomenon into consideration, saturation functions are used to replace sign functions to smooth the control torques. The relations between the upper bounds of tracking errors and the controller parameters are derived to reveal physical characteristic of the controller. Mathematical models of free-floating space manipulator are established and simulations are conducted in the end. The results show that the spacecrafts attitude can be regulated to the position as desired by using the proposed algorithm, the steady state error is 0.000 2 rad. In addition, the joint tracking trajectory is smooth, the joint tracking errors converges to zero quickly with a satisfactory continuous joint control input. The proposed research provides a feasible solution for spacecraft attitude regulation by using arm motion, and improves the precision of the spacecraft attitude regulation.
The problem of spacecraft attitude regulation based on the reaction of arm motion has attracted extensive attentions from both engineering and academic fields. Most of the solutions of the manipulators motion tracking problem just achieve asymptotical stabilization performance, so that these controllers cannot realize precise attitude regulation because of the existence of non-holonomic constraints. Thus, sliding mode control algorithms are adopted to stabilize the tracking error with zero transient process. Due to the switching effects of the variable structure controller, once the tracking error reaches the designed hyper-plane, it will be restricted to this plane permanently even with the existence of external disturbances. Thus, precise attitude regulation can be achieved. Furthermore, taking the non-zero initial tracking errors and chattering phenomenon into consideration, saturation functions are used to replace sign functions to smooth the control torques. The relations between the upper bounds of tracking errors and the controller parameters are derived to reveal physical characteristic of the controller. Mathematical models of free-floating space manipulator are established and simulations are conducted in the end. The results show that the spacecrafts attitude can be regulated to the position as desired by using the proposed algorithm, the steady state error is 0.000 2 rad. In addition, the joint tracking trajectory is smooth, the joint tracking errors converges to zero quickly with a satisfactory continuous joint control input. The proposed research provides a feasible solution for spacecraft attitude regulation by using arm motion, and improves the precision of the spacecraft attitude regulation.
2013, 27(5).
Abstract:
Joints are necessary components in large space deployable truss structures which have significant effects on dynamic behavior of these joint dominated structures. Previous researches usually analyzed effects of one or fewer joint characters on dynamics of jointed structures. Effects of joint stiffness, damping, location, number, clearance and contact stiffness on dynamics of jointed structures are systematically analyzed. Cantilever beam model containing linear joints is developed based on finite element method, influence of joint on natural frequencies and mode shapes of the jointed system are analyzed. Analytical results show that frequencies of jointed system decrease dramatically when peak mode shapes occur at joint locations, and there are cusp shapes present in mode shapes. System frequencies increase with joint damping increasing, there are different joint damping to achieve maximum system damping for different joint stiffness. Joint nonlinear force-displacement is described by describing function method, one-DOF model containing nonlinear joints is established to analyze joints freeplay and hysteresis nonlinearities. Analysis results show that nonlinear effects of freeplay and hysteresis make dynamic responses switch from one resonance frequency to another frequency when amplitude exceed demarcation values. Joint contact stiffness determine degree of system nonlinearity, while exciting force level, clearance and slipping force affect amplitude of dynamic response. Dynamic responses of joint dominated deployable truss structure under different sinusoidal exciting force levels are tested. The test results show obvious nonlinear behaviors contributed by joints, dynamic response shifts to lower frequency and higher amplitude as exciting force increasing. The test results are further compared with analytical results, and joint nonlinearity tested is coincident with hysteresis nonlinearity. Analysis method of joint effects on dynamic characteristics of jointed system is proposed, which can be used in optimal design of joint parameters to achieve optimum dynamic performance of jointed system.
Joints are necessary components in large space deployable truss structures which have significant effects on dynamic behavior of these joint dominated structures. Previous researches usually analyzed effects of one or fewer joint characters on dynamics of jointed structures. Effects of joint stiffness, damping, location, number, clearance and contact stiffness on dynamics of jointed structures are systematically analyzed. Cantilever beam model containing linear joints is developed based on finite element method, influence of joint on natural frequencies and mode shapes of the jointed system are analyzed. Analytical results show that frequencies of jointed system decrease dramatically when peak mode shapes occur at joint locations, and there are cusp shapes present in mode shapes. System frequencies increase with joint damping increasing, there are different joint damping to achieve maximum system damping for different joint stiffness. Joint nonlinear force-displacement is described by describing function method, one-DOF model containing nonlinear joints is established to analyze joints freeplay and hysteresis nonlinearities. Analysis results show that nonlinear effects of freeplay and hysteresis make dynamic responses switch from one resonance frequency to another frequency when amplitude exceed demarcation values. Joint contact stiffness determine degree of system nonlinearity, while exciting force level, clearance and slipping force affect amplitude of dynamic response. Dynamic responses of joint dominated deployable truss structure under different sinusoidal exciting force levels are tested. The test results show obvious nonlinear behaviors contributed by joints, dynamic response shifts to lower frequency and higher amplitude as exciting force increasing. The test results are further compared with analytical results, and joint nonlinearity tested is coincident with hysteresis nonlinearity. Analysis method of joint effects on dynamic characteristics of jointed system is proposed, which can be used in optimal design of joint parameters to achieve optimum dynamic performance of jointed system.
2013, 27(5).
Abstract:
The servomotor drive turret punch press is attracting more attentions and being developed more intensively due to the advantages of high speed, high accuracy, high flexibility, high productivity, low noise, cleaning and energy saving. To effectively improve the performance and lower the cost, it is necessary to develop new mechanisms and establish corresponding optimal design method with uniform performance indices. A new patented main driving mechanism and a new optimal design method are proposed. In the optimal design, the performance indices, i.e., the local motion/force transmission indices ITI, OTI, good transmission workspace good transmission workspace(GTW) and the global transmission indices GTIs are defined. The non-dimensional normalization method is used to get all feasible solutions in dimensional synthesis. Thereafter, the performance atlases, which can present all possible design solutions, are depicted. As a result, the feasible solution of the mechanism with good motion/force transmission performance is obtained. And the solution can be flexibly adjusted by designer according to the practical design requirements. The proposed mechanism is original, and the presented design method provides a feasible solution to the optimal design of the main driving mechanism for servo punch press.
The servomotor drive turret punch press is attracting more attentions and being developed more intensively due to the advantages of high speed, high accuracy, high flexibility, high productivity, low noise, cleaning and energy saving. To effectively improve the performance and lower the cost, it is necessary to develop new mechanisms and establish corresponding optimal design method with uniform performance indices. A new patented main driving mechanism and a new optimal design method are proposed. In the optimal design, the performance indices, i.e., the local motion/force transmission indices ITI, OTI, good transmission workspace good transmission workspace(GTW) and the global transmission indices GTIs are defined. The non-dimensional normalization method is used to get all feasible solutions in dimensional synthesis. Thereafter, the performance atlases, which can present all possible design solutions, are depicted. As a result, the feasible solution of the mechanism with good motion/force transmission performance is obtained. And the solution can be flexibly adjusted by designer according to the practical design requirements. The proposed mechanism is original, and the presented design method provides a feasible solution to the optimal design of the main driving mechanism for servo punch press.
2013, 27(5).
Abstract:
The tool point frequency response function(FRF) is commonly obtained by impacting test or semi-analytical techniques. Regardless of the approach, it is assumed that the workpiece system is rigid. The assumption is valid in common machining, but it doesnt work well in the cutting processes of thin-wall products. In order to solve the problem, a multi-degree-of-freedom dynamic model is employed to obtain the relative dynamic stiffness between the cutting tool and the workpiece system. The relative direct and cross FRFs between the cutting tool and workpiece system are achieved by relative excitation experiment, and compared with the tool point FRFs at x and y axial direction. The comparison results indicate that the relative excitation method could be used to obtain the relative dynamic compliance of machine-tool-workpiece system more actually and precisely. Based on the more precise relative FRFs, four evaluation criterions of dynamic stiffness are proposed, and the variation trend curves of these criterions during the last six months are achieved and analyzed. The analysis results show that the lowest natural frequency, the maximum and the average dynamic compliances at x axial direction deteriorate more quickly than that at y axial direction. Therefore, the main cutting direction and the large-size direction of workpieces should be arranged at y axial direction to slow down the deterioration of the dynamic stiffness of machining centers. The compliance of workpiece system is considered, which can help master the deterioration rules of the dynamic stiffness of machining centers, and enhance the reliability of machine centers and the consistency of machining processes.
The tool point frequency response function(FRF) is commonly obtained by impacting test or semi-analytical techniques. Regardless of the approach, it is assumed that the workpiece system is rigid. The assumption is valid in common machining, but it doesnt work well in the cutting processes of thin-wall products. In order to solve the problem, a multi-degree-of-freedom dynamic model is employed to obtain the relative dynamic stiffness between the cutting tool and the workpiece system. The relative direct and cross FRFs between the cutting tool and workpiece system are achieved by relative excitation experiment, and compared with the tool point FRFs at x and y axial direction. The comparison results indicate that the relative excitation method could be used to obtain the relative dynamic compliance of machine-tool-workpiece system more actually and precisely. Based on the more precise relative FRFs, four evaluation criterions of dynamic stiffness are proposed, and the variation trend curves of these criterions during the last six months are achieved and analyzed. The analysis results show that the lowest natural frequency, the maximum and the average dynamic compliances at x axial direction deteriorate more quickly than that at y axial direction. Therefore, the main cutting direction and the large-size direction of workpieces should be arranged at y axial direction to slow down the deterioration of the dynamic stiffness of machining centers. The compliance of workpiece system is considered, which can help master the deterioration rules of the dynamic stiffness of machining centers, and enhance the reliability of machine centers and the consistency of machining processes.
2013, 27(5).
Abstract:
A closed-form solution can be obtained for kinematic analysis of spatial mechanisms by using analytical method. However, extra solutions would occur when solving the constraint equations of mechanism kinematics unless the constraint equations are established with a proper method and the solving approach is appropriate. In order to obtain a kinematic solution of the spherical Stephenson-III six-bar mechanism, spherical analytical theory is employed to construct the constraint equations. Firstly, the mechanism is divided into a four-bar loop and a two-bar unit. On the basis of the decomposition, vectors of the mechanism nodes are derived according to spherical analytical theory and the principle of coordinate transformation. Secondly, the structural constraint equations are constructed by applying cosine formula of spherical triangles to the top platform of the mechanism. Thirdly, the constraint equations are solved by using Bezout s elimination method for forward analysis and Sylvester s resultant elimination method for inverse kinematics respectively. By the aid of computer symbolic systems, Mathematica and Maple, symbolic closed-form solution of forward and inverse displacement analysis of spherical Stephenson-III six-bar mechanism are obtained. Finally, numerical examples of forward and inverse analysis are presented to illustrate the proposed approach. The results indicate that the constraint equations established with the proposed method are much simpler than those reported by previous literature, and can be readily eliminated and solved.
A closed-form solution can be obtained for kinematic analysis of spatial mechanisms by using analytical method. However, extra solutions would occur when solving the constraint equations of mechanism kinematics unless the constraint equations are established with a proper method and the solving approach is appropriate. In order to obtain a kinematic solution of the spherical Stephenson-III six-bar mechanism, spherical analytical theory is employed to construct the constraint equations. Firstly, the mechanism is divided into a four-bar loop and a two-bar unit. On the basis of the decomposition, vectors of the mechanism nodes are derived according to spherical analytical theory and the principle of coordinate transformation. Secondly, the structural constraint equations are constructed by applying cosine formula of spherical triangles to the top platform of the mechanism. Thirdly, the constraint equations are solved by using Bezout s elimination method for forward analysis and Sylvester s resultant elimination method for inverse kinematics respectively. By the aid of computer symbolic systems, Mathematica and Maple, symbolic closed-form solution of forward and inverse displacement analysis of spherical Stephenson-III six-bar mechanism are obtained. Finally, numerical examples of forward and inverse analysis are presented to illustrate the proposed approach. The results indicate that the constraint equations established with the proposed method are much simpler than those reported by previous literature, and can be readily eliminated and solved.
2013, 27(5).
Abstract:
Most current researches working on improving stiffness focus on the application of control theories. But controller in closed-loop hydraulic control system takes effect only after the controlled position is deviated, so the control action is lagged. Thus dynamic performance against force disturbance and dynamic load stiffness cant be improved evidently by advanced control algorithms. In this paper, the elementary principle of maintaining piston position unchanged under sudden external force load change by charging additional oil is analyzed. On this basis, the conception of raising dynamic stiffness of electro hydraulic position servo system by flow feedforward compensation is put forward. And a scheme using double servo valves to realize flow feedforward compensation is presented, in which another fast response servo valve is added to the regular electro hydraulic servo system and specially utilized to compensate the compressed oil volume caused by load impact in time. The two valves are arranged in parallel to control the cylinder jointly. Furthermore, the model of flow compensation is derived, by which the product of the amplitude and width of the valves pulse command signal can be calculated. And determination rules of the amplitude and width of pulse signal are concluded by analysis and simulations. Using the proposed scheme, simulations and experiments at different positions with different force changes are conducted. The simulation and experimental results show that the system dynamic performance against load force impact is largely improved with decreased maximal dynamic position deviation and shortened settling time. That is, system dynamic load stiffness is evidently raised. This paper proposes a new method which can effectively improve the dynamic stiffness of electro-hydraulic servo systems.
Most current researches working on improving stiffness focus on the application of control theories. But controller in closed-loop hydraulic control system takes effect only after the controlled position is deviated, so the control action is lagged. Thus dynamic performance against force disturbance and dynamic load stiffness cant be improved evidently by advanced control algorithms. In this paper, the elementary principle of maintaining piston position unchanged under sudden external force load change by charging additional oil is analyzed. On this basis, the conception of raising dynamic stiffness of electro hydraulic position servo system by flow feedforward compensation is put forward. And a scheme using double servo valves to realize flow feedforward compensation is presented, in which another fast response servo valve is added to the regular electro hydraulic servo system and specially utilized to compensate the compressed oil volume caused by load impact in time. The two valves are arranged in parallel to control the cylinder jointly. Furthermore, the model of flow compensation is derived, by which the product of the amplitude and width of the valves pulse command signal can be calculated. And determination rules of the amplitude and width of pulse signal are concluded by analysis and simulations. Using the proposed scheme, simulations and experiments at different positions with different force changes are conducted. The simulation and experimental results show that the system dynamic performance against load force impact is largely improved with decreased maximal dynamic position deviation and shortened settling time. That is, system dynamic load stiffness is evidently raised. This paper proposes a new method which can effectively improve the dynamic stiffness of electro-hydraulic servo systems.
2013, 27(5).
Abstract:
In the grinding of high quality fused silica parts with complex surface or structure using ball-headed metal bonded diamond wheel with small diameter, the existing dressing methods are not suitable to dress the ball-headed diamond wheel precisely due to that they are either on-line in process dressing which may causes collision problem or without consideration for the effects of the tool setting error and electrode wear. An on-machine precision preparation and dressing method is proposed for ball-headed diamond wheel based on electrical discharge machining. By using this method the cylindrical diamond wheel with small diameter is manufactured to hemispherical-headed form. The obtained ball-headed diamond wheel is dressed after several grinding passes to recover geometrical accuracy and sharpness which is lost due to the wheel wear. A tool setting method based on high precision optical system is presented to reduce the wheel center setting error and dimension error. The effect of electrode tool wear is investigated by electrical dressing experiments, and the electrode tool wear compensation model is established based on the experimental results which show that the value of wear ratio coefficient K tends to be constant with the increasing of the feed length of electrode and the mean value of K is 0.156. Grinding experiments of fused silica are carried out on a test bench to evaluate the performance of the preparation and dressing method. The experimental results show that the surface roughness of the finished workpiece is 0.03 m. The effect of the grinding parameter and dressing frequency on the surface roughness is investigated based on the measurement results of the surface roughness. This research provides an on-machine preparation and dressing method for ball-headed metal bonded diamond wheel used in the grinding of fused silica, which provides a solution to the tool setting method and the effect of electrode tool wear.
In the grinding of high quality fused silica parts with complex surface or structure using ball-headed metal bonded diamond wheel with small diameter, the existing dressing methods are not suitable to dress the ball-headed diamond wheel precisely due to that they are either on-line in process dressing which may causes collision problem or without consideration for the effects of the tool setting error and electrode wear. An on-machine precision preparation and dressing method is proposed for ball-headed diamond wheel based on electrical discharge machining. By using this method the cylindrical diamond wheel with small diameter is manufactured to hemispherical-headed form. The obtained ball-headed diamond wheel is dressed after several grinding passes to recover geometrical accuracy and sharpness which is lost due to the wheel wear. A tool setting method based on high precision optical system is presented to reduce the wheel center setting error and dimension error. The effect of electrode tool wear is investigated by electrical dressing experiments, and the electrode tool wear compensation model is established based on the experimental results which show that the value of wear ratio coefficient K tends to be constant with the increasing of the feed length of electrode and the mean value of K is 0.156. Grinding experiments of fused silica are carried out on a test bench to evaluate the performance of the preparation and dressing method. The experimental results show that the surface roughness of the finished workpiece is 0.03 m. The effect of the grinding parameter and dressing frequency on the surface roughness is investigated based on the measurement results of the surface roughness. This research provides an on-machine preparation and dressing method for ball-headed metal bonded diamond wheel used in the grinding of fused silica, which provides a solution to the tool setting method and the effect of electrode tool wear.
2013, 27(5).
Abstract:
High fidelity analysis are utilized in modern engineering design optimization problems which involve expensive black-box models. For computation-intensive engineering design problems, efficient global optimization methods must be developed to relieve the computational burden. A new metamodel-based global optimization method using fuzzy clustering for design space reduction (MGO-FCR) is presented. The uniformly distributed initial sample points are generated by Latin hypercube design to construct the radial basis function metamodel, whose accuracy is improved with increasing number of sample points gradually. Fuzzy c-mean method and Gath-Geva clustering method are applied to divide the design space into several small interesting cluster spaces for low and high dimensional problems respectively. Modeling efficiency and accuracy are directly related to the design space, so unconcerned spaces are eliminated by the proposed reduction principle and two pseudo reduction algorithms. The reduction principle is developed to determine whether the current design space should be reduced and which space is eliminated. The first pseudo reduction algorithm improves the speed of clustering, while the second pseudo reduction algorithm ensures the design space to be reduced. Through several numerical benchmark functions, comparative studies with adaptive response surface method, approximated unimodal region elimination method and mode-pursuing sampling are carried out. The optimization results reveal that this method captures the real global optimum for all the numerical benchmark functions. And the number of function evaluations show that the efficiency of this method is favorable especially for high dimensional problems. Based on this global design optimization method, a design optimization of a lifting surface in high speed flow is carried out and this method saves about 10 h compared with genetic algorithms. This method possesses favorable performance on efficiency, robustness and capability of global convergence and gives a new optimization strategy for engineering design optimization problems involving expensive black box models.
High fidelity analysis are utilized in modern engineering design optimization problems which involve expensive black-box models. For computation-intensive engineering design problems, efficient global optimization methods must be developed to relieve the computational burden. A new metamodel-based global optimization method using fuzzy clustering for design space reduction (MGO-FCR) is presented. The uniformly distributed initial sample points are generated by Latin hypercube design to construct the radial basis function metamodel, whose accuracy is improved with increasing number of sample points gradually. Fuzzy c-mean method and Gath-Geva clustering method are applied to divide the design space into several small interesting cluster spaces for low and high dimensional problems respectively. Modeling efficiency and accuracy are directly related to the design space, so unconcerned spaces are eliminated by the proposed reduction principle and two pseudo reduction algorithms. The reduction principle is developed to determine whether the current design space should be reduced and which space is eliminated. The first pseudo reduction algorithm improves the speed of clustering, while the second pseudo reduction algorithm ensures the design space to be reduced. Through several numerical benchmark functions, comparative studies with adaptive response surface method, approximated unimodal region elimination method and mode-pursuing sampling are carried out. The optimization results reveal that this method captures the real global optimum for all the numerical benchmark functions. And the number of function evaluations show that the efficiency of this method is favorable especially for high dimensional problems. Based on this global design optimization method, a design optimization of a lifting surface in high speed flow is carried out and this method saves about 10 h compared with genetic algorithms. This method possesses favorable performance on efficiency, robustness and capability of global convergence and gives a new optimization strategy for engineering design optimization problems involving expensive black box models.
2013, 27(5).
Abstract:
The current research of hydrodynamic bearing in blood pump mainly focuses on the bearing structure design. Compared with the typical plane slider bearing and Rayleigh step bearing, spiral groove bearing has excellent performance in load-carrying capacity. However, the load-carrying capacity would decrease significantly with increasing flow rate in conventional designs. In this paper, the special treatment is made to the upper spiral groove bearing to make sure that both the circulatory flowing and load-carrying capacity are high. Three-dimensional computational fluid dynamics(CFD) models in the space between rotor and shaft are developed by using FLUENT software. Effects of groove number, film height and groove depth on load-carrying capacity of the spiral groove bearings are investigated by orthogonal experiment design. The experimental results show that film height is the most remarkable factor to the load-carrying capacity. The variation tendency of load-carrying capacity reveals that the best combination of geometry is the one with groove number of 8, film height 0.03 mm and groove depth 0.08 mm. The velocity and pressure distributions in spiral groove bearings are also analyzed, and the analysis result shows that the distributions are in conformity with the design of the blood pump based on the principle of hydrodynamic bearing. The displacement of the rotor with the best combination parameters is tested by using laser displacement sensors, the testing result shows that the suspending performance is satisfactory both in axial and radial directions. This research proposes a bearing design method which has sufficient load-carrying capacity to support rotor as an effective passive hydrodynamic bearing.
The current research of hydrodynamic bearing in blood pump mainly focuses on the bearing structure design. Compared with the typical plane slider bearing and Rayleigh step bearing, spiral groove bearing has excellent performance in load-carrying capacity. However, the load-carrying capacity would decrease significantly with increasing flow rate in conventional designs. In this paper, the special treatment is made to the upper spiral groove bearing to make sure that both the circulatory flowing and load-carrying capacity are high. Three-dimensional computational fluid dynamics(CFD) models in the space between rotor and shaft are developed by using FLUENT software. Effects of groove number, film height and groove depth on load-carrying capacity of the spiral groove bearings are investigated by orthogonal experiment design. The experimental results show that film height is the most remarkable factor to the load-carrying capacity. The variation tendency of load-carrying capacity reveals that the best combination of geometry is the one with groove number of 8, film height 0.03 mm and groove depth 0.08 mm. The velocity and pressure distributions in spiral groove bearings are also analyzed, and the analysis result shows that the distributions are in conformity with the design of the blood pump based on the principle of hydrodynamic bearing. The displacement of the rotor with the best combination parameters is tested by using laser displacement sensors, the testing result shows that the suspending performance is satisfactory both in axial and radial directions. This research proposes a bearing design method which has sufficient load-carrying capacity to support rotor as an effective passive hydrodynamic bearing.
2013, 27(5).
Abstract:
It is desired to require a walking robot for the elderly and the disabled to have large capacity, high stiffness, stability, etc. However, the existing walking robots cannot achieve these requirements because of the weight-payload ratio and simple function. Therefore, Improvement of enhancing capacity and functions of the walking robot is an important research issue. According to walking requirements and combining modularization and reconfigurable ideas, a quadruped/biped reconfigurable walking robot with parallel leg mechanism is proposed. The proposed robot can be used for both a biped and a quadruped walking robot. The kinematics and performance analysis of a 3-UPU parallel mechanism which is the basic leg mechanism of a quadruped walking robot are conducted and the structural parameters are optimized. The results show that performance of the walking robot is optimal when the circumradius R, r of the upper and lower platform of leg mechanism are 161.7 mm, 57.7 mm, respectively. Based on the optimal results, the kinematics and dynamics of the quadruped walking robot in the static walking mode are derived with the application of parallel mechanism and influence coefficient theory, and the optimal coordination distribution of the dynamic load for the quadruped walking robot with over-determinate inputs is analyzed, which solves dynamic load coupling caused by the branches constraint of the robot in the walk process. Besides laying a theoretical foundation for development of the prototype, the kinematics and dynamics studies on the quadruped walking robot also boost the theoretical research of the quadruped walking and the practical applications of parallel mechanism.
It is desired to require a walking robot for the elderly and the disabled to have large capacity, high stiffness, stability, etc. However, the existing walking robots cannot achieve these requirements because of the weight-payload ratio and simple function. Therefore, Improvement of enhancing capacity and functions of the walking robot is an important research issue. According to walking requirements and combining modularization and reconfigurable ideas, a quadruped/biped reconfigurable walking robot with parallel leg mechanism is proposed. The proposed robot can be used for both a biped and a quadruped walking robot. The kinematics and performance analysis of a 3-UPU parallel mechanism which is the basic leg mechanism of a quadruped walking robot are conducted and the structural parameters are optimized. The results show that performance of the walking robot is optimal when the circumradius R, r of the upper and lower platform of leg mechanism are 161.7 mm, 57.7 mm, respectively. Based on the optimal results, the kinematics and dynamics of the quadruped walking robot in the static walking mode are derived with the application of parallel mechanism and influence coefficient theory, and the optimal coordination distribution of the dynamic load for the quadruped walking robot with over-determinate inputs is analyzed, which solves dynamic load coupling caused by the branches constraint of the robot in the walk process. Besides laying a theoretical foundation for development of the prototype, the kinematics and dynamics studies on the quadruped walking robot also boost the theoretical research of the quadruped walking and the practical applications of parallel mechanism.
2013, 27(5).
Abstract:
The flow in the positive displacement blower is very complex. The existing two-dimensional numerical simulation cannot provide the detailed flow information, especially flow characteristics along the axial direction, which is unfavorable to improve the performance of positive displacement blower. To investigate the effects of spiral inlet and outlet on the aerodynamic performance of positive displacement blower, three-dimensional unsteady flow characteristics in a three-lobe positive displacement blower with and without the spiral inlet and outlet are simulated by solving Navier-Stokes equations coupled with RNG k- turbulent model. In the numerical simulation, the dynamic mesh technique and overset mesh updating method are used. The computational results are compared with the experimental measurements on the variation of flow rate with the outlet pressure to verify the validity of the numerical method presented. The results show that the mass flow rate with the change of pressure is slightly affected by the application of spiral inlet and outlet, but the internal flow state is largely affected. In the exhaust region, the fluctuations of pressure, velocity and temperature as well as the average values of velocity are significantly reduced. This illustrates that the spiral outlet can effectively suppress the fluctuations of pressure, thus reducing reflux shock and energy dissipation. In the intake area, the average value of pressure, velocity and temperature are slightly declined, but the fluctuations of them are significantly reduced, indicating that the spiral inlet plays the role in making the flow more stable. The numerical results obtained reveal the three-dimensional flow characteristics of the positive displacement blower with spiral inlet and outlet, and provide useful reference to improve performance and empirical correction in the noise-reduction design of the positive displacement blowers.
The flow in the positive displacement blower is very complex. The existing two-dimensional numerical simulation cannot provide the detailed flow information, especially flow characteristics along the axial direction, which is unfavorable to improve the performance of positive displacement blower. To investigate the effects of spiral inlet and outlet on the aerodynamic performance of positive displacement blower, three-dimensional unsteady flow characteristics in a three-lobe positive displacement blower with and without the spiral inlet and outlet are simulated by solving Navier-Stokes equations coupled with RNG k- turbulent model. In the numerical simulation, the dynamic mesh technique and overset mesh updating method are used. The computational results are compared with the experimental measurements on the variation of flow rate with the outlet pressure to verify the validity of the numerical method presented. The results show that the mass flow rate with the change of pressure is slightly affected by the application of spiral inlet and outlet, but the internal flow state is largely affected. In the exhaust region, the fluctuations of pressure, velocity and temperature as well as the average values of velocity are significantly reduced. This illustrates that the spiral outlet can effectively suppress the fluctuations of pressure, thus reducing reflux shock and energy dissipation. In the intake area, the average value of pressure, velocity and temperature are slightly declined, but the fluctuations of them are significantly reduced, indicating that the spiral inlet plays the role in making the flow more stable. The numerical results obtained reveal the three-dimensional flow characteristics of the positive displacement blower with spiral inlet and outlet, and provide useful reference to improve performance and empirical correction in the noise-reduction design of the positive displacement blowers.
2013, 27(5).
Abstract:
The spring-loaded inverted pendulum(SLIP) has been widely studied in both animals and robots. Generally, the majority of the relevant theoretical studies deal with elastic leg, the linear leg length-force relationship of which is obviously conflict with the biological observations. A planar spring-mass model with a nonlinear spring leg is presented to explore the intrinsic mechanism of legged locomotion with elastic component. The leg model is formulated via decoupling the stiffness coefficient and exponent of the leg compression in order that the unified stiffness can be scaled as convex, concave as well as linear profile. The apex return map of the SLIP runner is established to investigate dynamical behavior of the fixed point. The basin of attraction and Floquet Multiplier are introduced to evaluate the self-stability and initial state sensitivity of the SLIP model with different stiffness profiles. The numerical results show that larger stiffness exponent can increase top speed of stable running and also can enlarge the size of attraction domain of the fixed point. In addition, the parameter variation is conducted to detect the effect of parameter dependency, and demonstrates that on the fixed energy level and stiffness profile, the faster running speed with larger convergence rate of the stable fixed point under small local perturbation can be achieved via decreasing the angle of attack and increasing the stiffness coefficient. The perturbation recovery test is implemented to judge the ability of the model resisting large external disturbance. The result shows that the convex stiffness performs best in enhancing the robustness of SLIP runner negotiating irregular terrain. This research sheds light on the running performance of the SLIP runner with nonlinear leg spring from a theoretical perspective, and also guides the design and control of the bio-inspired legged robot.
The spring-loaded inverted pendulum(SLIP) has been widely studied in both animals and robots. Generally, the majority of the relevant theoretical studies deal with elastic leg, the linear leg length-force relationship of which is obviously conflict with the biological observations. A planar spring-mass model with a nonlinear spring leg is presented to explore the intrinsic mechanism of legged locomotion with elastic component. The leg model is formulated via decoupling the stiffness coefficient and exponent of the leg compression in order that the unified stiffness can be scaled as convex, concave as well as linear profile. The apex return map of the SLIP runner is established to investigate dynamical behavior of the fixed point. The basin of attraction and Floquet Multiplier are introduced to evaluate the self-stability and initial state sensitivity of the SLIP model with different stiffness profiles. The numerical results show that larger stiffness exponent can increase top speed of stable running and also can enlarge the size of attraction domain of the fixed point. In addition, the parameter variation is conducted to detect the effect of parameter dependency, and demonstrates that on the fixed energy level and stiffness profile, the faster running speed with larger convergence rate of the stable fixed point under small local perturbation can be achieved via decreasing the angle of attack and increasing the stiffness coefficient. The perturbation recovery test is implemented to judge the ability of the model resisting large external disturbance. The result shows that the convex stiffness performs best in enhancing the robustness of SLIP runner negotiating irregular terrain. This research sheds light on the running performance of the SLIP runner with nonlinear leg spring from a theoretical perspective, and also guides the design and control of the bio-inspired legged robot.
2013, 27(5).
Abstract:
The problem of fault reasoning has aroused great concern in scientific and engineering fields. However, fault investigation and reasoning of complex system is not a simple reasoning decision-making problem. It has become a typical multi-constraint and multi-objective reticulate optimization decision-making problem under many influencing factors and constraints. So far, little research has been carried out in this field. This paper transforms the fault reasoning problem of complex system into a paths-searching problem starting from known symptoms to fault causes. Three optimization objectives are considered simultaneously: maximum probability of average fault, maximum average importance, and minimum average complexity of test. Under the constraints of both known symptoms and the causal relationship among different components, a multi-objective optimization mathematical model is set up, taking minimizing cost of fault reasoning as the target function. Since the problem is non-deterministic polynomial-hard(NP-hard), a modified multi-objective ant colony algorithm is proposed, in which a reachability matrix is set up to constrain the feasible search nodes of the ants and a new pseudo-random-proportional rule and a pheromone adjustment mechinism are constructed to balance conflicts between the optimization objectives. At last, a Pareto optimal set is acquired. Evaluation functions based on validity and tendency of reasoning paths are defined to optimize noninferior set, through which the final fault causes can be identified according to decision-making demands, thus realize fault reasoning of the multi-constraint and multi-objective complex system. Reasoning results demonstrate that the improved multi-objective ant colony optimization(IMACO) can realize reasoning and locating fault positions precisely by solving the multi-objective fault diagnosis model, which provides a new method to solve the problem of multi-constraint and multi-objective fault diagnosis and reasoning of complex system.
The problem of fault reasoning has aroused great concern in scientific and engineering fields. However, fault investigation and reasoning of complex system is not a simple reasoning decision-making problem. It has become a typical multi-constraint and multi-objective reticulate optimization decision-making problem under many influencing factors and constraints. So far, little research has been carried out in this field. This paper transforms the fault reasoning problem of complex system into a paths-searching problem starting from known symptoms to fault causes. Three optimization objectives are considered simultaneously: maximum probability of average fault, maximum average importance, and minimum average complexity of test. Under the constraints of both known symptoms and the causal relationship among different components, a multi-objective optimization mathematical model is set up, taking minimizing cost of fault reasoning as the target function. Since the problem is non-deterministic polynomial-hard(NP-hard), a modified multi-objective ant colony algorithm is proposed, in which a reachability matrix is set up to constrain the feasible search nodes of the ants and a new pseudo-random-proportional rule and a pheromone adjustment mechinism are constructed to balance conflicts between the optimization objectives. At last, a Pareto optimal set is acquired. Evaluation functions based on validity and tendency of reasoning paths are defined to optimize noninferior set, through which the final fault causes can be identified according to decision-making demands, thus realize fault reasoning of the multi-constraint and multi-objective complex system. Reasoning results demonstrate that the improved multi-objective ant colony optimization(IMACO) can realize reasoning and locating fault positions precisely by solving the multi-objective fault diagnosis model, which provides a new method to solve the problem of multi-constraint and multi-objective fault diagnosis and reasoning of complex system.
2013, 27(5).
Abstract:
Time domain averaging(TDA) is essentially a comb filter, it cannot extract the specified harmonics which may be caused by some faults, such as gear eccentric. Meanwhile, TDA always suffers from period cutting error(PCE) to different extent. Several improved TDA methods have been proposed, however they cannot completely eliminate the waveform reconstruction error caused by PCE. In order to overcome the shortcomings of conventional methods, a flexible time domain averaging(FTDA) technique is established, which adapts to the analyzed signal through adjusting each harmonic of the comb filter. In this technique, the explicit form of FTDA is first constructed by frequency domain sampling. Subsequently, chirp Z-transform(CZT) is employed in the algorithm of FTDA, which can improve the calculating efficiency significantly. Since the signal is reconstructed in the continuous time domain, there is no PCE in the FTDA. To validate the effectiveness of FTDA in the signal de-noising, interpolation and harmonic reconstruction, a simulated multi-components periodic signal that corrupted by noise is processed by FTDA. The simulation results show that the FTDA is capable of recovering the periodic components from the background noise effectively. Moreover, it can improve the signal-to-noise ratio by 7.9 dB compared with conventional ones. Experiments are also carried out on gearbox test rigs with chipped tooth and eccentricity gear, respectively. It is shown that the FTDA can identify the direction and severity of the eccentricity gear, and further enhances the amplitudes of impulses by 35%. The proposed technique not only solves the problem of PCE, but also provides a useful tool for the fault symptom extraction of rotating machinery.
Time domain averaging(TDA) is essentially a comb filter, it cannot extract the specified harmonics which may be caused by some faults, such as gear eccentric. Meanwhile, TDA always suffers from period cutting error(PCE) to different extent. Several improved TDA methods have been proposed, however they cannot completely eliminate the waveform reconstruction error caused by PCE. In order to overcome the shortcomings of conventional methods, a flexible time domain averaging(FTDA) technique is established, which adapts to the analyzed signal through adjusting each harmonic of the comb filter. In this technique, the explicit form of FTDA is first constructed by frequency domain sampling. Subsequently, chirp Z-transform(CZT) is employed in the algorithm of FTDA, which can improve the calculating efficiency significantly. Since the signal is reconstructed in the continuous time domain, there is no PCE in the FTDA. To validate the effectiveness of FTDA in the signal de-noising, interpolation and harmonic reconstruction, a simulated multi-components periodic signal that corrupted by noise is processed by FTDA. The simulation results show that the FTDA is capable of recovering the periodic components from the background noise effectively. Moreover, it can improve the signal-to-noise ratio by 7.9 dB compared with conventional ones. Experiments are also carried out on gearbox test rigs with chipped tooth and eccentricity gear, respectively. It is shown that the FTDA can identify the direction and severity of the eccentricity gear, and further enhances the amplitudes of impulses by 35%. The proposed technique not only solves the problem of PCE, but also provides a useful tool for the fault symptom extraction of rotating machinery.
2013, 27(5).
Abstract:
The existing methods for blade polishing mainly focus on robot polishing and manual grinding. Due to the difficulty in high-precision control of the polishing force, the blade surface precision is very low in robot polishing, in particular, quality of the inlet and exhaust edges can not satisfy the processing requirements. Manual grinding has low efficiency, high labor intensity and unstable processing quality, moreover, the polished surface is vulnerable to burn, and the surface precision and integrity are difficult to ensure. In order to further improve the profile accuracy and surface quality, a pneumatic flexible polishing force-exerting mechanism is designed and a dual-mode switching composite adaptive control(DSCAC) strategy is proposed, which combines Bang-Bang control and model reference adaptive control based on fuzzy neural network(MRACFNN) together. By the mode decision-making mechanism, Bang-Bang control is used to track the control command signal quickly when the actual polishing force is far away from the target value, and MRACFNN is utilized in smaller error ranges to improve the system robustness and control precision. Based on the mathematical model of the force-exerting mechanism, simulation analysis is implemented on DSCAC. Simulation results show that the output polishing force can better track the given signal. Finally, the blade polishing experiments are carried out on the designed polishing equipment. Experimental results show that DSCAC can effectively mitigate the influence of gas compressibility, valve dead-time effect, valve nonlinear flow, cylinder friction, measurement noise and other interference on the control precision of polishing force, which has high control precision, strong robustness, strong anti-interference ability and other advantages compared with MRACFNN. The proposed research achieves high-precision control of the polishing force, effectively improves the blade machining precision and surface consistency, and significantly reduces the surface roughness.
The existing methods for blade polishing mainly focus on robot polishing and manual grinding. Due to the difficulty in high-precision control of the polishing force, the blade surface precision is very low in robot polishing, in particular, quality of the inlet and exhaust edges can not satisfy the processing requirements. Manual grinding has low efficiency, high labor intensity and unstable processing quality, moreover, the polished surface is vulnerable to burn, and the surface precision and integrity are difficult to ensure. In order to further improve the profile accuracy and surface quality, a pneumatic flexible polishing force-exerting mechanism is designed and a dual-mode switching composite adaptive control(DSCAC) strategy is proposed, which combines Bang-Bang control and model reference adaptive control based on fuzzy neural network(MRACFNN) together. By the mode decision-making mechanism, Bang-Bang control is used to track the control command signal quickly when the actual polishing force is far away from the target value, and MRACFNN is utilized in smaller error ranges to improve the system robustness and control precision. Based on the mathematical model of the force-exerting mechanism, simulation analysis is implemented on DSCAC. Simulation results show that the output polishing force can better track the given signal. Finally, the blade polishing experiments are carried out on the designed polishing equipment. Experimental results show that DSCAC can effectively mitigate the influence of gas compressibility, valve dead-time effect, valve nonlinear flow, cylinder friction, measurement noise and other interference on the control precision of polishing force, which has high control precision, strong robustness, strong anti-interference ability and other advantages compared with MRACFNN. The proposed research achieves high-precision control of the polishing force, effectively improves the blade machining precision and surface consistency, and significantly reduces the surface roughness.
2013, 27(5).
Abstract:
The working platforms supported with multiple extensible legs must be leveled before they come into operation. Although the supporting stiffness and reliability of the platform are improved with the increasing number of the supporting legs, the increased overdetermination of the multi-leg platform systems leads to leveling coupling problem among legs and virtual leg problem in which some of the supporting legs bear zero or quasi zero loads. These problems make it quite complex and time consuming to level such a multi-leg platform. Based on rigid body kinematics, an approximate equation is formulated to rapidly calculate the leg extension for leveling a rigid platform, then a proportional speed control strategy is proposed to reduce the unexpected platform distortion and leveling coupling between supporting legs. Taking both the load coupling between supporting legs and the elastic flexibility of the working platform into consideration, an optimal balancing legs loads(OBLL) model is firstly put forward to deal with the traditional virtual leg problem. By taking advantage of the concept of supporting stiffness matrix, a coupling extension method(CEM) is developed to solve this OBLL problem for multi-leg flexible platform. At the end, with the concept of supporting stiffness matrix and static transmissibility matrix, an optimal load balancing leveling method is proposed to achieve geometric leveling and legs loads balancing simultaneously. Three numerical examples are given out to illustrate the performance of proposed methods. This paper proposes a method which can effectively quantify all of the legs extension at the same time, achieve geometric leveling and legs loads balancing simultaneously. By using the proposed methods, the stability, precision and efficiency of auto-leveling control process can be improved.
The working platforms supported with multiple extensible legs must be leveled before they come into operation. Although the supporting stiffness and reliability of the platform are improved with the increasing number of the supporting legs, the increased overdetermination of the multi-leg platform systems leads to leveling coupling problem among legs and virtual leg problem in which some of the supporting legs bear zero or quasi zero loads. These problems make it quite complex and time consuming to level such a multi-leg platform. Based on rigid body kinematics, an approximate equation is formulated to rapidly calculate the leg extension for leveling a rigid platform, then a proportional speed control strategy is proposed to reduce the unexpected platform distortion and leveling coupling between supporting legs. Taking both the load coupling between supporting legs and the elastic flexibility of the working platform into consideration, an optimal balancing legs loads(OBLL) model is firstly put forward to deal with the traditional virtual leg problem. By taking advantage of the concept of supporting stiffness matrix, a coupling extension method(CEM) is developed to solve this OBLL problem for multi-leg flexible platform. At the end, with the concept of supporting stiffness matrix and static transmissibility matrix, an optimal load balancing leveling method is proposed to achieve geometric leveling and legs loads balancing simultaneously. Three numerical examples are given out to illustrate the performance of proposed methods. This paper proposes a method which can effectively quantify all of the legs extension at the same time, achieve geometric leveling and legs loads balancing simultaneously. By using the proposed methods, the stability, precision and efficiency of auto-leveling control process can be improved.
2013, 27(5).
Abstract:
The high-speed computational performance is gained at the cost of huge hardware resource, which restricts the application of high-accuracy algorithms because of the limited hardware cost in practical use. To solve the problem, a novel method for designing the field programmable gate array(FPGA)-based non-uniform rational B-spline(NURBS) interpolator and motion controller, which adopts the embedded multiprocessor technique, is proposed in this study. The hardware and software design for the multiprocessor, one of which is for NURBS interpolation and the other for position servo control, is presented. Performance analysis and experiments on an X-Y table are carried out, hardware cost as well as consuming time for interpolation and motion control is compared with the existing methods. The experimental and comparing results indicate that, compared with the existing methods, the proposed method can reduce the hardware cost by 97.5% using higher-accuracy interpolation algorithm within the period of 0.5 ms. A method which ensures the real-time performance and interpolation accuracy, and reduces the hardware cost significantly is proposed, and its practical in the use of industrial application.
The high-speed computational performance is gained at the cost of huge hardware resource, which restricts the application of high-accuracy algorithms because of the limited hardware cost in practical use. To solve the problem, a novel method for designing the field programmable gate array(FPGA)-based non-uniform rational B-spline(NURBS) interpolator and motion controller, which adopts the embedded multiprocessor technique, is proposed in this study. The hardware and software design for the multiprocessor, one of which is for NURBS interpolation and the other for position servo control, is presented. Performance analysis and experiments on an X-Y table are carried out, hardware cost as well as consuming time for interpolation and motion control is compared with the existing methods. The experimental and comparing results indicate that, compared with the existing methods, the proposed method can reduce the hardware cost by 97.5% using higher-accuracy interpolation algorithm within the period of 0.5 ms. A method which ensures the real-time performance and interpolation accuracy, and reduces the hardware cost significantly is proposed, and its practical in the use of industrial application.
2013, 27(5).
Abstract:
Existing methods of local search mostly focus on how to reach optimal solution. However, in some emergency situations, search time is the hard constraint for job shop scheduling problem while optimal solution is not necessary. In this situation, the existing method of local search is not fast enough. This paper presents an emergency local search(ELS) approach which can reach feasible and nearly optimal solution in limited search time. The ELS approach is desirable for the aforementioned emergency situations where search time is limited and a nearly optimal solution is sufficient, which consists of three phases. Firstly, in order to reach a feasible and nearly optimal solution, infeasible solutions are repaired and a repair technique named group repair is proposed. Secondly, in order to save time, the amount of local search moves need to be reduced and this is achieved by a quickly search method named critical path search(CPS). Finally, CPS sometimes stops at a solution far from the optimal one. In order to jump out the search dilemma of CPS, a jump technique based on critical part is used to improve CPS. Furthermore, the schedule system based on ELS has been developed and experiments based on this system completed on the computer of Intel Pentium(R) 2.93 GHz. The experimental result shows that the optimal solutions of small scale instances are reached in 2 s, and the nearly optimal solutions of large scale instances are reached in 4 s. The proposed ELS approach can stably reach nearly optimal solutions with manageable search time, and can be applied on some emergency situations.
Existing methods of local search mostly focus on how to reach optimal solution. However, in some emergency situations, search time is the hard constraint for job shop scheduling problem while optimal solution is not necessary. In this situation, the existing method of local search is not fast enough. This paper presents an emergency local search(ELS) approach which can reach feasible and nearly optimal solution in limited search time. The ELS approach is desirable for the aforementioned emergency situations where search time is limited and a nearly optimal solution is sufficient, which consists of three phases. Firstly, in order to reach a feasible and nearly optimal solution, infeasible solutions are repaired and a repair technique named group repair is proposed. Secondly, in order to save time, the amount of local search moves need to be reduced and this is achieved by a quickly search method named critical path search(CPS). Finally, CPS sometimes stops at a solution far from the optimal one. In order to jump out the search dilemma of CPS, a jump technique based on critical part is used to improve CPS. Furthermore, the schedule system based on ELS has been developed and experiments based on this system completed on the computer of Intel Pentium(R) 2.93 GHz. The experimental result shows that the optimal solutions of small scale instances are reached in 2 s, and the nearly optimal solutions of large scale instances are reached in 4 s. The proposed ELS approach can stably reach nearly optimal solutions with manageable search time, and can be applied on some emergency situations.
2013, 27(5).
Abstract:
The feature space extracted from vibration signals with various faults is often nonlinear and of high dimension. Currently, nonlinear dimensionality reduction methods are available for extracting low-dimensional embeddings, such as manifold learning. However, these methods are all based on manual intervention, which have some shortages in stability, and suppressing the disturbance noise. To extract features automatically, a manifold learning method with self-organization mapping is introduced for the first time. Under the non-uniform sample distribution reconstructed by the phase space, the expectation maximization(EM) iteration algorithm is used to divide the local neighborhoods adaptively without manual intervention. After that, the local tangent space alignment(LTSA) algorithm is adopted to compress the high-dimensional phase space into a more truthful low-dimensional representation. Finally, the signal is reconstructed by the kernel regression. Several typical states include the Lorenz system, engine fault with piston pin defect, and bearing fault with outer-race defect are analyzed. Compared with the LTSA and continuous wavelet transform, the results show that the background noise can be fully restrained and the entire periodic repetition of impact components is well separated and identified. A new way to automatically and precisely extract the impulsive components from mechanical signals is proposed.
The feature space extracted from vibration signals with various faults is often nonlinear and of high dimension. Currently, nonlinear dimensionality reduction methods are available for extracting low-dimensional embeddings, such as manifold learning. However, these methods are all based on manual intervention, which have some shortages in stability, and suppressing the disturbance noise. To extract features automatically, a manifold learning method with self-organization mapping is introduced for the first time. Under the non-uniform sample distribution reconstructed by the phase space, the expectation maximization(EM) iteration algorithm is used to divide the local neighborhoods adaptively without manual intervention. After that, the local tangent space alignment(LTSA) algorithm is adopted to compress the high-dimensional phase space into a more truthful low-dimensional representation. Finally, the signal is reconstructed by the kernel regression. Several typical states include the Lorenz system, engine fault with piston pin defect, and bearing fault with outer-race defect are analyzed. Compared with the LTSA and continuous wavelet transform, the results show that the background noise can be fully restrained and the entire periodic repetition of impact components is well separated and identified. A new way to automatically and precisely extract the impulsive components from mechanical signals is proposed.
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