2014 Vol.27(05)
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2014, 28(05).
doi: 10.3901/CJME.2014.0724.126
Abstract:
The existing research of steering comfort mainly focuses on the subjective evaluation, aiming at designing and optimizing the steering system. In the development of steering system, especially the evaluation of steering comfort, the objective evaluation methods considered the kinematic characteristics of driver steering maneuver are not proposed, which means that the objective evaluation of steering cannot be conducted with the evaluation of kinematic characteristics of driver in steering maneuver. In order to propose the objective evaluation methods of steering comfort, the evaluation of steering movement quality of driver is developed on the basis of the study of the kinematic characteristics of steering maneuver. First, the steering motion trajectories of the driver in both comfortable and certain extreme uncomfortable operation conditions are detected using the Vicon motion capture system. The operation conditions are under the restrictions of the vertical height and horizontal distance between steering wheel center and the H-point of driver, and the steering resisting torque else. Next, the movement quality evaluation of driver steering maneuver is assessed using twelve kinds of evaluation indices based on the kinematic analyses of the steering motion trajectories to propose an objective evaluation method. Finally, an integrated discomfort index of steering maneuver is proposed on the basis of the regression analysis of subjective evaluation rating and the movement quality evaluation indices, including the Jerk, Discomfort and Joint Torque indices. The test results show that the proposed integrated discomfort index gives a good fitting with the subjective evaluation of discomfort, which means it can be used to evaluate or predict the discomfort level of steering maneuver. This paper proposes an objective evaluation method of steering comfort based on the movement quality evaluation of driver steering maneuver.
The existing research of steering comfort mainly focuses on the subjective evaluation, aiming at designing and optimizing the steering system. In the development of steering system, especially the evaluation of steering comfort, the objective evaluation methods considered the kinematic characteristics of driver steering maneuver are not proposed, which means that the objective evaluation of steering cannot be conducted with the evaluation of kinematic characteristics of driver in steering maneuver. In order to propose the objective evaluation methods of steering comfort, the evaluation of steering movement quality of driver is developed on the basis of the study of the kinematic characteristics of steering maneuver. First, the steering motion trajectories of the driver in both comfortable and certain extreme uncomfortable operation conditions are detected using the Vicon motion capture system. The operation conditions are under the restrictions of the vertical height and horizontal distance between steering wheel center and the H-point of driver, and the steering resisting torque else. Next, the movement quality evaluation of driver steering maneuver is assessed using twelve kinds of evaluation indices based on the kinematic analyses of the steering motion trajectories to propose an objective evaluation method. Finally, an integrated discomfort index of steering maneuver is proposed on the basis of the regression analysis of subjective evaluation rating and the movement quality evaluation indices, including the Jerk, Discomfort and Joint Torque indices. The test results show that the proposed integrated discomfort index gives a good fitting with the subjective evaluation of discomfort, which means it can be used to evaluate or predict the discomfort level of steering maneuver. This paper proposes an objective evaluation method of steering comfort based on the movement quality evaluation of driver steering maneuver.
2014, 28(05).
doi: 10.3901/CJME.2014.0526.100
Abstract:
It is a common phenomenon that the cracks originating from a hole can cause structural damage in engineering. However, the fracture mechanics studies of hole edge crack problems are not sufficient. The problem of an elliptical hole with two collinear edge cracks of unequal length in an infinite plate under uniform tension at infinity is investigated. Based on the complex variable method, the analytical solutions of stress functions and stress intensity factors are provided. The stress distribution along the axes and the edge of the elliptical hole is given graphically. The numerical results show that there is obvious stress concentration near the hole and cracks, and the stresses tend to applied loads at distances far from the defect, which conform to Saint-Venant’s principle. Hence, the stress functions are proved to be right. Under special conditions, the present configuration becomes the Griffith crack, two symmetrical cracks emanating from an elliptical hole, two cracks of unequal length emanating from a circular hole, a crack at the edge of a circular hole, or a crack emanating from an elliptical hole. Compared with available results, stress intensity factors for these special shapes of ellipses and cracks show good coincidence. The stress intensity factor for two cracks of unequal length at the edge of an elliptical hole increases with the crack length and the major-to-minor axis ratio of the elliptical hole. The stress distribution in an infinite plate containing an elliptic hole with unsymmetrical cracks is given for the first time.
It is a common phenomenon that the cracks originating from a hole can cause structural damage in engineering. However, the fracture mechanics studies of hole edge crack problems are not sufficient. The problem of an elliptical hole with two collinear edge cracks of unequal length in an infinite plate under uniform tension at infinity is investigated. Based on the complex variable method, the analytical solutions of stress functions and stress intensity factors are provided. The stress distribution along the axes and the edge of the elliptical hole is given graphically. The numerical results show that there is obvious stress concentration near the hole and cracks, and the stresses tend to applied loads at distances far from the defect, which conform to Saint-Venant’s principle. Hence, the stress functions are proved to be right. Under special conditions, the present configuration becomes the Griffith crack, two symmetrical cracks emanating from an elliptical hole, two cracks of unequal length emanating from a circular hole, a crack at the edge of a circular hole, or a crack emanating from an elliptical hole. Compared with available results, stress intensity factors for these special shapes of ellipses and cracks show good coincidence. The stress intensity factor for two cracks of unequal length at the edge of an elliptical hole increases with the crack length and the major-to-minor axis ratio of the elliptical hole. The stress distribution in an infinite plate containing an elliptic hole with unsymmetrical cracks is given for the first time.
2014, 28(05).
doi: 10.3901/CJME.2014.0619.115
Abstract:
Most gait studies of multi-legged robots in past neglected the dexterity of robot body and the relationship between stride length and body height. This paper investigates the performance of a radial symmetrical hexapod robot based on the dexterity of parallel mechanism. Assuming the constraints between the supporting feet and the ground with hinges, the supporting legs and the hexapod body are taken as a parallel mechanism, and each swing leg is regarded as a serial manipulator. The hexapod robot can be considered as a series of hybrid serial-parallel mechanisms while walking on the ground. Locomotion performance can be got by analyzing these equivalent mechanisms. The kinematics of the whole robotic system is established, and the influence of foothold position on the workspace of robot body is analyzed. A new method to calculate the stride length of multi-legged robots is proposed by analyzing the relationship between the workspaces of two adjacent equivalent parallel mechanisms in one gait cycle. Referring to service region and service sphere, weight service sphere and weight service region are put forward to evaluate the dexterity of robot body. The dexterity of single point in workspace and the dexterity distribution in vertical and horizontal projection plane are demonstrated. Simulation shows when the foothold offset goes up to 174 mm, the dexterity of robot body achieves its maximum value 0.1644 in mixed gait. The proposed methods based on parallel mechanisms can be used to calculate the stride length and the dexterity of multi-legged robot, and provide new approach to determine the stride length, body height, footholds in gait planning of multi-legged robot.
Most gait studies of multi-legged robots in past neglected the dexterity of robot body and the relationship between stride length and body height. This paper investigates the performance of a radial symmetrical hexapod robot based on the dexterity of parallel mechanism. Assuming the constraints between the supporting feet and the ground with hinges, the supporting legs and the hexapod body are taken as a parallel mechanism, and each swing leg is regarded as a serial manipulator. The hexapod robot can be considered as a series of hybrid serial-parallel mechanisms while walking on the ground. Locomotion performance can be got by analyzing these equivalent mechanisms. The kinematics of the whole robotic system is established, and the influence of foothold position on the workspace of robot body is analyzed. A new method to calculate the stride length of multi-legged robots is proposed by analyzing the relationship between the workspaces of two adjacent equivalent parallel mechanisms in one gait cycle. Referring to service region and service sphere, weight service sphere and weight service region are put forward to evaluate the dexterity of robot body. The dexterity of single point in workspace and the dexterity distribution in vertical and horizontal projection plane are demonstrated. Simulation shows when the foothold offset goes up to 174 mm, the dexterity of robot body achieves its maximum value 0.1644 in mixed gait. The proposed methods based on parallel mechanisms can be used to calculate the stride length and the dexterity of multi-legged robot, and provide new approach to determine the stride length, body height, footholds in gait planning of multi-legged robot.
2014, 28(05).
doi: 10.3901/CJME.2014.0529.107
Abstract:
Hydrostatic mechanical face seals for reactor coolant pumps are very important for the safety and reliability of pressurized-water reactor power plants. More accurate models on the operating mechanism of the seals are needed to help improve their performance. The thermal fluid–solid interaction (TFSI) mechanism of the hydrostatic seal is investigated in this study. Numerical models of the flow field and seal assembly are developed. Based on the mechanism for the continuity condition of the physical quantities at the fluid–solid interface, an on-line numerical TFSI model for the hydrostatic mechanical seal is proposed using an iterative coupling method. Dynamic mesh technology is adopted to adapt to the changing boundary shape. Experiments were performed on a test rig using a full-size test seal to obtain the leakage rate as a function of the differential pressure. The effectiveness and accuracy of the TFSI model were verified by comparing the simulation results and experimental data. Using the TFSI model, the behavior of the seal is presented, including mechanical and thermal deformation, and the temperature field. The influences of the rotating speed and differential pressure of the sealing device on the temperature field, which occur widely in the actual use of the seal, are studied. This research proposes an on-line and assembly-based TFSI model for hydrostatic mechanical face seals, and the model is validated by full-sized experiments.
Hydrostatic mechanical face seals for reactor coolant pumps are very important for the safety and reliability of pressurized-water reactor power plants. More accurate models on the operating mechanism of the seals are needed to help improve their performance. The thermal fluid–solid interaction (TFSI) mechanism of the hydrostatic seal is investigated in this study. Numerical models of the flow field and seal assembly are developed. Based on the mechanism for the continuity condition of the physical quantities at the fluid–solid interface, an on-line numerical TFSI model for the hydrostatic mechanical seal is proposed using an iterative coupling method. Dynamic mesh technology is adopted to adapt to the changing boundary shape. Experiments were performed on a test rig using a full-size test seal to obtain the leakage rate as a function of the differential pressure. The effectiveness and accuracy of the TFSI model were verified by comparing the simulation results and experimental data. Using the TFSI model, the behavior of the seal is presented, including mechanical and thermal deformation, and the temperature field. The influences of the rotating speed and differential pressure of the sealing device on the temperature field, which occur widely in the actual use of the seal, are studied. This research proposes an on-line and assembly-based TFSI model for hydrostatic mechanical face seals, and the model is validated by full-sized experiments.
2014, 28(05).
doi: 10.3901/CJME.2014.0530.105
Abstract:
Finding a basis of unification for the modeling of mechatronic systems is the search subject of several works. This paper is a part of a general research designed to the application of topology as a new approach for the modeling of mechatronic systems. Particularly, the modeling of a one stage spur gear transmission using a topological approach is tackled. This approach is based on the concepts of topological collections and transformations and implemented using the MGS(modeling of general systems) language. The topological collections are used to specify the interconnection laws of the one stage spur gear transmission and the transformations are used to specify the local behavior laws of its different components. In order to validate this approach, simulation results are presented and compared with those obtained with MODELICA language using Dymola solver. Since good results are achieved, this approach might be used as a basis of unification for the modeling of mechatronic systems.
Finding a basis of unification for the modeling of mechatronic systems is the search subject of several works. This paper is a part of a general research designed to the application of topology as a new approach for the modeling of mechatronic systems. Particularly, the modeling of a one stage spur gear transmission using a topological approach is tackled. This approach is based on the concepts of topological collections and transformations and implemented using the MGS(modeling of general systems) language. The topological collections are used to specify the interconnection laws of the one stage spur gear transmission and the transformations are used to specify the local behavior laws of its different components. In order to validate this approach, simulation results are presented and compared with those obtained with MODELICA language using Dymola solver. Since good results are achieved, this approach might be used as a basis of unification for the modeling of mechatronic systems.
2014, 28(05).
doi: 10.3901/CJME.2014.0723.125
Abstract:
Precision drilling with picosecond laser has been advocated to significantly improve the quality of micro-holes with reduced recast layer thickness and almost no heat affected zone. However, a detailed comparison between nanosecond and picosecond laser drilling techniques has rarely been reported in previous research. In the present study, a series of micro-holes are manufactured on stainless steel 304 using a nanosecond and a picosecond laser drilling system, respectively. The quality of the micro-holes, e.g., recast layer, micro-crack, circularity, and conicity, etc, is evaluated by employing an optical microscope, an optical interferometer, and a scanning electron microscope. Additionally, the micro-structure of the samples between the edges of the micro-holes and the parent material is compared following etching treatment. The researching results show that a great amount of spattering material accumulated at the entrance ends of the nanosecond laser drilled micro-holes. The formation of a recast layer with a thickness of ~25 m is detected on the side walls, associated with initiation of micro-cracks. Tapering phenomenon is also observed and the circularity of the micro-holes is rather poor. With regard to the micro-holes drilled by picosecond laser, the entrance ends, the exit ends, and the side walls are quite smooth without accumulation of spattering material, formation of recast layer and micro-cracks. The circularity of the micro-holes is fairly good without observation of tapering phenomenon. Furthermore, there is no obvious difference as for the micro-structure between the edges of the micro-holes and the parent material. This study proposes a picosecond laser helical drilling technique which can be used for effective manufacturing of high quality micro-holes.
Precision drilling with picosecond laser has been advocated to significantly improve the quality of micro-holes with reduced recast layer thickness and almost no heat affected zone. However, a detailed comparison between nanosecond and picosecond laser drilling techniques has rarely been reported in previous research. In the present study, a series of micro-holes are manufactured on stainless steel 304 using a nanosecond and a picosecond laser drilling system, respectively. The quality of the micro-holes, e.g., recast layer, micro-crack, circularity, and conicity, etc, is evaluated by employing an optical microscope, an optical interferometer, and a scanning electron microscope. Additionally, the micro-structure of the samples between the edges of the micro-holes and the parent material is compared following etching treatment. The researching results show that a great amount of spattering material accumulated at the entrance ends of the nanosecond laser drilled micro-holes. The formation of a recast layer with a thickness of ~25 m is detected on the side walls, associated with initiation of micro-cracks. Tapering phenomenon is also observed and the circularity of the micro-holes is rather poor. With regard to the micro-holes drilled by picosecond laser, the entrance ends, the exit ends, and the side walls are quite smooth without accumulation of spattering material, formation of recast layer and micro-cracks. The circularity of the micro-holes is fairly good without observation of tapering phenomenon. Furthermore, there is no obvious difference as for the micro-structure between the edges of the micro-holes and the parent material. This study proposes a picosecond laser helical drilling technique which can be used for effective manufacturing of high quality micro-holes.
2014, 28(05).
doi: 10.3901/CJME.2014.0611.108
Abstract:
Compared with the traditional non-cutting measurement, machining tests can more accurately reflect the kinematic errors of five-axis machine tools in the actual machining process for the users. However, measurement and calculation of the machining tests in the literature are quite difficult and time-consuming. A new method of the machining tests for the trunnion axis of five-axis machine tool is proposed. Firstly, a simple mathematical model of the cradle-type five-axis machine tool was established by optimizing the coordinate system settings based on robot kinematics. Then, the machining tests based on error-sensitive directions were proposed to identify the kinematic errors of the trunnion axis of cradle-type five-axis machine tool. By adopting the error-sensitive vectors in the matrix calculation, the functional relationship equations between the machining errors of the test piece in the error-sensitive directions and the kinematic errors of C-axis and A-axis of five-axis machine tool rotary table was established based on the model of the kinematic errors. According to our previous work, the kinematic errors of C-axis can be treated as the known quantities, and the kinematic errors of A-axis can be obtained from the equations. This method was tested in Mikron UCP600 vertical machining center. The machining errors in the error-sensitive directions can be obtained by CMM inspection from the finished test piece to identify the kinematic errors of five-axis machine tool trunnion axis. Experimental results demonstrated that the proposed method can reduce the complexity, cost, and the time consumed substantially, and has a wider applicability. This paper proposes a new method of the machining tests for the trunnion axis of five-axis machine tool.
Compared with the traditional non-cutting measurement, machining tests can more accurately reflect the kinematic errors of five-axis machine tools in the actual machining process for the users. However, measurement and calculation of the machining tests in the literature are quite difficult and time-consuming. A new method of the machining tests for the trunnion axis of five-axis machine tool is proposed. Firstly, a simple mathematical model of the cradle-type five-axis machine tool was established by optimizing the coordinate system settings based on robot kinematics. Then, the machining tests based on error-sensitive directions were proposed to identify the kinematic errors of the trunnion axis of cradle-type five-axis machine tool. By adopting the error-sensitive vectors in the matrix calculation, the functional relationship equations between the machining errors of the test piece in the error-sensitive directions and the kinematic errors of C-axis and A-axis of five-axis machine tool rotary table was established based on the model of the kinematic errors. According to our previous work, the kinematic errors of C-axis can be treated as the known quantities, and the kinematic errors of A-axis can be obtained from the equations. This method was tested in Mikron UCP600 vertical machining center. The machining errors in the error-sensitive directions can be obtained by CMM inspection from the finished test piece to identify the kinematic errors of five-axis machine tool trunnion axis. Experimental results demonstrated that the proposed method can reduce the complexity, cost, and the time consumed substantially, and has a wider applicability. This paper proposes a new method of the machining tests for the trunnion axis of five-axis machine tool.
2014, 28(05).
doi: 10.3901/CJME.2014.0529.104
Abstract:
Joining of aluminum to steel has attracted significant attention from the welding research community, automotive and rail transportation industries. Many current welding methods have been developed and applied, however, they can not precisely control the heat input to work-piece, they are high costs, low efficiency and consist lots of complex welding devices, and the generated intermetallic compound layer in weld bead interface is thicker. A novel pulsed double electrode gas metal arc welding(Pulsed DE-GMAW) method is developed. To achieve a stable welding process for joining of aluminum to steel, a mathematical model of coupled arc is established, and a new control scheme that uses the average feedback arc voltage of main loop to adjust the wire feed speed to control coupled arc length is proposed and developed. Then, the impulse control simulation of coupled arc length, wire feed speed and wire extension is conducted to demonstrate the mathematical model and predict the stability of welding process by changing the distance of contact tip to work-piece(CTWD). To prove the proposed PSO based PID control scheme’s feasibility, the rapid prototyping experimental system is setup and the bead-on-plate control experiments are conducted to join aluminum to steel. The impulse control simulation shows that the established model can accurately represent the variation of coupled arc length, wire feed speed and the average main arc voltage when the welding process is disturbed, and the developed controller has a faster response and adjustment, only runs about 0.1 s. The captured electric signals show the main arc voltage gradually closes to the supposed arc voltage by adjusting the wire feed speed in 0.8 s. The obtained typical current waveform demonstrates that the main current can be reduced by controlling the bypass current under maintaining a relative large total current. The control experiment proves the accuracy of proposed model and feasibility of new control scheme further. The beautiful and smooth weld beads are also obtained by this method. Pulsed DE-GMAW can thus be considered as an alternative method for low cost, high efficiency joining of aluminum to steel.
Joining of aluminum to steel has attracted significant attention from the welding research community, automotive and rail transportation industries. Many current welding methods have been developed and applied, however, they can not precisely control the heat input to work-piece, they are high costs, low efficiency and consist lots of complex welding devices, and the generated intermetallic compound layer in weld bead interface is thicker. A novel pulsed double electrode gas metal arc welding(Pulsed DE-GMAW) method is developed. To achieve a stable welding process for joining of aluminum to steel, a mathematical model of coupled arc is established, and a new control scheme that uses the average feedback arc voltage of main loop to adjust the wire feed speed to control coupled arc length is proposed and developed. Then, the impulse control simulation of coupled arc length, wire feed speed and wire extension is conducted to demonstrate the mathematical model and predict the stability of welding process by changing the distance of contact tip to work-piece(CTWD). To prove the proposed PSO based PID control scheme’s feasibility, the rapid prototyping experimental system is setup and the bead-on-plate control experiments are conducted to join aluminum to steel. The impulse control simulation shows that the established model can accurately represent the variation of coupled arc length, wire feed speed and the average main arc voltage when the welding process is disturbed, and the developed controller has a faster response and adjustment, only runs about 0.1 s. The captured electric signals show the main arc voltage gradually closes to the supposed arc voltage by adjusting the wire feed speed in 0.8 s. The obtained typical current waveform demonstrates that the main current can be reduced by controlling the bypass current under maintaining a relative large total current. The control experiment proves the accuracy of proposed model and feasibility of new control scheme further. The beautiful and smooth weld beads are also obtained by this method. Pulsed DE-GMAW can thus be considered as an alternative method for low cost, high efficiency joining of aluminum to steel.
2014, 28(05).
doi: 10.3901/CJME.2014.0618.113
Abstract:
Parallel kinematic machines have drawn considerable attention and have been widely used in some special fields. However, high precision is still one of the challenges when they are used for advanced machine tools. One of the main reasons is that the kinematic chains of parallel kinematic machines are composed of elongated links that can easily suffer deformations, especially at high speeds and under heavy loads. A 3-RRR parallel kinematic machine is taken as a study object for investigating its accuracy with the consideration of the deformations of its links during the motion process. Based on the dynamic model constructed by the Newton-Euler method, all the inertia loads and constraint forces of the links are computed and their deformations are derived. Then the kinematic errors of the machine are derived with the consideration of the deformations of the links. Through further derivation, the accuracy of the machine is given in a simple explicit expression, which will be helpful to increase the calculating speed. The accuracy of this machine when following a selected circle path is simulated. The influences of magnitude of the maximum acceleration and external loads on the running accuracy of the machine are investigated. The results show that the external loads will deteriorate the accuracy of the machine tremendously when their direction coincides with the direction of the worst stiffness of the machine. The proposed method provides a solution for predicting the running accuracy of the parallel kinematic machines and can also be used in their design optimization as well as selection of suitable running parameters.
Parallel kinematic machines have drawn considerable attention and have been widely used in some special fields. However, high precision is still one of the challenges when they are used for advanced machine tools. One of the main reasons is that the kinematic chains of parallel kinematic machines are composed of elongated links that can easily suffer deformations, especially at high speeds and under heavy loads. A 3-RRR parallel kinematic machine is taken as a study object for investigating its accuracy with the consideration of the deformations of its links during the motion process. Based on the dynamic model constructed by the Newton-Euler method, all the inertia loads and constraint forces of the links are computed and their deformations are derived. Then the kinematic errors of the machine are derived with the consideration of the deformations of the links. Through further derivation, the accuracy of the machine is given in a simple explicit expression, which will be helpful to increase the calculating speed. The accuracy of this machine when following a selected circle path is simulated. The influences of magnitude of the maximum acceleration and external loads on the running accuracy of the machine are investigated. The results show that the external loads will deteriorate the accuracy of the machine tremendously when their direction coincides with the direction of the worst stiffness of the machine. The proposed method provides a solution for predicting the running accuracy of the parallel kinematic machines and can also be used in their design optimization as well as selection of suitable running parameters.
2014, 28(05).
doi: 10.3901/CJME.2014.0725.127
Abstract:
Direct drive servovalves are mostly restricted to low flow rate and low bandwidth applications due to the considerable flow forces. Current studies mainly focus on enhancing the driving force, which in turn is limited to the development of the magnetic material. Aiming at reducing the flow forces, a novel rotary direct drive servovalve(RDDV) is introduced in this paper. This RDDV servovalve is designed in a rotating structure and its axially symmetric spool rotates within a certain angle range in the valve chamber. The servovalve orifices are formed by the matching between the square wave shaped land on the spool and the rectangular ports on the sleeve. In order to study the RDDV servovalve performance, flow rate model and mechanical model are established, wherein flow rates and flow induced torques at different spool rotation angles or spool radiuses are obtained. The model analysis shows that the driving torque can be alleviated due to the proposed valve structure. Computational fluid dynamics(CFD) analysis using ANSYS/FLUENT is applied to evaluate and validate the theoretical analysis. In addition, experiments on the flow rate and the mechanical characteristic of the RDDV servovalve are carried out. Both simulation and experimental results conform to the results of the theoretical model analysis, which proves that this novel and innovative structure for direct drive servovalves can reduce the flow force on the spool and improve valve frequency response characteristics. This research proposes a novel rotary direct drive servovalve, which can reduce the flow forces effectively.
Direct drive servovalves are mostly restricted to low flow rate and low bandwidth applications due to the considerable flow forces. Current studies mainly focus on enhancing the driving force, which in turn is limited to the development of the magnetic material. Aiming at reducing the flow forces, a novel rotary direct drive servovalve(RDDV) is introduced in this paper. This RDDV servovalve is designed in a rotating structure and its axially symmetric spool rotates within a certain angle range in the valve chamber. The servovalve orifices are formed by the matching between the square wave shaped land on the spool and the rectangular ports on the sleeve. In order to study the RDDV servovalve performance, flow rate model and mechanical model are established, wherein flow rates and flow induced torques at different spool rotation angles or spool radiuses are obtained. The model analysis shows that the driving torque can be alleviated due to the proposed valve structure. Computational fluid dynamics(CFD) analysis using ANSYS/FLUENT is applied to evaluate and validate the theoretical analysis. In addition, experiments on the flow rate and the mechanical characteristic of the RDDV servovalve are carried out. Both simulation and experimental results conform to the results of the theoretical model analysis, which proves that this novel and innovative structure for direct drive servovalves can reduce the flow force on the spool and improve valve frequency response characteristics. This research proposes a novel rotary direct drive servovalve, which can reduce the flow forces effectively.
2014, 28(05).
doi: 10.3901/CJME.2014.0717.119
Abstract:
Linear motors generate high heat and cause significant deformation in high speed direct feed drive mechanisms. It is relevant to estimate their deformation behavior to improve their application in precision machine tools. This paper describes a method to estimate its thermal deformation based on updated finite element(FE) model methods. Firstly, a FE model is established for a linear motor drive test rig that includes the correlation between temperature rise and its resulting deformation. The relationship between the input and output variables of the FE model is identified with a modified multivariate input/output least square support vector regression machine. Additionally, the temperature rise and displacements at some critical points on the mechanism are obtained experimentally by a system of thermocouples and an interferometer. The FE model is updated through intelligent comparison between the experimentally measured values and the results from the regression machine. The experiments for testing thermal behavior along with the updated FE model simulations is conducted on the test rig in reciprocating cycle drive conditions. The results show that the intelligently updated FE model can be implemented to analyze the temperature variation distribution of the mechanism and to estimate its thermal behavior. The accuracy of the thermal behavior estimation with the optimally updated method can be more than double that of the initial theoretical FE model. This paper provides a simulation method that is effective to estimate the thermal behavior of the direct feed drive mechanism with high accuracy.
Linear motors generate high heat and cause significant deformation in high speed direct feed drive mechanisms. It is relevant to estimate their deformation behavior to improve their application in precision machine tools. This paper describes a method to estimate its thermal deformation based on updated finite element(FE) model methods. Firstly, a FE model is established for a linear motor drive test rig that includes the correlation between temperature rise and its resulting deformation. The relationship between the input and output variables of the FE model is identified with a modified multivariate input/output least square support vector regression machine. Additionally, the temperature rise and displacements at some critical points on the mechanism are obtained experimentally by a system of thermocouples and an interferometer. The FE model is updated through intelligent comparison between the experimentally measured values and the results from the regression machine. The experiments for testing thermal behavior along with the updated FE model simulations is conducted on the test rig in reciprocating cycle drive conditions. The results show that the intelligently updated FE model can be implemented to analyze the temperature variation distribution of the mechanism and to estimate its thermal behavior. The accuracy of the thermal behavior estimation with the optimally updated method can be more than double that of the initial theoretical FE model. This paper provides a simulation method that is effective to estimate the thermal behavior of the direct feed drive mechanism with high accuracy.
2014, 28(05).
doi: 10.3901/CJME.2014.0721.121
Abstract:
Longitudinal vibration, torsional vibration and their coupled vibration are the main vibration modes of the crankshaft-sliding bearing system. However, these vibrations of the propeller-crankshaft-sliding bearing system generated by the fluid exciting force on the propeller are much more complex. Currently, the torsional and longitudinal vibrations have been studied separately while the research on their coupled vibration is few, and the influence of the propeller structure to dynamic characteristics of a crankshaft has not been studied yet. In order to describe the dynamic properties of a crankshaft accurately, a nonlinear dynamic model is proposed taking the effect of torsional-longitudinal coupling and the variable inertia of propeller, connecting rod and piston into account. Numerical simulation cases are carried out to calculate the response data of the system in time and frequency domains under the working speed and over-speed, respectively. Results of vibration analysis of the propeller and crankshaft system coupled in torsional and longitudinal direction indicate that the system dynamic behaviors are relatively complicated especially in the components of the frequency response. For example, the 4 times of an exciting frequency acting on the propeller by fluid appears at 130 r/min, while not yield at 105 r/min. While the possible abnormal vibration at over-speed just needs to be vigilant. So when designing the propeller shafting used in marine diesel engines, strength calculation and vibration analysis based only on linear model may cause great errors and the proposed research provides some references to design diesel engine propeller shafting used in large marines.
Longitudinal vibration, torsional vibration and their coupled vibration are the main vibration modes of the crankshaft-sliding bearing system. However, these vibrations of the propeller-crankshaft-sliding bearing system generated by the fluid exciting force on the propeller are much more complex. Currently, the torsional and longitudinal vibrations have been studied separately while the research on their coupled vibration is few, and the influence of the propeller structure to dynamic characteristics of a crankshaft has not been studied yet. In order to describe the dynamic properties of a crankshaft accurately, a nonlinear dynamic model is proposed taking the effect of torsional-longitudinal coupling and the variable inertia of propeller, connecting rod and piston into account. Numerical simulation cases are carried out to calculate the response data of the system in time and frequency domains under the working speed and over-speed, respectively. Results of vibration analysis of the propeller and crankshaft system coupled in torsional and longitudinal direction indicate that the system dynamic behaviors are relatively complicated especially in the components of the frequency response. For example, the 4 times of an exciting frequency acting on the propeller by fluid appears at 130 r/min, while not yield at 105 r/min. While the possible abnormal vibration at over-speed just needs to be vigilant. So when designing the propeller shafting used in marine diesel engines, strength calculation and vibration analysis based only on linear model may cause great errors and the proposed research provides some references to design diesel engine propeller shafting used in large marines.
2014, 28(05).
doi: 10.3901/CJME.2014.0617.112
Abstract:
In piezoceramic ultrasonic devices, the piezoceramic stacks may fail permanently or function improperly if their working temperatures overstep the Curie temperature of the piezoceramic material. While the end of the horn usually serves near the melting point of the molten metal and is enclosed in an airtight chamber, so that it is difficult to experimentally measure the temperature of the transducer and its variation with time, which bring heavy difficulty to the design of the ultrasonic molten metal treatment system. To find a way out, conjugate heat transfer analysis of an ultrasonic molten metal treatment system is performed with coupled fluid and heat transfer finite element method. In modeling of the system, the RNG model and the SIMPLE algorithm are adopted for turbulence and nonlinear coupling between the momentum equation and the energy equation. Forced air cooling as well as natural air cooling is analyzed to compare the difference of temperature evolution. Numerical results show that, after about 350 s of working time, temperatures in the surface of the ceramic stacks in forced air cooling drop about 7 K compared with that in natural cooling. At 240 s, The molten metal surface emits heat radiation with a maximum rate of about 19 036 W/m2, while the heat insulation disc absorbs heat radiation at a maximum rate of about 7922 W/m2, which indicates the effectiveness of heat insulation of the asbestos pad. Transient heat transfer film coefficient and its distribution, which are difficult to be measured experimentally are also obtained through numerical simulation. At 240 s, the heat transfer film coefficient in the surface of the transducer ranges from –17.86 to 20.17 W/(m2 • K). Compared with the trial and error method based on the test, the proposed research provides a more effective way in the design and analysis of the temperature control of the molten metal treatment system.
In piezoceramic ultrasonic devices, the piezoceramic stacks may fail permanently or function improperly if their working temperatures overstep the Curie temperature of the piezoceramic material. While the end of the horn usually serves near the melting point of the molten metal and is enclosed in an airtight chamber, so that it is difficult to experimentally measure the temperature of the transducer and its variation with time, which bring heavy difficulty to the design of the ultrasonic molten metal treatment system. To find a way out, conjugate heat transfer analysis of an ultrasonic molten metal treatment system is performed with coupled fluid and heat transfer finite element method. In modeling of the system, the RNG model and the SIMPLE algorithm are adopted for turbulence and nonlinear coupling between the momentum equation and the energy equation. Forced air cooling as well as natural air cooling is analyzed to compare the difference of temperature evolution. Numerical results show that, after about 350 s of working time, temperatures in the surface of the ceramic stacks in forced air cooling drop about 7 K compared with that in natural cooling. At 240 s, The molten metal surface emits heat radiation with a maximum rate of about 19 036 W/m2, while the heat insulation disc absorbs heat radiation at a maximum rate of about 7922 W/m2, which indicates the effectiveness of heat insulation of the asbestos pad. Transient heat transfer film coefficient and its distribution, which are difficult to be measured experimentally are also obtained through numerical simulation. At 240 s, the heat transfer film coefficient in the surface of the transducer ranges from –17.86 to 20.17 W/(m2 • K). Compared with the trial and error method based on the test, the proposed research provides a more effective way in the design and analysis of the temperature control of the molten metal treatment system.
2014, 28(05).
doi: 10.3901/CJME.2014.0725.128
Abstract:
The identification of maximum road friction coefficient and optimal slip ratio is crucial to vehicle dynamics and control. However, it is always not easy to identify the maximum road friction coefficient with high robustness and good adaptability to various vehicle operating conditions. The existing investigations on robust identification of maximum road friction coefficient are unsatisfactory. In this paper, an identification approach based on road type recognition is proposed for the robust identification of maximum road friction coefficient and optimal slip ratio. The instantaneous road friction coefficient is estimated through the recursive least square with a forgetting factor method based on the single wheel model, and the estimated road friction coefficient and slip ratio are grouped in a set of samples in a small time interval before the current time, which are updated with time progressing. The current road type is recognized by comparing the samples of the estimated road friction coefficient with the standard road friction coefficient of each typical road, and the minimum statistical error is used as the recognition principle to improve identification robustness. Once the road type is recognized, the maximum road friction coefficient and optimal slip ratio are determined. The numerical simulation tests are conducted on two typical road friction conditions(single-friction and joint-friction) by using CarSim software. The test results show that there is little identification error between the identified maximum road friction coefficient and the pre-set value in CarSim. The proposed identification method has good robustness performance to external disturbances and good adaptability to various vehicle operating conditions and road variations, and the identification results can be used for the adjustment of vehicle active safety control strategies.
The identification of maximum road friction coefficient and optimal slip ratio is crucial to vehicle dynamics and control. However, it is always not easy to identify the maximum road friction coefficient with high robustness and good adaptability to various vehicle operating conditions. The existing investigations on robust identification of maximum road friction coefficient are unsatisfactory. In this paper, an identification approach based on road type recognition is proposed for the robust identification of maximum road friction coefficient and optimal slip ratio. The instantaneous road friction coefficient is estimated through the recursive least square with a forgetting factor method based on the single wheel model, and the estimated road friction coefficient and slip ratio are grouped in a set of samples in a small time interval before the current time, which are updated with time progressing. The current road type is recognized by comparing the samples of the estimated road friction coefficient with the standard road friction coefficient of each typical road, and the minimum statistical error is used as the recognition principle to improve identification robustness. Once the road type is recognized, the maximum road friction coefficient and optimal slip ratio are determined. The numerical simulation tests are conducted on two typical road friction conditions(single-friction and joint-friction) by using CarSim software. The test results show that there is little identification error between the identified maximum road friction coefficient and the pre-set value in CarSim. The proposed identification method has good robustness performance to external disturbances and good adaptability to various vehicle operating conditions and road variations, and the identification results can be used for the adjustment of vehicle active safety control strategies.
2014, 28(05).
doi: 10.3901/CJME.2014.0528.103
Abstract:
A root hinge drive assembly is preferred in place of the classical viscous damper in a large solar array system. It has advantages including better deployment control and higher reliability. But the traditional single degree of freedom model should be improved. A multiple degrees of freedom dynamics model is presented for the solar arrays deployment to guide the drive assembly design. The established model includes the functions of the torsion springs, the synchronization mechanism and the lock-up impact. A numerical computation method is proposed to solve the dynamics coupling problem. Then considering the drive torque requirement calculated by the proposed model, a root hinge drive assembly is developed based on the reliability engineering design methods, and dual actuators are used as a redundancy design. Pseudo-efficiency is introduced and the major factors influencing the (pseudo-) efficiency of the gear mechanism designed with high reduction ratio are studied for further test data analysis. A ground prototype deployment test is conducted to verify the capacity of the drive assembly. The test device consists of a large-area solar array system and a root hinge drive assembly. The RHDA development time is about 43 s. The theoretical drive torque is compared with the test values which are obtained according to the current data and the reduction efficiency analysis, and the results show that the presented model and the calibration methods are proper enough.
A root hinge drive assembly is preferred in place of the classical viscous damper in a large solar array system. It has advantages including better deployment control and higher reliability. But the traditional single degree of freedom model should be improved. A multiple degrees of freedom dynamics model is presented for the solar arrays deployment to guide the drive assembly design. The established model includes the functions of the torsion springs, the synchronization mechanism and the lock-up impact. A numerical computation method is proposed to solve the dynamics coupling problem. Then considering the drive torque requirement calculated by the proposed model, a root hinge drive assembly is developed based on the reliability engineering design methods, and dual actuators are used as a redundancy design. Pseudo-efficiency is introduced and the major factors influencing the (pseudo-) efficiency of the gear mechanism designed with high reduction ratio are studied for further test data analysis. A ground prototype deployment test is conducted to verify the capacity of the drive assembly. The test device consists of a large-area solar array system and a root hinge drive assembly. The RHDA development time is about 43 s. The theoretical drive torque is compared with the test values which are obtained according to the current data and the reduction efficiency analysis, and the results show that the presented model and the calibration methods are proper enough.
2014, 28(05).
doi: 10.3901/CJME.2014.0728.129
Abstract:
Durning the design process of hydrostatic rotary worktable, the processing and assembly tolerance, (the offset of worktable and the gap of the oil film’s thickness) is ignored. But it will cause that the real bearing of oil pocket deviates from the initial design value, and then the performance of rotary worktable will be reduced significantly. Up to now, no effort is found toward the research of influence of the processing and assembly tolerance on the performance of the rotary worktable. So the hydrostatic oil film is assumed as the elastomer in this paper, and then the bearing capacity of the oil pocket is studied with and without the mass offset of the worktable by taking an expression between the bearing capacity and the oil film’s thickness of the oil pocket as the deform compatibility equation. The influence of the processing tolerance of the oil sealing belt’s gap on the bearing capacity of the oil pocket is analyzed. In the light of the liquid hydrostatic worktable of Gantry Moving Milling Center using on the scene, the oil pocket’s pressure of the worktable is tested using Rotary Worktable Test System under the circumstance of the mass offset of the worktable and the gap tolerance of the oil sealing belt, and then the equivalent offset of worktable, the average pressure of the oil pocket and the actual thickness of the oil film are analyzed respectively. The test results show that the bearing capacity component of the oil pocket caused by G is consistent, and the component caused by M is relative to the position of the oil pocket. When the oil sealing belt’s gap is larger than the theoretical value, the bearing capacity of the oil pocket is smaller than the others; whereas the bearing capacity of the oil pocket is larger than the others. The maximum and minimum equivalent offsets are 0.256 4 mm and 0.047 5 mm, respectively, and the average oil pocket pressure varies from 0.345 MPa to 0.460 MPa, the maximum and minimum value of the actual oil film thickness are 109.976 m (No. 7 oil pocket) and 93.467 m (No. 10 oil pocket), respectively. The research results can be used to detect the offset of the worktable and the actual thickness of the oil film under processing and assembly tolerance, and provides a basis way for detecting the processing and assembly tolerance of rotary worktable signing reasonably of Gantry Moving Milling Center.
Durning the design process of hydrostatic rotary worktable, the processing and assembly tolerance, (the offset of worktable and the gap of the oil film’s thickness) is ignored. But it will cause that the real bearing of oil pocket deviates from the initial design value, and then the performance of rotary worktable will be reduced significantly. Up to now, no effort is found toward the research of influence of the processing and assembly tolerance on the performance of the rotary worktable. So the hydrostatic oil film is assumed as the elastomer in this paper, and then the bearing capacity of the oil pocket is studied with and without the mass offset of the worktable by taking an expression between the bearing capacity and the oil film’s thickness of the oil pocket as the deform compatibility equation. The influence of the processing tolerance of the oil sealing belt’s gap on the bearing capacity of the oil pocket is analyzed. In the light of the liquid hydrostatic worktable of Gantry Moving Milling Center using on the scene, the oil pocket’s pressure of the worktable is tested using Rotary Worktable Test System under the circumstance of the mass offset of the worktable and the gap tolerance of the oil sealing belt, and then the equivalent offset of worktable, the average pressure of the oil pocket and the actual thickness of the oil film are analyzed respectively. The test results show that the bearing capacity component of the oil pocket caused by G is consistent, and the component caused by M is relative to the position of the oil pocket. When the oil sealing belt’s gap is larger than the theoretical value, the bearing capacity of the oil pocket is smaller than the others; whereas the bearing capacity of the oil pocket is larger than the others. The maximum and minimum equivalent offsets are 0.256 4 mm and 0.047 5 mm, respectively, and the average oil pocket pressure varies from 0.345 MPa to 0.460 MPa, the maximum and minimum value of the actual oil film thickness are 109.976 m (No. 7 oil pocket) and 93.467 m (No. 10 oil pocket), respectively. The research results can be used to detect the offset of the worktable and the actual thickness of the oil film under processing and assembly tolerance, and provides a basis way for detecting the processing and assembly tolerance of rotary worktable signing reasonably of Gantry Moving Milling Center.
2014, 28(05).
doi: 10.3901/CJME.2014.0527.102
Abstract:
The active magnetic bearing(AMB) suspends the rotating shaft and maintains it in levitated position by applying controlled electromagnetic forces on the rotor in radial and axial directions. Although the development of various control methods is rapid, PID control strategy is still the most widely used control strategy in many applications, including AMBs. In order to tune PID controller, a particle swarm optimization(PSO) method is applied. Therefore, a comparative analysis of particle swarm optimization(PSO) algorithms is carried out, where two PSO algorithms, namely (1) PSO with linearly decreasing inertia weight(LDW-PSO), and (2) PSO algorithm with constriction factor approach(CFA-PSO), are independently tested for different PID structures. The computer simulations are carried out with the aim of minimizing the objective function defined as the integral of time multiplied by the absolute value of error(ITAE). In order to validate the performance of the analyzed PSO algorithms, one-axis and two-axis radial rotor/active magnetic bearing systems are examined. The results show that PSO algorithms are effective and easily implemented methods, providing stable convergence and good computational efficiency of different PID structures for the rotor/AMB systems. Moreover, the PSO algorithms prove to be easily used for controller tuning in case of both SISO and MIMO system, which consider the system delay and the interference among the horizontal and vertical rotor axes.
The active magnetic bearing(AMB) suspends the rotating shaft and maintains it in levitated position by applying controlled electromagnetic forces on the rotor in radial and axial directions. Although the development of various control methods is rapid, PID control strategy is still the most widely used control strategy in many applications, including AMBs. In order to tune PID controller, a particle swarm optimization(PSO) method is applied. Therefore, a comparative analysis of particle swarm optimization(PSO) algorithms is carried out, where two PSO algorithms, namely (1) PSO with linearly decreasing inertia weight(LDW-PSO), and (2) PSO algorithm with constriction factor approach(CFA-PSO), are independently tested for different PID structures. The computer simulations are carried out with the aim of minimizing the objective function defined as the integral of time multiplied by the absolute value of error(ITAE). In order to validate the performance of the analyzed PSO algorithms, one-axis and two-axis radial rotor/active magnetic bearing systems are examined. The results show that PSO algorithms are effective and easily implemented methods, providing stable convergence and good computational efficiency of different PID structures for the rotor/AMB systems. Moreover, the PSO algorithms prove to be easily used for controller tuning in case of both SISO and MIMO system, which consider the system delay and the interference among the horizontal and vertical rotor axes.
2014, 28(05).
doi: 10.3901/CJME.2014.0529.106
Abstract:
Multi-way principal component analysis (MPCA) has received considerable attention and been widely used in process monitoring. A traditional MPCA algorithm unfolds multiple batches of historical data into a two-dimensional matrix and cut the matrix along the time axis to form subspaces. However, low efficiency of subspaces and difficult fault isolation are the common disadvantages for the principal component model. This paper presents a new subspace construction method based on kernel density estimation function that can effectively reduce the storage amount of the subspace information. The MPCA model and the knowledge base are built based on the new subspace. Then, fault detection and isolation with the squared prediction error (SPE) statistic and the Hotelling (T2) statistic are also realized in process monitoring. When a fault occurs, fault isolation based on the SPE statistic is achieved by residual contribution analysis of different variables. For fault isolation of subspace based on the T2 statistic, the relationship between the statistic indicator and state variables is constructed, and the constraint conditions are presented to check the validity of fault isolation. Then, to improve the robustness of fault isolation to unexpected disturbances, the statistic method is adopted to set the relation between single subspace and multiple subspaces to increase the corrective rate of fault isolation. Finally fault detection and isolation based on the improved MPCA is used to monitor the automatic shift control system (ASCS) to prove the correctness and effectiveness of the algorithm. The research proposes a new subspace construction method to reduce the required storage capacity and to prove the robustness of the principal component model, and sets the relationship between the state variables and fault detection indicators for fault isolation.
Multi-way principal component analysis (MPCA) has received considerable attention and been widely used in process monitoring. A traditional MPCA algorithm unfolds multiple batches of historical data into a two-dimensional matrix and cut the matrix along the time axis to form subspaces. However, low efficiency of subspaces and difficult fault isolation are the common disadvantages for the principal component model. This paper presents a new subspace construction method based on kernel density estimation function that can effectively reduce the storage amount of the subspace information. The MPCA model and the knowledge base are built based on the new subspace. Then, fault detection and isolation with the squared prediction error (SPE) statistic and the Hotelling (T2) statistic are also realized in process monitoring. When a fault occurs, fault isolation based on the SPE statistic is achieved by residual contribution analysis of different variables. For fault isolation of subspace based on the T2 statistic, the relationship between the statistic indicator and state variables is constructed, and the constraint conditions are presented to check the validity of fault isolation. Then, to improve the robustness of fault isolation to unexpected disturbances, the statistic method is adopted to set the relation between single subspace and multiple subspaces to increase the corrective rate of fault isolation. Finally fault detection and isolation based on the improved MPCA is used to monitor the automatic shift control system (ASCS) to prove the correctness and effectiveness of the algorithm. The research proposes a new subspace construction method to reduce the required storage capacity and to prove the robustness of the principal component model, and sets the relationship between the state variables and fault detection indicators for fault isolation.
2014, 28(05).
doi: 10.3901/CJME.2014.0722.122
Abstract:
It is significant to develop a robot hand with high rigidity by a 6-DOF parallel manipulator(PM). However, the existing 6-DOF PMs include spherical joint which has less capability of pulling force bearing, less rotation range and lower precision under alternately heavy loads. A novel 6-DOF PM with three planar limbs and equipped with three fingers is proposed and its kinematics and statics are analyzed systematically. A 3-dimension simulation mechanism of the proposed manipulator is constructed and its structure characteristics is analyzed. The kinematics formulae for solving the displacement, velocity, acceleration of the platform, the active legs and the fingers are established. The statics formulae are derived for solving the active forces of PM and the finger mechanisms. An analytic example is given for solving the kinematics and statics of proposed manipulator and the analytic solved results are verified by the simulation mechanism. It is proved from the error analysis of analytic solutions and simulation solutions that the derived analytic formulae are correct and provide the theoretical and technical foundations for its manufacturing, control and application.
It is significant to develop a robot hand with high rigidity by a 6-DOF parallel manipulator(PM). However, the existing 6-DOF PMs include spherical joint which has less capability of pulling force bearing, less rotation range and lower precision under alternately heavy loads. A novel 6-DOF PM with three planar limbs and equipped with three fingers is proposed and its kinematics and statics are analyzed systematically. A 3-dimension simulation mechanism of the proposed manipulator is constructed and its structure characteristics is analyzed. The kinematics formulae for solving the displacement, velocity, acceleration of the platform, the active legs and the fingers are established. The statics formulae are derived for solving the active forces of PM and the finger mechanisms. An analytic example is given for solving the kinematics and statics of proposed manipulator and the analytic solved results are verified by the simulation mechanism. It is proved from the error analysis of analytic solutions and simulation solutions that the derived analytic formulae are correct and provide the theoretical and technical foundations for its manufacturing, control and application.
2014, 28(05).
doi: 10.3901/CJME.2014.0616.109
Abstract:
The design work of motional cable in products is vital due to the difficulty in estimating the potential issues in current researches. In this paper, a physics-based modeling and simulation method for the motional cable harness design is presented. The model, based on continuum mechanics, is established by analyzing the force of microelement in equilibrium. During the analysis procedure, three coordinate systems: inertial, Frenet and main-axis coordinate systems are used. By variable substitution and dimensionless processing, the equation set is discretized by differential quadrature method and subsequently becomes an overdetermined nonlinear equation set with boundary conditions solved by Levenberg-Marquardt method. With the profile of motional cable harness obtained from the integral of arithmetic solution, a motion simulation system based on “path” and “profile” as well as the experimental equipments is built. Using the same parameters as input for the simulation and the real cable harness correspondingly, the issue in designing, such as collision, can be easily found by the simulation system. This research obtains a better result which has no potential collisions by redesign, and the proposed method can be used as an accurate and efficient way in motional cable harness design work.
The design work of motional cable in products is vital due to the difficulty in estimating the potential issues in current researches. In this paper, a physics-based modeling and simulation method for the motional cable harness design is presented. The model, based on continuum mechanics, is established by analyzing the force of microelement in equilibrium. During the analysis procedure, three coordinate systems: inertial, Frenet and main-axis coordinate systems are used. By variable substitution and dimensionless processing, the equation set is discretized by differential quadrature method and subsequently becomes an overdetermined nonlinear equation set with boundary conditions solved by Levenberg-Marquardt method. With the profile of motional cable harness obtained from the integral of arithmetic solution, a motion simulation system based on “path” and “profile” as well as the experimental equipments is built. Using the same parameters as input for the simulation and the real cable harness correspondingly, the issue in designing, such as collision, can be easily found by the simulation system. This research obtains a better result which has no potential collisions by redesign, and the proposed method can be used as an accurate and efficient way in motional cable harness design work.
2014, 28(05).
doi: 10.3901/CJME.2014.0619.114
Abstract:
Steering control of a capsule robot in curve environment by magnetic navigation is not yet solved completely. A petal-shaped capsule robot with less steering resistance based on multiple wedge effects is presented, and an optimization method with two processes for determining the orientation of a pre-applied universal magnetic spin vector is proposed. To realize quick and non-contact steering swimming, a fuzzy comprehensive evaluation method for optimizing the steering driving angle is presented based on two evaluation indexes including the average steering speed and the average steering trajectory deviation, achieving the initial optimal orientation of a universal magnetic spin vector. To further reduce robotic magnetic vibration, a main target method for optimizing its final orientation, which is used for fine adjustment, is employed under the constrains of the magnetic moments. Swimming experimental results in curve pipe verified the effectiveness of the optimization method, which can be effectively used to realize non-contact steering swimming of the petal-shaped robot and reduce its vibration.
Steering control of a capsule robot in curve environment by magnetic navigation is not yet solved completely. A petal-shaped capsule robot with less steering resistance based on multiple wedge effects is presented, and an optimization method with two processes for determining the orientation of a pre-applied universal magnetic spin vector is proposed. To realize quick and non-contact steering swimming, a fuzzy comprehensive evaluation method for optimizing the steering driving angle is presented based on two evaluation indexes including the average steering speed and the average steering trajectory deviation, achieving the initial optimal orientation of a universal magnetic spin vector. To further reduce robotic magnetic vibration, a main target method for optimizing its final orientation, which is used for fine adjustment, is employed under the constrains of the magnetic moments. Swimming experimental results in curve pipe verified the effectiveness of the optimization method, which can be effectively used to realize non-contact steering swimming of the petal-shaped robot and reduce its vibration.
2014, 28(05).
doi: 10.3901/CJME.2014.0527.101
Abstract:
The intermittent connection(IC) of the field-bus in networked manufacturing systems is a common but hard troubleshooting network problem, which may result in system level failures or safety issues. However, there is no online IC location identification method available to detect and locate the position of the problem. To tackle this problem, a novel model based online fault location identification method for localized IC problem is proposed. First, the error event patterns are identified and classified according to different node sources in each error frame. Then generalized zero inflated Poisson process(GZIP) model for each node is established by using time stamped error event sequence. Finally, the location of the IC fault is determined by testing whether the parameters of the fitted stochastic model is statistically significant or not using the confident intervals of the estimated parameters. To illustrate the proposed method, case studies are conducted on a 3-node controller area network(CAN) test-bed, in which IC induced faults are imposed on a network drop cable using computer controlled on-off switches. The experimental results show the parameters of the GZIP model for the problematic node are statistically significant(larger than 0), and the patterns of the confident intervals of the estimated parameters are directly linked to the problematic node, which agrees with the experimental setup. The proposed online IC location identification method can successfully identify the location of the drop cable on which IC faults occurs on the CAN network.
The intermittent connection(IC) of the field-bus in networked manufacturing systems is a common but hard troubleshooting network problem, which may result in system level failures or safety issues. However, there is no online IC location identification method available to detect and locate the position of the problem. To tackle this problem, a novel model based online fault location identification method for localized IC problem is proposed. First, the error event patterns are identified and classified according to different node sources in each error frame. Then generalized zero inflated Poisson process(GZIP) model for each node is established by using time stamped error event sequence. Finally, the location of the IC fault is determined by testing whether the parameters of the fitted stochastic model is statistically significant or not using the confident intervals of the estimated parameters. To illustrate the proposed method, case studies are conducted on a 3-node controller area network(CAN) test-bed, in which IC induced faults are imposed on a network drop cable using computer controlled on-off switches. The experimental results show the parameters of the GZIP model for the problematic node are statistically significant(larger than 0), and the patterns of the confident intervals of the estimated parameters are directly linked to the problematic node, which agrees with the experimental setup. The proposed online IC location identification method can successfully identify the location of the drop cable on which IC faults occurs on the CAN network.
2014, 28(05).
doi: 10.3901/CJME.2014.0616.111
Abstract:
Tribological properties of impregnated graphite are greatly influenced by preparation technology and working conditions and it’s highly susceptible to corrosion environmental impacts, but the experimental research about it are few. In this paper, three kinds of impregnated graphite samples are prepared with different degree of graphitization, the tribological properties of these samples in the dry friction environment and in a corrosive environment are analyzed and contrasted. The tribo-test results show that the friction coefficient of samples is reduced and the amount of wear of samples increase when the graphitization degree of samples increases in dry friction condition. While in a corrosive environment (samples are soaked N2O4), the friction coefficient and amount of wear are changed little if the graphitization degree of samples are low. If the degree of graphitization increase, the friction coefficient and amount of wear of samples increase too, the amount of wear is 2 to 3 times as the samples tested in the non-corrosive environment under pv value of 30 MPa • ms. The impregnated graphite, which friction coefficient is stable and graphitization degree is in mid level, such #2, is more appropriate to have a work in the corrosion conditions. In this paper, preparation and tribological properties especially in corrosive environment of the impregnated graphite is studied, the research conclusion can provide an experimental and theoretical basis for the selection and process improvement of graphite materials, and also provide some important design parameters for contact seal works in a corrosive environment.
Tribological properties of impregnated graphite are greatly influenced by preparation technology and working conditions and it’s highly susceptible to corrosion environmental impacts, but the experimental research about it are few. In this paper, three kinds of impregnated graphite samples are prepared with different degree of graphitization, the tribological properties of these samples in the dry friction environment and in a corrosive environment are analyzed and contrasted. The tribo-test results show that the friction coefficient of samples is reduced and the amount of wear of samples increase when the graphitization degree of samples increases in dry friction condition. While in a corrosive environment (samples are soaked N2O4), the friction coefficient and amount of wear are changed little if the graphitization degree of samples are low. If the degree of graphitization increase, the friction coefficient and amount of wear of samples increase too, the amount of wear is 2 to 3 times as the samples tested in the non-corrosive environment under pv value of 30 MPa • ms. The impregnated graphite, which friction coefficient is stable and graphitization degree is in mid level, such #2, is more appropriate to have a work in the corrosion conditions. In this paper, preparation and tribological properties especially in corrosive environment of the impregnated graphite is studied, the research conclusion can provide an experimental and theoretical basis for the selection and process improvement of graphite materials, and also provide some important design parameters for contact seal works in a corrosive environment.
2014, 28(05).
doi: 10.3901/CJME.2014.0616.110
Abstract:
Corner contact in gear pair causes vibration and noise, which has attracted many attentions. However, teeth errors and deformation make it difficulty to determine the point situated at corner contact and study the mechanism of teeth impact friction in the current researches. Based on the mechanism of corner contact, the process of corner contact is divided into two stages of impact and scratch, and the calculation model including gear equivalent error－combined deformation is established along the line of action. According to the distributive law, gear equivalent error is synthesized by base pitch error, normal backlash and tooth profile modification on the line of action. The combined tooth compliance of the first point lying in corner contact before the normal path is inversed along the line of action, on basis of the theory of engagement and the curve of tooth synthetic compliance & load-history. Combined secondarily the equivalent error with the combined deflection, the position standard of the point situated at corner contact is probed. Then the impact positions and forces, from the beginning to the end during corner contact before the normal path, are calculated accurately. Due to the above results, the lash model during corner contact is founded, and the impact force and frictional coefficient are quantified. A numerical example is performed and the averaged impact friction coefficient based on the presented calculation method is validated. This research obtains the results which could be referenced to understand the complex mechanism of teeth impact friction and quantitative calculation of the friction force and coefficient, and to gear exact design for tribology.
Corner contact in gear pair causes vibration and noise, which has attracted many attentions. However, teeth errors and deformation make it difficulty to determine the point situated at corner contact and study the mechanism of teeth impact friction in the current researches. Based on the mechanism of corner contact, the process of corner contact is divided into two stages of impact and scratch, and the calculation model including gear equivalent error－combined deformation is established along the line of action. According to the distributive law, gear equivalent error is synthesized by base pitch error, normal backlash and tooth profile modification on the line of action. The combined tooth compliance of the first point lying in corner contact before the normal path is inversed along the line of action, on basis of the theory of engagement and the curve of tooth synthetic compliance & load-history. Combined secondarily the equivalent error with the combined deflection, the position standard of the point situated at corner contact is probed. Then the impact positions and forces, from the beginning to the end during corner contact before the normal path, are calculated accurately. Due to the above results, the lash model during corner contact is founded, and the impact force and frictional coefficient are quantified. A numerical example is performed and the averaged impact friction coefficient based on the presented calculation method is validated. This research obtains the results which could be referenced to understand the complex mechanism of teeth impact friction and quantitative calculation of the friction force and coefficient, and to gear exact design for tribology.
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