2015 Vol.28(01)
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2015, 29(01).
doi: 10.3901/CJME.2014.1110.165
Abstract:
The current researches of wheel vibration and sound radiation mainly focus on the low noise damped wheel. Compared with the traditional research, the relationship between the sound and wheel/rail contact is difficulty and worth studying. However, there are few studies on the effect of wheel load on wheel vibration and sound radiation. In this paper, laboratory test carried out in a semi-anechoic room investigates the effect of wheel load on wheel natural frequencies, damping ratios, wheel vibration and its sound radiation. The laboratory test results show that the vibration of the wheel and total sound radiation decrease significantly with the increase of the wheel load from 0 t to 1 t. The sound energy level of the wheel decreases by 3.7 dB. When the wheel load exceeds 1 t, the attenuation trend of the vibration and sound radiation of the wheel becomes slow. And the increase of the wheel load causes the growth of the wheel natural frequencies and the mode damping ratios. Based on the finite element method (FEM) and boundary element method (BEM), a rolling noise prediction model is developed to calculate the influence of wheel load on the wheel vibration and sound radiation. In the calculation, the used wheel/rail excitation is the measured wheel/rail roughness. The calculated results show that the sound power level of the wheel decreases by about 0.4 dB when the wheel load increases by 0.5 t. The sound radiation of the wheel decreases slowly with wheel load increase, and this conclusion is verified by the field test. This research systematically studies the effect of wheel load on wheel vibration and sound radiation, gives the relationship between the sound and wheel/rail contact and analyzes the reasons, therefore, it provides a reference for further research.
The current researches of wheel vibration and sound radiation mainly focus on the low noise damped wheel. Compared with the traditional research, the relationship between the sound and wheel/rail contact is difficulty and worth studying. However, there are few studies on the effect of wheel load on wheel vibration and sound radiation. In this paper, laboratory test carried out in a semi-anechoic room investigates the effect of wheel load on wheel natural frequencies, damping ratios, wheel vibration and its sound radiation. The laboratory test results show that the vibration of the wheel and total sound radiation decrease significantly with the increase of the wheel load from 0 t to 1 t. The sound energy level of the wheel decreases by 3.7 dB. When the wheel load exceeds 1 t, the attenuation trend of the vibration and sound radiation of the wheel becomes slow. And the increase of the wheel load causes the growth of the wheel natural frequencies and the mode damping ratios. Based on the finite element method (FEM) and boundary element method (BEM), a rolling noise prediction model is developed to calculate the influence of wheel load on the wheel vibration and sound radiation. In the calculation, the used wheel/rail excitation is the measured wheel/rail roughness. The calculated results show that the sound power level of the wheel decreases by about 0.4 dB when the wheel load increases by 0.5 t. The sound radiation of the wheel decreases slowly with wheel load increase, and this conclusion is verified by the field test. This research systematically studies the effect of wheel load on wheel vibration and sound radiation, gives the relationship between the sound and wheel/rail contact and analyzes the reasons, therefore, it provides a reference for further research.
2015, 29(01).
doi: 10.3901/CJME.2014.1031.162
Abstract:
The machine tool equipped with the dual-drive servo feed system could realize high feed speed as well as sharp precision. Currently, there is no report about the thermal behaviors of the dual-drive machine, and the current research of the thermal characteristics of machines mainly focuses on steady simulation. To explore the influence of thermal characterizations on the precision of a jib boring machine assembled dual-drive feed system, the thermal equilibrium tests and the research on thermal-mechanical transient behaviors are carried out. A laser interferometer, infrared thermography and a temperature-displacement acquisition system are applied to measure the temperature distribution and thermal deformation at different feed speeds. Subsequently, the finite element method (FEM) is used to analyze the transient thermal behaviors of the boring machine. The complex boundary conditions, such as heat sources and convective heat transfer coefficient, are calculated. Finally, transient variances in temperatures and deformations are compared with the measured values, and the errors between the measurement and the simulation of the temperature and the thermal error are 2 ℃ and 2.5 μm, respectively. The researching results demonstrate that the FEM model can predict the thermal error and temperature distribution very well under specified operating condition. Moreover, the uneven temperature gradient is due to the asynchronous dual-drive structure that results in thermal deformation. Additionally, the positioning accuracy decreases as the measured point became further away from the motor, and the thermal error and equilibrium period both increase with feed speeds. The research proposes a systematical method to measure and simulate the boring machine transient thermal behaviors.
The machine tool equipped with the dual-drive servo feed system could realize high feed speed as well as sharp precision. Currently, there is no report about the thermal behaviors of the dual-drive machine, and the current research of the thermal characteristics of machines mainly focuses on steady simulation. To explore the influence of thermal characterizations on the precision of a jib boring machine assembled dual-drive feed system, the thermal equilibrium tests and the research on thermal-mechanical transient behaviors are carried out. A laser interferometer, infrared thermography and a temperature-displacement acquisition system are applied to measure the temperature distribution and thermal deformation at different feed speeds. Subsequently, the finite element method (FEM) is used to analyze the transient thermal behaviors of the boring machine. The complex boundary conditions, such as heat sources and convective heat transfer coefficient, are calculated. Finally, transient variances in temperatures and deformations are compared with the measured values, and the errors between the measurement and the simulation of the temperature and the thermal error are 2 ℃ and 2.5 μm, respectively. The researching results demonstrate that the FEM model can predict the thermal error and temperature distribution very well under specified operating condition. Moreover, the uneven temperature gradient is due to the asynchronous dual-drive structure that results in thermal deformation. Additionally, the positioning accuracy decreases as the measured point became further away from the motor, and the thermal error and equilibrium period both increase with feed speeds. The research proposes a systematical method to measure and simulate the boring machine transient thermal behaviors.
2015, 29(01).
doi: 10.3901/CJME.2014.1120.171
Abstract:
Low weight and good toughness thin plate parts are widely used in modern industry, but its flexibility seriously impacts the machinability. Plenty of studies focus on the influence of machine tool and cutting tool on the machining errors. However, few researches focus on compensating machining errors through the fixture. In order to improve the machining accuracy of thin plate-shape part in face milling, this paper presents a novel method for compensating the surface errors by prebending the workpiece during the milling process. First, a machining error prediction model using finite element method is formulated, which simplifies the contacts between the workpiece and fixture with spring constraints. Milling forces calculated by the micro-unit cutting force model are loaded on the error prediction model to predict the machining error. The error prediction results are substituted into the given formulas to obtain the prebending clamping forces and clamping positions. Consequently, the workpiece is prebent in terms of the calculated clamping forces and positions during the face milling operation to reduce the machining error. Finally, simulation and experimental tests are carried out to validate the correctness and efficiency of the proposed error compensation method. The experimental measured flatness results show that the flatness improves by approximately 30 percent through this error compensation method. The proposed method not only predicts the machining errors in face milling thin plate-shape parts but also reduces the machining errors by taking full advantage of the workpiece prebending caused by fixture, meanwhile, it provides a novel idea and theoretical basis for reducing milling errors and improving the milling accuracy.
Low weight and good toughness thin plate parts are widely used in modern industry, but its flexibility seriously impacts the machinability. Plenty of studies focus on the influence of machine tool and cutting tool on the machining errors. However, few researches focus on compensating machining errors through the fixture. In order to improve the machining accuracy of thin plate-shape part in face milling, this paper presents a novel method for compensating the surface errors by prebending the workpiece during the milling process. First, a machining error prediction model using finite element method is formulated, which simplifies the contacts between the workpiece and fixture with spring constraints. Milling forces calculated by the micro-unit cutting force model are loaded on the error prediction model to predict the machining error. The error prediction results are substituted into the given formulas to obtain the prebending clamping forces and clamping positions. Consequently, the workpiece is prebent in terms of the calculated clamping forces and positions during the face milling operation to reduce the machining error. Finally, simulation and experimental tests are carried out to validate the correctness and efficiency of the proposed error compensation method. The experimental measured flatness results show that the flatness improves by approximately 30 percent through this error compensation method. The proposed method not only predicts the machining errors in face milling thin plate-shape parts but also reduces the machining errors by taking full advantage of the workpiece prebending caused by fixture, meanwhile, it provides a novel idea and theoretical basis for reducing milling errors and improving the milling accuracy.
2015, 29(01).
doi: 10.3901/CJME.2014.0825.140
Abstract:
The service condition determines the Rolling Contact Fatigue(RCF) failure mechanism and lifetime under ascertain material structure integrity parameter of thermal spray coating. The available literature on the RCF testing of thermal spray coatings under various condition services is considerable; it is generally difficult to synthesize all of the result to obtain a comprehensive understanding of the parameters which has a great effect on a thermal spray coating’s resistance of RCF. The effects of service conditions(lubrication states, contact stresses, revolve speed, and slip ratio) on the changing of thermal spray coatings’ contact fatigue lifetime is introduced systematically. The effects of different service condition on RCF failure mechanism of thermal spray coating from the change of material structure integrity are also summarized. Moreover, In order to enhance the RCF performance, the parameter optimal design formula of service condition and material structure integrity is proposed based on the effect of service condition on thermal spray coatings’ contact fatigue lifetime and RCF failure mechanism. The shortage of available literature and the forecast focus in future researches are discussed based on available research. The explicit result of RCF lifetime law and parameter optimal design formula in term of lubrication states, contact stresses, revolve speed, and slip ratio, is significant to improve the RCF performance on the engineering application.
The service condition determines the Rolling Contact Fatigue(RCF) failure mechanism and lifetime under ascertain material structure integrity parameter of thermal spray coating. The available literature on the RCF testing of thermal spray coatings under various condition services is considerable; it is generally difficult to synthesize all of the result to obtain a comprehensive understanding of the parameters which has a great effect on a thermal spray coating’s resistance of RCF. The effects of service conditions(lubrication states, contact stresses, revolve speed, and slip ratio) on the changing of thermal spray coatings’ contact fatigue lifetime is introduced systematically. The effects of different service condition on RCF failure mechanism of thermal spray coating from the change of material structure integrity are also summarized. Moreover, In order to enhance the RCF performance, the parameter optimal design formula of service condition and material structure integrity is proposed based on the effect of service condition on thermal spray coatings’ contact fatigue lifetime and RCF failure mechanism. The shortage of available literature and the forecast focus in future researches are discussed based on available research. The explicit result of RCF lifetime law and parameter optimal design formula in term of lubrication states, contact stresses, revolve speed, and slip ratio, is significant to improve the RCF performance on the engineering application.
2015, 29(01).
doi: 10.3901/CJME.2014.0918.152
Abstract:
The vehicle semi-active suspension with magneto-rheological damper(MRD) has been a hot topic since this decade, in which the robust control synthesis considering load variation is a challenging task. In this paper, a new semi-active controller based upon the inverse model and sliding mode control (SMC) strategies is proposed for the quarter-vehicle suspension with the magneto-rheological (MR) damper, wherein an ideal skyhook suspension is employed as the control reference model and the vehicle sprung mass is considered as an uncertain parameter. According to the asymptotical stability of SMC, the dynamic errors between the plant and reference systems are used to derive the control damping force acquired by the MR quarter-vehicle suspension system. The proposed modified Bouc-wen hysteretic force-velocity (F-v) model and its inverse model of MR damper, as well as the proposed continuous modulation (CM) filtering algorithm without phase shift are employed to convert the control damping force into the direct drive current of the MR damper. Moreover, the proposed semi-active sliding mode controller (SSMC)-based MR quarter-vehicle suspension is systematically evaluated through comparing the time and frequency domain responses of the sprung and unsprung mass displacement accelerations, suspension travel and the tire dynamic force with those of the passive quarter-vehicle suspension, under three kinds of varied amplitude harmonic, rounded pulse and real-road measured random excitations. The evaluation results illustrate that the proposed SSMC can greatly suppress the vehicle suspension vibration due to uncertainty of the load, and thus improve the ride comfort and handling safety. The study establishes a solid theoretical foundation as the universal control scheme for the adaptive semi-active control of the MR full-vehicle suspension decoupled into four MR quarter-vehicle sub-suspension systems.
The vehicle semi-active suspension with magneto-rheological damper(MRD) has been a hot topic since this decade, in which the robust control synthesis considering load variation is a challenging task. In this paper, a new semi-active controller based upon the inverse model and sliding mode control (SMC) strategies is proposed for the quarter-vehicle suspension with the magneto-rheological (MR) damper, wherein an ideal skyhook suspension is employed as the control reference model and the vehicle sprung mass is considered as an uncertain parameter. According to the asymptotical stability of SMC, the dynamic errors between the plant and reference systems are used to derive the control damping force acquired by the MR quarter-vehicle suspension system. The proposed modified Bouc-wen hysteretic force-velocity (F-v) model and its inverse model of MR damper, as well as the proposed continuous modulation (CM) filtering algorithm without phase shift are employed to convert the control damping force into the direct drive current of the MR damper. Moreover, the proposed semi-active sliding mode controller (SSMC)-based MR quarter-vehicle suspension is systematically evaluated through comparing the time and frequency domain responses of the sprung and unsprung mass displacement accelerations, suspension travel and the tire dynamic force with those of the passive quarter-vehicle suspension, under three kinds of varied amplitude harmonic, rounded pulse and real-road measured random excitations. The evaluation results illustrate that the proposed SSMC can greatly suppress the vehicle suspension vibration due to uncertainty of the load, and thus improve the ride comfort and handling safety. The study establishes a solid theoretical foundation as the universal control scheme for the adaptive semi-active control of the MR full-vehicle suspension decoupled into four MR quarter-vehicle sub-suspension systems.
2015, 29(01).
doi: 10.3901/CJME.2014.0620.116
Abstract:
High chromium cast iron(HCCI) is taken as material of coal water slurry pump impeller, but it is susceptible to produce serious abrasive wear and erosion wear because of souring of hard coal particles. The research on optimization of heat treatments to improve abrasive wear properties of HCCI is insufficient, so effect of heat treatments on the microstructure, hardness, toughness, and wear resistance of Cr26 HCCI is investigated to determine the optimal heat treatment process for HCCI. A series of heat treatments are employed. The microstructures of HCCI specimens are examined by using optical microscopy and scanning electron microscopy. The hardness and impact fracture toughness of as-cast and heat treated specimens are measured. The wear tests are assessed by a Type M200 ring-on block wear tester. The results show the following: With increase of the quenching temperature from 950 ℃ to 1050 ℃, the hardness of Cr26 HCCI increased to a certain value, kept for a time and then decreased. The optimal heat treatment process is 2 h quenching treatment at 1000 ℃, followed by a subsequent 2 h tempering at 400 ℃. The hardness of HCCI is related to the precipitation and redissolution of secondary carbides in the process of heat treatment. The subsequent tempering treatment would result in a slight decrease of hardness but increase of toughness. The wear resistance is much related to the “supporting” effect of the matrix and the “protective” effect of the hard carbide embedded in the matrix, and the wear resistance is further dependent on the hardness and the toughness of the matrix. This research can provide an important insight on developing an optimized heat treatment method to improve the wear resistance of HCCI.
High chromium cast iron(HCCI) is taken as material of coal water slurry pump impeller, but it is susceptible to produce serious abrasive wear and erosion wear because of souring of hard coal particles. The research on optimization of heat treatments to improve abrasive wear properties of HCCI is insufficient, so effect of heat treatments on the microstructure, hardness, toughness, and wear resistance of Cr26 HCCI is investigated to determine the optimal heat treatment process for HCCI. A series of heat treatments are employed. The microstructures of HCCI specimens are examined by using optical microscopy and scanning electron microscopy. The hardness and impact fracture toughness of as-cast and heat treated specimens are measured. The wear tests are assessed by a Type M200 ring-on block wear tester. The results show the following: With increase of the quenching temperature from 950 ℃ to 1050 ℃, the hardness of Cr26 HCCI increased to a certain value, kept for a time and then decreased. The optimal heat treatment process is 2 h quenching treatment at 1000 ℃, followed by a subsequent 2 h tempering at 400 ℃. The hardness of HCCI is related to the precipitation and redissolution of secondary carbides in the process of heat treatment. The subsequent tempering treatment would result in a slight decrease of hardness but increase of toughness. The wear resistance is much related to the “supporting” effect of the matrix and the “protective” effect of the hard carbide embedded in the matrix, and the wear resistance is further dependent on the hardness and the toughness of the matrix. This research can provide an important insight on developing an optimized heat treatment method to improve the wear resistance of HCCI.
2015, 29(01).
doi: 10.3901/CJME.2014.0723.123
Abstract:
The dynamic behavior of the stranded wire helical spring is described by a modified Bouc-Wen model while the model parameters must be identified using an identification method and experimental data. Existing identification methods usually relies either solely nonlinear iterative algorithms or manually trial and error. Therefore, the identification process can be rather time consuming and effort taking. As a result, these methods are not ideal for engineering applications. To come up with a more practical method, a three-stage identification method is proposed. Periodic loading and identification simulations are carried out to verify the effectiveness of the proposed method. Noises are added to the simulated data to test the performance of the proposed method when dealing with noise contaminated data. The simulation results indicate that the proposed method is able to give satisfying results when the noise levels are set to be 0.01, 0.03, 0.05 and 0.07. In addition, the proposed method is also applied to experimental data and compared with an existing method. The experimental data is acquired through a periodic loading test. The experiment results suggest that the proposed method features better accuracy compared with the existing method. An effective approach is proposed for identifying the model parameters of the stranded wire helical spring.
The dynamic behavior of the stranded wire helical spring is described by a modified Bouc-Wen model while the model parameters must be identified using an identification method and experimental data. Existing identification methods usually relies either solely nonlinear iterative algorithms or manually trial and error. Therefore, the identification process can be rather time consuming and effort taking. As a result, these methods are not ideal for engineering applications. To come up with a more practical method, a three-stage identification method is proposed. Periodic loading and identification simulations are carried out to verify the effectiveness of the proposed method. Noises are added to the simulated data to test the performance of the proposed method when dealing with noise contaminated data. The simulation results indicate that the proposed method is able to give satisfying results when the noise levels are set to be 0.01, 0.03, 0.05 and 0.07. In addition, the proposed method is also applied to experimental data and compared with an existing method. The experimental data is acquired through a periodic loading test. The experiment results suggest that the proposed method features better accuracy compared with the existing method. An effective approach is proposed for identifying the model parameters of the stranded wire helical spring.
2015, 29(01).
doi: 10.3901/CJME.2014.1021.159
Abstract:
Current research on pump-turbine units is focused on the unstable operation at off-design conditions, with the characteristic curves in generating mode being S-shaped. Unlike in the traditional water turbines, pump-turbine operation along the S-shaped curve can lead to difficulties during load rejection with unusual increases in the water pressure, which leads to machine vibrations. This paper describes both model tests and numerical simulations. A reduced scale model of a low specific speed pump-turbine was used for the performance tests, with comparisons to computational fluid dynamics(CFD) results. Predictions using the detached eddy simulation(DES) turbulence model, which is a combined Reynolds averaged Naviers-Stokes(RANS) and large eddy simulation(LES) model, are compared with the two-equation turbulence mode results. The external characteristics as well as the internal flow are for various guide vane openings to understand the unsteady flow along the so called S characteristics of a pump-turbine. Comparison of the experimental data with the CFD results for various conditions and times shows that DES model gives better agreement with experimental data than the two-equation turbulence model. For low flow conditions, the centrifugal forces and the large incident angle create large vortices between the guide vanes and the runner inlet in the runner passage, which is the main factor leading to the S-shaped characteristics. The turbulence model used here gives more accurate simulations of the internal flow characteristics of the pump-turbine and a more detailed force analysis which shows the mechanisms controlling of the S characteristics.
Current research on pump-turbine units is focused on the unstable operation at off-design conditions, with the characteristic curves in generating mode being S-shaped. Unlike in the traditional water turbines, pump-turbine operation along the S-shaped curve can lead to difficulties during load rejection with unusual increases in the water pressure, which leads to machine vibrations. This paper describes both model tests and numerical simulations. A reduced scale model of a low specific speed pump-turbine was used for the performance tests, with comparisons to computational fluid dynamics(CFD) results. Predictions using the detached eddy simulation(DES) turbulence model, which is a combined Reynolds averaged Naviers-Stokes(RANS) and large eddy simulation(LES) model, are compared with the two-equation turbulence mode results. The external characteristics as well as the internal flow are for various guide vane openings to understand the unsteady flow along the so called S characteristics of a pump-turbine. Comparison of the experimental data with the CFD results for various conditions and times shows that DES model gives better agreement with experimental data than the two-equation turbulence model. For low flow conditions, the centrifugal forces and the large incident angle create large vortices between the guide vanes and the runner inlet in the runner passage, which is the main factor leading to the S-shaped characteristics. The turbulence model used here gives more accurate simulations of the internal flow characteristics of the pump-turbine and a more detailed force analysis which shows the mechanisms controlling of the S characteristics.
2015, 29(01).
doi: 10.3901/CJME.2014.1118.170
Abstract:
The instability of the rotor dynamic system supported by oil journal bearing is encountered frequently, such as the half-speed whirl of the rotor, which is caused by oil film lubricant with nonlinearity. Currently, more attention is paid to the physical characteristics of oil film due to an oil-lubricated journal bearing being the important supporting component of the bearing-rotor systems and its nonlinear nature. In order to analyze the lubrication characteristics of journal bearings efficiently and save computational efforts, an approximate solution of nonlinear oil film forces of a finite length turbulent journal bearing with couple stress flow is proposed based on Sommerfeld and Ocvirk numbers. Reynolds equation in lubrication of a finite length turbulent journal bearing is solved based on multi-parametric principle. Load-carrying capacity of nonlinear oil film is obtained, and the results obtained by different methods are compared. The validation of the proposed method is verified, meanwhile, the relationships of load-carrying capacity versus eccentricity ratio and width-to-diameter ratio under turbulent and couple stress working conditions are analyzed. The numerical results show that both couple stress flow and eccentricity ratio have obvious influence on oil film pressure distribution, and the proposed method approximates the load-carrying capacity of turbulent journal bearings efficiently with various width-to-diameter ratios. This research proposes an approximate solution of oil film load-carrying capacity of turbulent journal bearings with different width-to-diameter ratios, which are suitable for high eccentricity ratios and heavy loads.
The instability of the rotor dynamic system supported by oil journal bearing is encountered frequently, such as the half-speed whirl of the rotor, which is caused by oil film lubricant with nonlinearity. Currently, more attention is paid to the physical characteristics of oil film due to an oil-lubricated journal bearing being the important supporting component of the bearing-rotor systems and its nonlinear nature. In order to analyze the lubrication characteristics of journal bearings efficiently and save computational efforts, an approximate solution of nonlinear oil film forces of a finite length turbulent journal bearing with couple stress flow is proposed based on Sommerfeld and Ocvirk numbers. Reynolds equation in lubrication of a finite length turbulent journal bearing is solved based on multi-parametric principle. Load-carrying capacity of nonlinear oil film is obtained, and the results obtained by different methods are compared. The validation of the proposed method is verified, meanwhile, the relationships of load-carrying capacity versus eccentricity ratio and width-to-diameter ratio under turbulent and couple stress working conditions are analyzed. The numerical results show that both couple stress flow and eccentricity ratio have obvious influence on oil film pressure distribution, and the proposed method approximates the load-carrying capacity of turbulent journal bearings efficiently with various width-to-diameter ratios. This research proposes an approximate solution of oil film load-carrying capacity of turbulent journal bearings with different width-to-diameter ratios, which are suitable for high eccentricity ratios and heavy loads.
2015, 29(01).
doi: 10.3901/CJME.2014.0929.155
Abstract:
Optimum design is a key approach to make full use of potential advantages of a parallel manipulator. The optimum design of multi-parameter parallel manipulators(more than three design parameters), such as Stewart manipulator, relies on analysis based and algorithm based optimum design methods, which fall to be accurate or intuitive. To solve this problem and achieve both accurate and intuition, atlas based optimum design of a general Stewart parallel manipulator is established, with rational selection of design parameters. Based on the defined spherical usable workspace(SUW), primary kinematic performance indices of the Stewart manipulator, involving workspace and condition number are introduced and analyzed. Then, corresponding performance atlases are drawn with the established non-dimensional design space, and impact of joint distribution angles on the manipulator performance is analyzed and illustrated. At last, an example on atlas based optimum design of the Stewart manipulator is accomplished to illustrate the optimum design process, considering the end-effector posture. Deduced atlases can be flexibly applied to both quantitative and qualitative analysis to get the desired optimal design for the Stewart manipulator with respect to related performance requirements. Besides, the established optimum design method can be further applied to other multi-parameter parallel manipulators.
Optimum design is a key approach to make full use of potential advantages of a parallel manipulator. The optimum design of multi-parameter parallel manipulators(more than three design parameters), such as Stewart manipulator, relies on analysis based and algorithm based optimum design methods, which fall to be accurate or intuitive. To solve this problem and achieve both accurate and intuition, atlas based optimum design of a general Stewart parallel manipulator is established, with rational selection of design parameters. Based on the defined spherical usable workspace(SUW), primary kinematic performance indices of the Stewart manipulator, involving workspace and condition number are introduced and analyzed. Then, corresponding performance atlases are drawn with the established non-dimensional design space, and impact of joint distribution angles on the manipulator performance is analyzed and illustrated. At last, an example on atlas based optimum design of the Stewart manipulator is accomplished to illustrate the optimum design process, considering the end-effector posture. Deduced atlases can be flexibly applied to both quantitative and qualitative analysis to get the desired optimal design for the Stewart manipulator with respect to related performance requirements. Besides, the established optimum design method can be further applied to other multi-parameter parallel manipulators.
2015, 29(01).
doi: 10.3901/CJME.2014.0909.147
Abstract:
Chain drive system is widely used in the conditions of high-speed, overload, variable speed and load. Many studies are focused on the meshing theory and wear characteristics of chain drive system, but system design, analysis, and noise characteristics of the chain drive system are weak. System design and noise characteristic are studied for a new type Gemini chain of dual-clutch automatic transmission. Based on the meshing theory of silent chain, the design parameters of the Gemini chain system are calculated and the mathematical models and dynamic analysis models of the Gemini chain system are established. Dynamic characteristics of the Gemini chain system is simulated and the contact force of plate and pin, plate and sprockets, the chain tension forces, the transmission error and the stress of plates and pins are analyzed. According to the simulation results of the Gemini chain system, the noise experiment about system is carried out. The noise values are tested at different speed and load and spectral characteristics are analyzed. The results of simulation and experimental show that the contact forces of plate and pin, plate and sprockets are smaller than the allowable stress values, the chain tension force is less than ultimate tension and transmission error is limited in 1.2%. The noise values can meet the requirements of industrial design, and it is proved that the design and analysis method of the Gemini chain system is scientific and feasible. The design and test system is built from analysis to test of Gemini chain system. This research presented will provide a corresponding theoretical guidance for the design and dynamic characteristics and noise characteristics of chain drive system.
Chain drive system is widely used in the conditions of high-speed, overload, variable speed and load. Many studies are focused on the meshing theory and wear characteristics of chain drive system, but system design, analysis, and noise characteristics of the chain drive system are weak. System design and noise characteristic are studied for a new type Gemini chain of dual-clutch automatic transmission. Based on the meshing theory of silent chain, the design parameters of the Gemini chain system are calculated and the mathematical models and dynamic analysis models of the Gemini chain system are established. Dynamic characteristics of the Gemini chain system is simulated and the contact force of plate and pin, plate and sprockets, the chain tension forces, the transmission error and the stress of plates and pins are analyzed. According to the simulation results of the Gemini chain system, the noise experiment about system is carried out. The noise values are tested at different speed and load and spectral characteristics are analyzed. The results of simulation and experimental show that the contact forces of plate and pin, plate and sprockets are smaller than the allowable stress values, the chain tension force is less than ultimate tension and transmission error is limited in 1.2%. The noise values can meet the requirements of industrial design, and it is proved that the design and analysis method of the Gemini chain system is scientific and feasible. The design and test system is built from analysis to test of Gemini chain system. This research presented will provide a corresponding theoretical guidance for the design and dynamic characteristics and noise characteristics of chain drive system.
2015, 29(01).
doi: 10.3901/CJME.2014.1107.164
Abstract:
The current research of complex nonlinear system robust optimization mainly focuses on the features of design parameters, such as probability density functions, boundary conditions, etc. After parameters study, high-dimensional curve or robust control design is used to find an accurate robust solution. However, there may exist complex interaction between parameters and practical engineering system. With the increase of the number of parameters, it is getting hard to determine high-dimensional curves and robust control methods, thus it’s difficult to get the robust design solutions. In this paper, a method of global sensitivity analysis based on divided variables in groups is proposed. By making relevant variables in one group and keeping each other independent among sets of variables, global sensitivity analysis is conducted in grouped variables and the importance of parameters is evaluated by calculating the contribution value of each parameter to the total variance of system response. By ranking the importance of input parameters, relatively important parameters are chosen to conduct robust design analysis of the system. By applying this method to the robust optimization design of a real complex nonlinear system-a vehicle occupant restraint system with multi-parameter, good solution is gained and the response variance of the objective function is reduced to 0.01, which indicates that the robustness of the occupant restraint system is improved in a great degree and the method is effective and valuable for the robust design of complex nonlinear system. This research proposes a new method which can be used to obtain solutions for complex nonlinear system robust design.
The current research of complex nonlinear system robust optimization mainly focuses on the features of design parameters, such as probability density functions, boundary conditions, etc. After parameters study, high-dimensional curve or robust control design is used to find an accurate robust solution. However, there may exist complex interaction between parameters and practical engineering system. With the increase of the number of parameters, it is getting hard to determine high-dimensional curves and robust control methods, thus it’s difficult to get the robust design solutions. In this paper, a method of global sensitivity analysis based on divided variables in groups is proposed. By making relevant variables in one group and keeping each other independent among sets of variables, global sensitivity analysis is conducted in grouped variables and the importance of parameters is evaluated by calculating the contribution value of each parameter to the total variance of system response. By ranking the importance of input parameters, relatively important parameters are chosen to conduct robust design analysis of the system. By applying this method to the robust optimization design of a real complex nonlinear system-a vehicle occupant restraint system with multi-parameter, good solution is gained and the response variance of the objective function is reduced to 0.01, which indicates that the robustness of the occupant restraint system is improved in a great degree and the method is effective and valuable for the robust design of complex nonlinear system. This research proposes a new method which can be used to obtain solutions for complex nonlinear system robust design.
2015, 29(01).
doi: 10.3901/CJME.2014.1114.168
Abstract:
Chemical vapor deposition (CVD) diamond films have attracted more attentions due to their excellent mechanical properties. Whereas as-fabricated traditional diamond films in the previous studies don’t have enough adhesion or surface smoothness, which seriously impact their friction and wear performance, and thus limit their applications under extremely harsh conditions. A boron doped, undoped microcrystalline and fine grained composite diamond (BD-UM-FGCD) film is fabricated by a three-step method adopting hot filament CVD (HFCVD) method in the present study, presenting outstanding comprehensive performance, including the good adhesion between the substrate and the underlying boron doped diamond (BDD) layer, the extremely high hardness of the middle undoped microcrystalline diamond (UMCD) layer, as well as the low surface roughness and favorable polished convenience of the surface fine grained diamond (FGD) layer. The friction and wear behavior of this composite film sliding against low-carbon steel and silicon nitride balls are studied on a ball-on-plate rotational friction tester. Besides, its wear rate is further evaluated under a severer condition using an inner-hole polishing apparatus, with low-carbon steel wire as the counterpart. The test results show that the BD-UM-FGCD film performs very small friction coefficient and great friction behavior owing to its high surface smoothness, and meanwhile it also has excellent wear resistance because of the relatively high hardness of the surface FGD film and the extremely high hardness of the middle UMCD film. Moreover, under the industrial conditions for producing low-carbon steel wires, this composite film can sufficiently prolong the working lifetime of the drawing dies and improve their application effects. This research develops a novel composite diamond films owning great comprehensive properties, which have great potentials as protecting coatings on working surfaces of the wear-resistant and anti-frictional components.
Chemical vapor deposition (CVD) diamond films have attracted more attentions due to their excellent mechanical properties. Whereas as-fabricated traditional diamond films in the previous studies don’t have enough adhesion or surface smoothness, which seriously impact their friction and wear performance, and thus limit their applications under extremely harsh conditions. A boron doped, undoped microcrystalline and fine grained composite diamond (BD-UM-FGCD) film is fabricated by a three-step method adopting hot filament CVD (HFCVD) method in the present study, presenting outstanding comprehensive performance, including the good adhesion between the substrate and the underlying boron doped diamond (BDD) layer, the extremely high hardness of the middle undoped microcrystalline diamond (UMCD) layer, as well as the low surface roughness and favorable polished convenience of the surface fine grained diamond (FGD) layer. The friction and wear behavior of this composite film sliding against low-carbon steel and silicon nitride balls are studied on a ball-on-plate rotational friction tester. Besides, its wear rate is further evaluated under a severer condition using an inner-hole polishing apparatus, with low-carbon steel wire as the counterpart. The test results show that the BD-UM-FGCD film performs very small friction coefficient and great friction behavior owing to its high surface smoothness, and meanwhile it also has excellent wear resistance because of the relatively high hardness of the surface FGD film and the extremely high hardness of the middle UMCD film. Moreover, under the industrial conditions for producing low-carbon steel wires, this composite film can sufficiently prolong the working lifetime of the drawing dies and improve their application effects. This research develops a novel composite diamond films owning great comprehensive properties, which have great potentials as protecting coatings on working surfaces of the wear-resistant and anti-frictional components.
2015, 29(01).
doi: 10.3901/CJME.2014.1103.166
Abstract:
Due to the non-stationary characteristics of vibration signals acquired from rolling element bearing fault, the time-frequency analysis is often applied to describe the local information of these unstable signals smartly. However, it is difficult to classify the high dimensional feature matrix directly because of too large dimensions for many classifiers. This paper combines the concepts of time-frequency distribution(TFD) with non-negative matrix factorization(NMF), and proposes a novel TFD matrix factorization method to enhance representation and identification of bearing fault. Throughout this method, the TFD of a vibration signal is firstly accomplished to describe the localized faults with short-time Fourier transform(STFT). Then, the supervised NMF mapping is adopted to extract the fault features from TFD. Meanwhile, the fault samples can be clustered and recognized automatically by using the clustering property of NMF. The proposed method takes advantages of the NMF in the parts-based representation and the adaptive clustering. The localized fault features of interest can be extracted as well. To evaluate the performance of the proposed method, the 9 kinds of the bearing fault on a test bench is performed. The proposed method can effectively identify the fault severity and different fault types. Moreover, in comparison with the artificial neural network(ANN), NMF yields 99.3% mean accuracy which is much superior to ANN. This research presents a simple and practical resolution for the fault diagnosis problem of rolling element bearing in high dimensional feature space.
Due to the non-stationary characteristics of vibration signals acquired from rolling element bearing fault, the time-frequency analysis is often applied to describe the local information of these unstable signals smartly. However, it is difficult to classify the high dimensional feature matrix directly because of too large dimensions for many classifiers. This paper combines the concepts of time-frequency distribution(TFD) with non-negative matrix factorization(NMF), and proposes a novel TFD matrix factorization method to enhance representation and identification of bearing fault. Throughout this method, the TFD of a vibration signal is firstly accomplished to describe the localized faults with short-time Fourier transform(STFT). Then, the supervised NMF mapping is adopted to extract the fault features from TFD. Meanwhile, the fault samples can be clustered and recognized automatically by using the clustering property of NMF. The proposed method takes advantages of the NMF in the parts-based representation and the adaptive clustering. The localized fault features of interest can be extracted as well. To evaluate the performance of the proposed method, the 9 kinds of the bearing fault on a test bench is performed. The proposed method can effectively identify the fault severity and different fault types. Moreover, in comparison with the artificial neural network(ANN), NMF yields 99.3% mean accuracy which is much superior to ANN. This research presents a simple and practical resolution for the fault diagnosis problem of rolling element bearing in high dimensional feature space.
2015, 29(01).
doi: 10.3901/CJME.2014.1008.157
Abstract:
In design optimization of crane metal structures, present approaches are based on simple models and mixed variables, which are difficult to use in practice and usually lead to failure of optimized results for rounding variables. Crane metal structure optimal design(CMSOD) belongs to a constrained nonlinear optimization problem with discrete variables. A novel algorithm combining ant colony algorithm with a mutation-based local search(ACAM) is developed and used for a real CMSOD for the first time. In the algorithm model, the encoded mode of continuous array elements is introduced. This not only avoids the need to round optimization design variables during mixed variable optimization, but also facilitates the construction of heuristic information, and the storage and update of the ant colony pheromone. Together with the proposed ACAM, a genetic algorithm(GA) and particle swarm optimization(PSO) are used to optimize the metal structure of a crane. The optimization results show that the convergence speed of ACAM is approximately 20% of that of the GA and around 11% of that of the PSO. The objective function value given by ACAM is 22.23% less than the practical design value, a reduction of 16.42% over the GA and 3.27% over the PSO. The developed ACAM is an effective intelligent method for CMSOD and superior to other methods.
In design optimization of crane metal structures, present approaches are based on simple models and mixed variables, which are difficult to use in practice and usually lead to failure of optimized results for rounding variables. Crane metal structure optimal design(CMSOD) belongs to a constrained nonlinear optimization problem with discrete variables. A novel algorithm combining ant colony algorithm with a mutation-based local search(ACAM) is developed and used for a real CMSOD for the first time. In the algorithm model, the encoded mode of continuous array elements is introduced. This not only avoids the need to round optimization design variables during mixed variable optimization, but also facilitates the construction of heuristic information, and the storage and update of the ant colony pheromone. Together with the proposed ACAM, a genetic algorithm(GA) and particle swarm optimization(PSO) are used to optimize the metal structure of a crane. The optimization results show that the convergence speed of ACAM is approximately 20% of that of the GA and around 11% of that of the PSO. The objective function value given by ACAM is 22.23% less than the practical design value, a reduction of 16.42% over the GA and 3.27% over the PSO. The developed ACAM is an effective intelligent method for CMSOD and superior to other methods.
2015, 29(01).
doi: 10.3901/CJME.2014.1121.172
Abstract:
Current design rationale (DR) systems have not demonstrated the value of the approach in practice since little attention is put to the evaluation method of DR knowledge. To systematize knowledge management process for future computer-aided DR applications, a prerequisite is to provide the measure for the DR knowledge. In this paper, a new knowledge network evaluation method for DR management is presented. The method characterizes the DR knowledge value from four perspectives, namely, the design rationale structure scale, association knowledge and reasoning ability, degree of design justification support and degree of knowledge representation conciseness. The DR knowledge comprehensive value is also measured by the proposed method. To validate the proposed method, different style of DR knowledge network and the performance of the proposed measure are discussed. The evaluation method has been applied in two realistic design cases and compared with the structural measures. The research proposes the DR knowledge evaluation method which can provide object metric and selection basis for the DR knowledge reuse during the product design process. In addition, the method is proved to be more effective guidance and support for the application and management of DR knowledge.
Current design rationale (DR) systems have not demonstrated the value of the approach in practice since little attention is put to the evaluation method of DR knowledge. To systematize knowledge management process for future computer-aided DR applications, a prerequisite is to provide the measure for the DR knowledge. In this paper, a new knowledge network evaluation method for DR management is presented. The method characterizes the DR knowledge value from four perspectives, namely, the design rationale structure scale, association knowledge and reasoning ability, degree of design justification support and degree of knowledge representation conciseness. The DR knowledge comprehensive value is also measured by the proposed method. To validate the proposed method, different style of DR knowledge network and the performance of the proposed measure are discussed. The evaluation method has been applied in two realistic design cases and compared with the structural measures. The research proposes the DR knowledge evaluation method which can provide object metric and selection basis for the DR knowledge reuse during the product design process. In addition, the method is proved to be more effective guidance and support for the application and management of DR knowledge.
2015, 29(01).
doi: 10.3901/CJME.2014.0820.137
Abstract:
The application of the parallel mechanism is still limited in the humanoid robot fields, and the existing parallel humanoid robot joint has not yet been reflected the characteristics of the parallel mechanism completely, also failed to solve the problem, such as small workspace, effectively. From the structural and functional bionic point of view, a three degrees of freedom(DOFs) spherical parallel mechanism for the shoulder complex of the humanoid robot is presented. According to the structure and kinetic characteristics analysis of the human shoulder complex, 3-PSS/S(P for prismatic pair, S for spherical pair) is chosen as the original configuration for the shouder complex. Using genetic algorithm, the optimization of the 3-PSS/S spherical parallel mechanism is performed, and the orientation workspace of the prototype mechanism is enlarged obviously. Combining the practical structure characteristics of the human shouder complex, an offset output mode, which means the output rod of the mechanism turn to any direction at the point a certain distance from the rotation center of the mechanism, is put forward, which provide possibility for the consistent of the workspace of the mechanism and the actual motion space of the human body shoulder joint. The relationship of the attitude angles between different coordinate system is derived, which establishs the foundation for the motion descriptions under different conditions and control development. The 3-PSS/S spherical parallel mechanism is proposed for the shoulder complex, and the consistence of the workspace of the mechanism and the human shoulder complex is realized by the stuctural parameter optimization and the offset output design.
The application of the parallel mechanism is still limited in the humanoid robot fields, and the existing parallel humanoid robot joint has not yet been reflected the characteristics of the parallel mechanism completely, also failed to solve the problem, such as small workspace, effectively. From the structural and functional bionic point of view, a three degrees of freedom(DOFs) spherical parallel mechanism for the shoulder complex of the humanoid robot is presented. According to the structure and kinetic characteristics analysis of the human shoulder complex, 3-PSS/S(P for prismatic pair, S for spherical pair) is chosen as the original configuration for the shouder complex. Using genetic algorithm, the optimization of the 3-PSS/S spherical parallel mechanism is performed, and the orientation workspace of the prototype mechanism is enlarged obviously. Combining the practical structure characteristics of the human shouder complex, an offset output mode, which means the output rod of the mechanism turn to any direction at the point a certain distance from the rotation center of the mechanism, is put forward, which provide possibility for the consistent of the workspace of the mechanism and the actual motion space of the human body shoulder joint. The relationship of the attitude angles between different coordinate system is derived, which establishs the foundation for the motion descriptions under different conditions and control development. The 3-PSS/S spherical parallel mechanism is proposed for the shoulder complex, and the consistence of the workspace of the mechanism and the human shoulder complex is realized by the stuctural parameter optimization and the offset output design.
2015, 29(01).
doi: 10.3901/CJME.2014.0930.156
Abstract:
The compliance modeling is one of the most significant issues in the stage of preliminary design for parallel kinematic machine(PKM). The gravity ignored in traditional compliance analysis has a significant effect on pose accuracy of tool center point(TCP) when a PKM is horizontally placed. By taking gravity into account, this paper presents a semi-analytical approach for compliance analysis of a 3-DOF spindle head named the A3 head. The architecture behind the A3 head is a 3-RPS parallel mechanism having one translational and two rotational movement capabilities, which can be employed to form the main body of a 5-DOF hybrid kinematic machine especially designed for high-speed machining of large aircraft components. The force analysis is carried out by considering both the externally applied wrench imposed upon the platform as well as gravity of all moving components. Then, the deflection analysis is investigated to establish the relationship between the deflection twist and compliances of all joints and links using semi-analytical method. The merits of this approach lie in that platform deflection twist throughout the entire task workspace can be evaluated in a very efficient manner. The effectiveness of the proposed approach is verified by the FEA and experiment at different configurations and the results show that the discrepancy of the compliances is less than 0.04 μm/N1 and that of the deformations is less than 10μm. The computational and experimental results show that the deflection twist induced by gravity forces of the moving components has significant bearings on pose accuracy of the platform, providing an informative guidance for the improvement of the current design. The proposed approach can be easily applied to the compliance analysis of PKM by considering gravitational effects and to evaluate the deformation caused by gravity throughout the entire workspace.
The compliance modeling is one of the most significant issues in the stage of preliminary design for parallel kinematic machine(PKM). The gravity ignored in traditional compliance analysis has a significant effect on pose accuracy of tool center point(TCP) when a PKM is horizontally placed. By taking gravity into account, this paper presents a semi-analytical approach for compliance analysis of a 3-DOF spindle head named the A3 head. The architecture behind the A3 head is a 3-RPS parallel mechanism having one translational and two rotational movement capabilities, which can be employed to form the main body of a 5-DOF hybrid kinematic machine especially designed for high-speed machining of large aircraft components. The force analysis is carried out by considering both the externally applied wrench imposed upon the platform as well as gravity of all moving components. Then, the deflection analysis is investigated to establish the relationship between the deflection twist and compliances of all joints and links using semi-analytical method. The merits of this approach lie in that platform deflection twist throughout the entire task workspace can be evaluated in a very efficient manner. The effectiveness of the proposed approach is verified by the FEA and experiment at different configurations and the results show that the discrepancy of the compliances is less than 0.04 μm/N1 and that of the deformations is less than 10μm. The computational and experimental results show that the deflection twist induced by gravity forces of the moving components has significant bearings on pose accuracy of the platform, providing an informative guidance for the improvement of the current design. The proposed approach can be easily applied to the compliance analysis of PKM by considering gravitational effects and to evaluate the deformation caused by gravity throughout the entire workspace.
2015, 29(01).
doi: 10.3901/CJME.2014.0827.142
Abstract:
Traditional welding methods are limited in low heat input to workpiece and high welding wire melting rate. Twin-wire indirect arc(TWIA) welding is a new welding method characterized by high melting rate and low heat input. This method uses two wires: one connected to the negative electrode and another to the positive electrode of a direct-current(DC) power source. The workpiece is an independent, non-connected unit. A three dimensional finite element model of TWIA is devised. Electric and magnetic fields are calculated and their influence upon TWIA behavior and the welding process is discussed. The results show that with a 100 A welding current, the maximum temperature reached is 17 758 K, arc voltage is 14.646 V while maximum current density was 61 A/mm2 with a maximum Lorene force of 84.5 N. The above mentioned arc parameters near the cathode and anode regions are far higher than those in the arc column region. The Lorene force is the key reason for plasma velocity direction deviated and charged particles flowed in the channel formed by the cathode, anode and upper part of arc column regions. This led to most of the energy being supplied to the polar and upper part of arc column regions. The interaction between electric and magnetic fields is a major determinant in shaping TWIA as well as heat input on the workpiece. This is a first study of electromagnetic characteristics and their influences in the TWIA welding process, and it is significant in both a theoretical and practical sense.
Traditional welding methods are limited in low heat input to workpiece and high welding wire melting rate. Twin-wire indirect arc(TWIA) welding is a new welding method characterized by high melting rate and low heat input. This method uses two wires: one connected to the negative electrode and another to the positive electrode of a direct-current(DC) power source. The workpiece is an independent, non-connected unit. A three dimensional finite element model of TWIA is devised. Electric and magnetic fields are calculated and their influence upon TWIA behavior and the welding process is discussed. The results show that with a 100 A welding current, the maximum temperature reached is 17 758 K, arc voltage is 14.646 V while maximum current density was 61 A/mm2 with a maximum Lorene force of 84.5 N. The above mentioned arc parameters near the cathode and anode regions are far higher than those in the arc column region. The Lorene force is the key reason for plasma velocity direction deviated and charged particles flowed in the channel formed by the cathode, anode and upper part of arc column regions. This led to most of the energy being supplied to the polar and upper part of arc column regions. The interaction between electric and magnetic fields is a major determinant in shaping TWIA as well as heat input on the workpiece. This is a first study of electromagnetic characteristics and their influences in the TWIA welding process, and it is significant in both a theoretical and practical sense.
2015, 29(01).
doi: 10.3901/CJME.2014.1020.158
Abstract:
Most existing force feedback methods are still difficult to meet the requirements of real-time force calculation in virtual assembly and operation with complex objects. In addition, there is often an assumption that the controlled objects are completely free and the target object is only completely fixed or free, thus, the dynamics of the kinematic chain where the controlled objects are located are neglected during the physical simulation of the product manipulation with force feedback interaction. This paper proposes a physical simulation method of product assembly and operation manipulation based on statistically learned contact force prediction model and the coupling of force feedback and dynamics. In the proposed method, based on hidden Markov model (HMM) and local weighting learning (LWL), contact force prediction model is constructed, which can estimate the contact force in real time during interaction. Based on computational load balance model, the computing resources are dynamically assigned and the dynamics integral step is optimized. In addition, smoothing process is performed to the force feedback on the synchronization points. Consequently, we can solve the coupling and synchronization problems of high-frequency feedback force servo, low-frequency dynamics solver servo and scene rendering servo, and realize highly stable and accurate force feedback in the physical simulation of product assembly and operation manipulation. This research proposes a physical simulation method of product assembly and operation manipulation.
Most existing force feedback methods are still difficult to meet the requirements of real-time force calculation in virtual assembly and operation with complex objects. In addition, there is often an assumption that the controlled objects are completely free and the target object is only completely fixed or free, thus, the dynamics of the kinematic chain where the controlled objects are located are neglected during the physical simulation of the product manipulation with force feedback interaction. This paper proposes a physical simulation method of product assembly and operation manipulation based on statistically learned contact force prediction model and the coupling of force feedback and dynamics. In the proposed method, based on hidden Markov model (HMM) and local weighting learning (LWL), contact force prediction model is constructed, which can estimate the contact force in real time during interaction. Based on computational load balance model, the computing resources are dynamically assigned and the dynamics integral step is optimized. In addition, smoothing process is performed to the force feedback on the synchronization points. Consequently, we can solve the coupling and synchronization problems of high-frequency feedback force servo, low-frequency dynamics solver servo and scene rendering servo, and realize highly stable and accurate force feedback in the physical simulation of product assembly and operation manipulation. This research proposes a physical simulation method of product assembly and operation manipulation.
2015, 29(01).
doi: 10.3901/CJME.2014.1106.163
Abstract:
Currently, the approximation methods of the Gaussian filter by some other spline filters have been developed. However, these methods are only suitable for the study of one-dimensional filtering, when these methods are used for three-dimensional filtering, it is found that a rounding error and quantization error would be passed to the next in every part. In this paper, a new and high-precision implementation approach for Gaussian filter is described, which is suitable for three-dimensional reference filtering. Based on the theory of generalized B-spline function and the variational principle, the transmission characteristics of a digital filter can be changed through the sensitivity of the parameters (t1, t2), and which can also reduce the rounding error and quantization error by the filter in a parallel form instead of the cascade form. Finally, the approximation filter of Gaussian filter is obtained. In order to verify the feasibility of the new algorithm, the reference extraction of the conventional methods are also used and compared. The experiments are conducted on the measured optical surface, and the results show that the total calculation by the new algorithm only requires 0.07 s for 480480 data points; the amplitude deviation between the reference of the parallel form filter and the Gaussian filter is smaller; the new method is closer to the characteristic of the Gaussian filter through the analysis of three-dimensional roughness parameters, comparing with the cascade generalized B-spline approximating Gaussian. So the new algorithm is also efficient and accurate for the implementation of Gaussian filter in the application of surface roughness measurement.
Currently, the approximation methods of the Gaussian filter by some other spline filters have been developed. However, these methods are only suitable for the study of one-dimensional filtering, when these methods are used for three-dimensional filtering, it is found that a rounding error and quantization error would be passed to the next in every part. In this paper, a new and high-precision implementation approach for Gaussian filter is described, which is suitable for three-dimensional reference filtering. Based on the theory of generalized B-spline function and the variational principle, the transmission characteristics of a digital filter can be changed through the sensitivity of the parameters (t1, t2), and which can also reduce the rounding error and quantization error by the filter in a parallel form instead of the cascade form. Finally, the approximation filter of Gaussian filter is obtained. In order to verify the feasibility of the new algorithm, the reference extraction of the conventional methods are also used and compared. The experiments are conducted on the measured optical surface, and the results show that the total calculation by the new algorithm only requires 0.07 s for 480480 data points; the amplitude deviation between the reference of the parallel form filter and the Gaussian filter is smaller; the new method is closer to the characteristic of the Gaussian filter through the analysis of three-dimensional roughness parameters, comparing with the cascade generalized B-spline approximating Gaussian. So the new algorithm is also efficient and accurate for the implementation of Gaussian filter in the application of surface roughness measurement.
2015, 29(01).
doi: 10.3901/CJME.2014.1030.161
Abstract:
Color coding is often used to enhance decision quality in complex man-machine interfaces of integrated display systems. However, people are easily distracted by irrelevant colors and by the numerous data points and complex structures in the interface. Although an increasing number of studies are seriously focusing on the problem of achieving efficient color coding, few are able to determine the effects of target and distractor saturations on cognitive performance. To study the performances of target colors among distractors, a systematic experiment is conducted to assess the influence of high and low saturated targets on cognitive performance, and the affecting extent of different saturated distractors of homogeneous colors on targets. According to the analysis of the reaction time through the non-parametric statistical method, a calculation method of the cognitive performance of each color is proposed. Based on the calculation of the color differences and the accumulation of the reaction times, it is shown that with the different saturated distractors of homogeneous colors, the high saturated yellow targets perform better than the low saturated ones, and the green and blue targets have moderate performances. When searching for a singleton target placed on a black background, the color difference between the target and the distractor should be more than 20ΔE*ab units in the yellow saturation coding, whereas the color difference should be more than 40ΔE*ab units in the blue and green saturation coding. In addition, as regards saturation coding, the influence of the color difference between the target and the background on cognitive performance is greater than that of the color difference between the target and the distractor. Seemingly, the hue attribute determines whether the saturation difference between the target and the distractor affects the cognitive performance. Based on the experimental results, the simulation design of the instrument dials in a flight situation awareness interface is completed and tested. Simulation results show the feasibility of the method of choosing the target and distractor colors, and the proposed research provides the instruction for the color saturation design of the interface.
Color coding is often used to enhance decision quality in complex man-machine interfaces of integrated display systems. However, people are easily distracted by irrelevant colors and by the numerous data points and complex structures in the interface. Although an increasing number of studies are seriously focusing on the problem of achieving efficient color coding, few are able to determine the effects of target and distractor saturations on cognitive performance. To study the performances of target colors among distractors, a systematic experiment is conducted to assess the influence of high and low saturated targets on cognitive performance, and the affecting extent of different saturated distractors of homogeneous colors on targets. According to the analysis of the reaction time through the non-parametric statistical method, a calculation method of the cognitive performance of each color is proposed. Based on the calculation of the color differences and the accumulation of the reaction times, it is shown that with the different saturated distractors of homogeneous colors, the high saturated yellow targets perform better than the low saturated ones, and the green and blue targets have moderate performances. When searching for a singleton target placed on a black background, the color difference between the target and the distractor should be more than 20ΔE*ab units in the yellow saturation coding, whereas the color difference should be more than 40ΔE*ab units in the blue and green saturation coding. In addition, as regards saturation coding, the influence of the color difference between the target and the background on cognitive performance is greater than that of the color difference between the target and the distractor. Seemingly, the hue attribute determines whether the saturation difference between the target and the distractor affects the cognitive performance. Based on the experimental results, the simulation design of the instrument dials in a flight situation awareness interface is completed and tested. Simulation results show the feasibility of the method of choosing the target and distractor colors, and the proposed research provides the instruction for the color saturation design of the interface.
2015, 29(01).
doi: 10.3901/CJME.2014.1107.167
Abstract:
Fault tolerance is essential for quadruped robots when they work in remote areas or hazardous environments. Many fault-tolerant gaits planning method proposed in the past decade constrained more degrees of freedom(DOFs) of a robot than necessary. Thus a novel method to realize the fault-tolerant walking is proposed. The mobility of the robot is analyzed first by using the screw theory. The result shows that the translation of the center of body(CoB) can be kept with one faulty actuator if the rotations of the body are controlled. Thus the DOFs of the robot body are divided into two parts: the translation of the CoB and the rotation of the body. The kinematic model of the whole robot is built, the algorithm is developed to actively control the body orientations at the velocity level so that the planned CoB trajectory can be realized in spite of the constraint of the faulty actuator. This gait has a similar generation sequence with the normal gait and can be applied to the robot at any position. Simulations and experiments of the fault-tolerant gait with one faulty actuator are carried out. The CoB errors and the body rotation angles are measured. Comparing to the traditional fault-tolerant gait they can be reduced by at least 50%. A fault-tolerant gait planning algorithm is presented, which not only realizes the walking of a quadruped robot with a faulty actuator, but also efficiently improves the walking performances by taking full advantage of the remaining operational actuators according to the results of the simulations and experiments.
Fault tolerance is essential for quadruped robots when they work in remote areas or hazardous environments. Many fault-tolerant gaits planning method proposed in the past decade constrained more degrees of freedom(DOFs) of a robot than necessary. Thus a novel method to realize the fault-tolerant walking is proposed. The mobility of the robot is analyzed first by using the screw theory. The result shows that the translation of the center of body(CoB) can be kept with one faulty actuator if the rotations of the body are controlled. Thus the DOFs of the robot body are divided into two parts: the translation of the CoB and the rotation of the body. The kinematic model of the whole robot is built, the algorithm is developed to actively control the body orientations at the velocity level so that the planned CoB trajectory can be realized in spite of the constraint of the faulty actuator. This gait has a similar generation sequence with the normal gait and can be applied to the robot at any position. Simulations and experiments of the fault-tolerant gait with one faulty actuator are carried out. The CoB errors and the body rotation angles are measured. Comparing to the traditional fault-tolerant gait they can be reduced by at least 50%. A fault-tolerant gait planning algorithm is presented, which not only realizes the walking of a quadruped robot with a faulty actuator, but also efficiently improves the walking performances by taking full advantage of the remaining operational actuators according to the results of the simulations and experiments.
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