2016 Vol.29(2)
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2016, 30(2): 219-230.
doi: 10.3901/CJME.2015.1212.146
Abstract:
Human tracking is quite an important issue for intelligent robotic control and can be used in many scenarios, such as robotic services and human-robot cooperation. Most of current human-tracking methods are targeted for mobile/tracked robots, and few of them can be used for legged robots. Two novel human-tracking strategies, view priority strategy and distance priority strategy, are proposed specially for legged robots, which enable them to track humans in various complex terrains. View priority strategy focuses on keeping humans in its view angle arrange with priority, while its counterpart, distance priority strategy, focuses on keeping human at a reasonable distance with priority. To evaluate these strategies, two indexes(average and minimum tracking capability) are defined. With the help of these indexes, the view priority strategy shows advantages compared with distance priority strategy. The optimization is done in terms of these indexes, which let the robot has maximum tracking capability. The simulation results show that the robot can track humans with different curves like square, circular, sine and screw paths. Two novel control strategies are proposed which specially concerning legged robot characteristics to solve human tracking problems more efficiently in rescue circumstances.
Human tracking is quite an important issue for intelligent robotic control and can be used in many scenarios, such as robotic services and human-robot cooperation. Most of current human-tracking methods are targeted for mobile/tracked robots, and few of them can be used for legged robots. Two novel human-tracking strategies, view priority strategy and distance priority strategy, are proposed specially for legged robots, which enable them to track humans in various complex terrains. View priority strategy focuses on keeping humans in its view angle arrange with priority, while its counterpart, distance priority strategy, focuses on keeping human at a reasonable distance with priority. To evaluate these strategies, two indexes(average and minimum tracking capability) are defined. With the help of these indexes, the view priority strategy shows advantages compared with distance priority strategy. The optimization is done in terms of these indexes, which let the robot has maximum tracking capability. The simulation results show that the robot can track humans with different curves like square, circular, sine and screw paths. Two novel control strategies are proposed which specially concerning legged robot characteristics to solve human tracking problems more efficiently in rescue circumstances.
2016, 30(2): 231-238.
doi: 10.3901/CJME.2015.1120.137
Abstract:
The solution of tension distributions is infinite for cable-driven parallel manipulators(CDPMs) with redundant cables. A rapid optimization method for determining the optimal tension distribution is presented. The new optimization method is primarily based on the geometry properties of a polyhedron and convex analysis. The computational efficiency of the optimization method is improved by the designed projection algorithm, and a fast algorithm is proposed to determine which two of the lines are intersected at the optimal point. Moreover, a method for avoiding the operating point on the lower tension limit is developed. Simulation experiments are implemented on a six degree-of-freedom(6-DOF) CDPM with eight cables, and the results indicate that the new method is one order of magnitude faster than the standard simplex method. The optimal distribution of tension distribution is thus rapidly established on real-time by the proposed method.
The solution of tension distributions is infinite for cable-driven parallel manipulators(CDPMs) with redundant cables. A rapid optimization method for determining the optimal tension distribution is presented. The new optimization method is primarily based on the geometry properties of a polyhedron and convex analysis. The computational efficiency of the optimization method is improved by the designed projection algorithm, and a fast algorithm is proposed to determine which two of the lines are intersected at the optimal point. Moreover, a method for avoiding the operating point on the lower tension limit is developed. Simulation experiments are implemented on a six degree-of-freedom(6-DOF) CDPM with eight cables, and the results indicate that the new method is one order of magnitude faster than the standard simplex method. The optimal distribution of tension distribution is thus rapidly established on real-time by the proposed method.
2016, 30(2): 239-249.
doi: 10.3901/CJME.2015.1210.144
Abstract:
As functional components of machine tools, parallel mechanisms are widely used in high efficiency machining of aviation components, and accuracy is one of the critical technical indexes. Lots of researchers have focused on the accuracy problem of parallel mechanisms, but in terms of controlling the errors and improving the accuracy in the stage of design and manufacturing, further efforts are required. Aiming at the accuracy design of a 3-DOF parallel spindle head(A3 head), its error model, sensitivity analysis and tolerance allocation are investigated. Based on the inverse kinematic analysis, the error model of A3 head is established by using the first-order perturbation theory and vector chain method. According to the mapping property of motion and constraint Jacobian matrix, the compensatable and uncompensatable error sources which affect the accuracy in the end-effector are separated. Furthermore, sensitivity analysis is performed on the uncompensatable error sources. The sensitivity probabilistic model is established and the global sensitivity index is proposed to analyze the influence of the uncompensatable error sources on the accuracy in the end-effector of the mechanism. The results show that orientation error sources have bigger effect on the accuracy in the end-effector. Based upon the sensitivity analysis results, the tolerance design is converted into the issue of nonlinearly constrained optimization with the manufacturing cost minimum being the optimization objective. By utilizing the genetic algorithm, the allocation of the tolerances on each component is finally determined. According to the tolerance allocation results, the tolerance ranges of ten kinds of geometric error sources are obtained. These research achievements can provide fundamental guidelines for component manufacturing and assembly of this kind of parallel mechanisms.
As functional components of machine tools, parallel mechanisms are widely used in high efficiency machining of aviation components, and accuracy is one of the critical technical indexes. Lots of researchers have focused on the accuracy problem of parallel mechanisms, but in terms of controlling the errors and improving the accuracy in the stage of design and manufacturing, further efforts are required. Aiming at the accuracy design of a 3-DOF parallel spindle head(A3 head), its error model, sensitivity analysis and tolerance allocation are investigated. Based on the inverse kinematic analysis, the error model of A3 head is established by using the first-order perturbation theory and vector chain method. According to the mapping property of motion and constraint Jacobian matrix, the compensatable and uncompensatable error sources which affect the accuracy in the end-effector are separated. Furthermore, sensitivity analysis is performed on the uncompensatable error sources. The sensitivity probabilistic model is established and the global sensitivity index is proposed to analyze the influence of the uncompensatable error sources on the accuracy in the end-effector of the mechanism. The results show that orientation error sources have bigger effect on the accuracy in the end-effector. Based upon the sensitivity analysis results, the tolerance design is converted into the issue of nonlinearly constrained optimization with the manufacturing cost minimum being the optimization objective. By utilizing the genetic algorithm, the allocation of the tolerances on each component is finally determined. According to the tolerance allocation results, the tolerance ranges of ten kinds of geometric error sources are obtained. These research achievements can provide fundamental guidelines for component manufacturing and assembly of this kind of parallel mechanisms.
2016, 30(2): 250-259.
doi: 10.3901/CJME.2016.0104.001
Abstract:
Although it is common to eliminate the singularity of parallel mechanism by adding the branched chain with actuation redundancy, there is no theory and method for the configuration synthesis of the branched chain with actuation redundancy in parallel mechanism. Branched chains with actuation redundancy are synthesized for eliminating interior singularity of 3-translational and 1- rotational(3T1R) parallel mechanisms. Guided by the discriminance method of hybrid screw group according to Grassmann line geometry, all the possibilities are listed for the occurrence of interior singularities in 3T1R parallel mechanism. Based on the linear relevance of screw system and the principles of eliminating parallel mechanism singularity with actuation redundancy, different types of branched chains with actuation redundancy are synthesized systematically to indicate the layout and the number of the branched chainsinterior with actuation redundancy. A general method is proposed for the configuration synthesis of the branched chains with actuation redundancy of the redundant parallel mechanism, and it builds a solid foundation for the subsequent performance optimization of the redundant actuation parallel mechanism.
Although it is common to eliminate the singularity of parallel mechanism by adding the branched chain with actuation redundancy, there is no theory and method for the configuration synthesis of the branched chain with actuation redundancy in parallel mechanism. Branched chains with actuation redundancy are synthesized for eliminating interior singularity of 3-translational and 1- rotational(3T1R) parallel mechanisms. Guided by the discriminance method of hybrid screw group according to Grassmann line geometry, all the possibilities are listed for the occurrence of interior singularities in 3T1R parallel mechanism. Based on the linear relevance of screw system and the principles of eliminating parallel mechanism singularity with actuation redundancy, different types of branched chains with actuation redundancy are synthesized systematically to indicate the layout and the number of the branched chainsinterior with actuation redundancy. A general method is proposed for the configuration synthesis of the branched chains with actuation redundancy of the redundant parallel mechanism, and it builds a solid foundation for the subsequent performance optimization of the redundant actuation parallel mechanism.
2016, 30(2): 260-270.
doi: 10.3901/CJME.2015.0713.092
Abstract:
Many industrial applications and experiments have shown that sliding bearings often experience fluid film whip due to nonlinear fluid film forces which can cause rotor-stator rub-impact failures. The oil-film whips have attracted many studies while the water-film whips in the water lubricated sliding bearing have been little researched with the mechanism still an open problem. The dynamic fluid film forces in a water sliding bearing are investigated numerically with rotational, whirling and squeezing motions of the journal using a nonlinear model to identify the relationships between the three motions. Rotor speed-up and slow-down experiments are then conducted with the rotor system supported by a water lubricated sliding bearing to induce the water-film whirl/whip and verify the relationship. The experimental results show that the vibrations of the journal alternated between increasing and decreasing rather than continuously increasing as the rotational speed increased to twice the first critical speed, which can be explained well by the nonlinear model. The radial growth rate of the whirl motion greatly affects the whirl frequency of the journal and is responsible for the frequency lock in the water-film whip. Further analysis shows that increasing the lubricating water flow rate changes the water-film whirl/whip characteristics, reduces the first critical speed, advances the time when significant water-film whirling motion occurs, and also increases the vibration amplitude at the bearing center which may lead to the rotor-stator rub-impact. The study gives the insight into the water-film whirl and whip in the water lubricated sliding bearing.
Many industrial applications and experiments have shown that sliding bearings often experience fluid film whip due to nonlinear fluid film forces which can cause rotor-stator rub-impact failures. The oil-film whips have attracted many studies while the water-film whips in the water lubricated sliding bearing have been little researched with the mechanism still an open problem. The dynamic fluid film forces in a water sliding bearing are investigated numerically with rotational, whirling and squeezing motions of the journal using a nonlinear model to identify the relationships between the three motions. Rotor speed-up and slow-down experiments are then conducted with the rotor system supported by a water lubricated sliding bearing to induce the water-film whirl/whip and verify the relationship. The experimental results show that the vibrations of the journal alternated between increasing and decreasing rather than continuously increasing as the rotational speed increased to twice the first critical speed, which can be explained well by the nonlinear model. The radial growth rate of the whirl motion greatly affects the whirl frequency of the journal and is responsible for the frequency lock in the water-film whip. Further analysis shows that increasing the lubricating water flow rate changes the water-film whirl/whip characteristics, reduces the first critical speed, advances the time when significant water-film whirling motion occurs, and also increases the vibration amplitude at the bearing center which may lead to the rotor-stator rub-impact. The study gives the insight into the water-film whirl and whip in the water lubricated sliding bearing.
2016, 30(2): 271-280.
doi: 10.3901/CJME.2015.1013.121
Abstract:
For the high-speed gasoline engine turbocharger rotor, due to the heterogeneity of multiple parts material, manufacturing and assembly errors, running wear in impeller and uneven carbon of turbine, the random unbalance usually can be developed which will induce excessive rotor vibration, and even lead to nonlinear vibration accidents. However, the investigation of unbalance location on the nonlinear high-speed turbocharger rotordynamic characteristics is less. In order to discuss the rotor unbalance location effects of turbocharger with nonlinear floating ring bearings(FRBs), the realistic turbocharger of gasoline engine is taken as a research object. The rotordynamic equations of motion under the condition of unbalance are derived by applied unbalance force and nonlinear oil film force of FRBs. The FE model of turbocharger rotor-bearing system is modeled which includes the unbalance excitation and nonlinear FRBs. Under the conditions of four different applied locations of unbalance, the nonlinear transient analyses are performed based on the rotor FEM. The differences of dynamic behavior are obvious to the turbocharger rotor systems for four conditions, and the bifurcation phenomena are different. From the results of waterfall and transient response analysis, the speed for the appearance of fractional frequency is not identical and the amplitude magnitude is different from the different unbalance locations, and the non-synchronous vibration does not occur in the turbocharger and the amplitude is relative stable and minimum under the condition 4. The turbocharger vibration and non-synchronous components could be reduced or suppressed by controlling the applied location of unbalance, which is helpful for the dynamic design, fault diagnosis and vibration control of the high-speed gasoline engine turbochargers.
For the high-speed gasoline engine turbocharger rotor, due to the heterogeneity of multiple parts material, manufacturing and assembly errors, running wear in impeller and uneven carbon of turbine, the random unbalance usually can be developed which will induce excessive rotor vibration, and even lead to nonlinear vibration accidents. However, the investigation of unbalance location on the nonlinear high-speed turbocharger rotordynamic characteristics is less. In order to discuss the rotor unbalance location effects of turbocharger with nonlinear floating ring bearings(FRBs), the realistic turbocharger of gasoline engine is taken as a research object. The rotordynamic equations of motion under the condition of unbalance are derived by applied unbalance force and nonlinear oil film force of FRBs. The FE model of turbocharger rotor-bearing system is modeled which includes the unbalance excitation and nonlinear FRBs. Under the conditions of four different applied locations of unbalance, the nonlinear transient analyses are performed based on the rotor FEM. The differences of dynamic behavior are obvious to the turbocharger rotor systems for four conditions, and the bifurcation phenomena are different. From the results of waterfall and transient response analysis, the speed for the appearance of fractional frequency is not identical and the amplitude magnitude is different from the different unbalance locations, and the non-synchronous vibration does not occur in the turbocharger and the amplitude is relative stable and minimum under the condition 4. The turbocharger vibration and non-synchronous components could be reduced or suppressed by controlling the applied location of unbalance, which is helpful for the dynamic design, fault diagnosis and vibration control of the high-speed gasoline engine turbochargers.
2016, 30(2): 281-292.
doi: 10.3901/CJME.2015.1019.124
Abstract:
Extensive studies on nonlinear dynamics of gear systems with internal excitation or external excitation respectively have been carried out. However, the nonlinear characteristics of gear systems under combined internal and external excitations are scarcely investigated. An eight-degree-of-freedom(8-DOF) nonlinear spur gear-rotor-bearing model, which contains backlash, transmission error, eccentricity, gravity and input/output torque, is established, and the coupled lateral-torsional vibration characteristics are studied. Based on the equations of motion, the coupled spur gear-rotor-bearing system(SGRBS) is investigated using the Runge-Kutta numerical method, and the effects of rotational speed, error fluctuation and load fluctuation on the dynamic responses are explored. The results show that a diverse range of nonlinear dynamic characteristics such as periodic motion, quasi-periodic motion, chaotic behaviors and impacts exhibited in the system are strongly attributed to the interaction between internal and external excitations. Significantly, the changing rotational speed could effectively control the vibration of the system. Vibration level increases with the increasing error fluctuation. Whereas the load fluctuation has an influence on the nonlinear dynamic characteristics and the increasing excitation force amplitude makes the vibration amplitude increase, the chaotic motion may be restricted. The proposed model and numerical results can be used for diagnosis of faults and vibration control of practical SGRBS.
Extensive studies on nonlinear dynamics of gear systems with internal excitation or external excitation respectively have been carried out. However, the nonlinear characteristics of gear systems under combined internal and external excitations are scarcely investigated. An eight-degree-of-freedom(8-DOF) nonlinear spur gear-rotor-bearing model, which contains backlash, transmission error, eccentricity, gravity and input/output torque, is established, and the coupled lateral-torsional vibration characteristics are studied. Based on the equations of motion, the coupled spur gear-rotor-bearing system(SGRBS) is investigated using the Runge-Kutta numerical method, and the effects of rotational speed, error fluctuation and load fluctuation on the dynamic responses are explored. The results show that a diverse range of nonlinear dynamic characteristics such as periodic motion, quasi-periodic motion, chaotic behaviors and impacts exhibited in the system are strongly attributed to the interaction between internal and external excitations. Significantly, the changing rotational speed could effectively control the vibration of the system. Vibration level increases with the increasing error fluctuation. Whereas the load fluctuation has an influence on the nonlinear dynamic characteristics and the increasing excitation force amplitude makes the vibration amplitude increase, the chaotic motion may be restricted. The proposed model and numerical results can be used for diagnosis of faults and vibration control of practical SGRBS.
2016, 30(2): 293-300.
doi: 10.3901/CJME.2015.1218.151
Abstract:
With application of the lock-up clutch in the torque converter (TC), fuel economy is not much determined by its high-speed ratio transmission efficiency. As a benefit, more researches are focused on its low-speed ratio performance so as to improve vehivle gradeability and launching acceleration performance. According to the results of computational fluid dynamics (CFD) analysis, hydrodynamic loss inside the stator cascade accounts for 42% of the total energy loss at stalling speed ratio. It is found that upstream flow with large impingement angle results in boundary layer separation at the leading edge, which aggregates hydrodynamic loss and decreases circular flow rate dramatically at low-speed ratio. In this paper, a dual-blade stator is proposed to suppress the boundary layer separation, which is parameterized by using the non-uniform rational B spline (NURBS) method. The mean camber line and blade profile curve are expressed by a three control points quadratic open NURBS and a cubic closed one respectively. The key design parameters included the slot width and suction side shape of the primary blade are analyzed. The most effective slot width is found to be between 4% and 8% chord length, and the boundary layer separation can be suppressed completely by decreasing distribution of momentum moment at the primary blade and adding it to the leading edge of the secondary blade. As a result, circular flow rate and impeller torque capacity is increased by 17.9% and 9.6% respectively at stalling speed ratio, meanwhile, low-speed ratio efficiency is also improved. Maximum efficiency at high-speed ratio decreases by 0.5%, which can be ignored as the work of lock-up clutch. This research focuses on using the dual-blade stator to optimize low-speed ratio performance of the TC, which is benefit to vehicle power performance.
With application of the lock-up clutch in the torque converter (TC), fuel economy is not much determined by its high-speed ratio transmission efficiency. As a benefit, more researches are focused on its low-speed ratio performance so as to improve vehivle gradeability and launching acceleration performance. According to the results of computational fluid dynamics (CFD) analysis, hydrodynamic loss inside the stator cascade accounts for 42% of the total energy loss at stalling speed ratio. It is found that upstream flow with large impingement angle results in boundary layer separation at the leading edge, which aggregates hydrodynamic loss and decreases circular flow rate dramatically at low-speed ratio. In this paper, a dual-blade stator is proposed to suppress the boundary layer separation, which is parameterized by using the non-uniform rational B spline (NURBS) method. The mean camber line and blade profile curve are expressed by a three control points quadratic open NURBS and a cubic closed one respectively. The key design parameters included the slot width and suction side shape of the primary blade are analyzed. The most effective slot width is found to be between 4% and 8% chord length, and the boundary layer separation can be suppressed completely by decreasing distribution of momentum moment at the primary blade and adding it to the leading edge of the secondary blade. As a result, circular flow rate and impeller torque capacity is increased by 17.9% and 9.6% respectively at stalling speed ratio, meanwhile, low-speed ratio efficiency is also improved. Maximum efficiency at high-speed ratio decreases by 0.5%, which can be ignored as the work of lock-up clutch. This research focuses on using the dual-blade stator to optimize low-speed ratio performance of the TC, which is benefit to vehicle power performance.
2016, 30(2): 301-314.
doi: 10.3901/CJME.2015.1222.153
Abstract:
Blade fouling has been proved to be a great threat to compressor performance in operating stage. The current researches on fouling-induced performance degradations of centrifugal compressors are based mainly on simplified roughness models without taking into account the realistic factors such as spatial non-uniformity and randomness of the fouling-induced surface roughness. Moreover, little attention has been paid to the robust design optimization of centrifugal compressor impellers with considerations of blade fouling. In this paper, a multi-objective robust design optimization method is developed for centrifugal impellers under surface roughness uncertainties due to blade fouling. A three-dimensional surface roughness map is proposed to describe the nonuniformity and randomness of realistic fouling accumulations on blades. To lower computational cost in robust design optimization, the support vector regression (SVR) metamodel is combined with the Monte Carlo simulation (MCS) method to conduct the uncertainty analysis of fouled impeller performance. The analyzed results show that the critical fouled region associated with impeller performance degradations lies at the leading edge of blade tip. The SVR metamodel has been proved to be an efficient and accurate means in the detection of impeller performance variations caused by roughness uncertainties. After design optimization, the robust optimal design is found to be more efficient and less sensitive to fouling uncertainties while maintaining good impeller performance in the clean condition. This research proposes a systematic design optimization method for centrifugal compressors with considerations of blade fouling, providing a practical guidance to the design of advanced centrifugal compressors.
Blade fouling has been proved to be a great threat to compressor performance in operating stage. The current researches on fouling-induced performance degradations of centrifugal compressors are based mainly on simplified roughness models without taking into account the realistic factors such as spatial non-uniformity and randomness of the fouling-induced surface roughness. Moreover, little attention has been paid to the robust design optimization of centrifugal compressor impellers with considerations of blade fouling. In this paper, a multi-objective robust design optimization method is developed for centrifugal impellers under surface roughness uncertainties due to blade fouling. A three-dimensional surface roughness map is proposed to describe the nonuniformity and randomness of realistic fouling accumulations on blades. To lower computational cost in robust design optimization, the support vector regression (SVR) metamodel is combined with the Monte Carlo simulation (MCS) method to conduct the uncertainty analysis of fouled impeller performance. The analyzed results show that the critical fouled region associated with impeller performance degradations lies at the leading edge of blade tip. The SVR metamodel has been proved to be an efficient and accurate means in the detection of impeller performance variations caused by roughness uncertainties. After design optimization, the robust optimal design is found to be more efficient and less sensitive to fouling uncertainties while maintaining good impeller performance in the clean condition. This research proposes a systematic design optimization method for centrifugal compressors with considerations of blade fouling, providing a practical guidance to the design of advanced centrifugal compressors.
2016, 30(2): 315-324.
doi: 10.3901/CJME.2015.1224.154
Abstract:
Improper design of volute geometry can be the main cause that leads to unsteady pressure pulsation and radial force in pumps. Therefore, it is important to understand the influence of volute geometrical parameters on hydrodynamic characteristics of pump and the mechanism. However, the existing studies are limited to investigate the influence of only one or two volute geometrical parameters each time, and a systematic study of the influence of the combinations of different volute geometrical parameters on the pumps hydrodynamic characteristics is missing. In this paper, a study on the understanding of the influence of volute geometrical variations on hydrodynamic characteristics of a high speed circulator pump by using computational fluid dynamics(CFD) technology is presented. Five main volute geometrical parameters D3, A8, 0, 0 and Rt are selected and 25 different volute configurations are generated by using design of experiments(DOE) method. The 3D unsteady flow numerical simulations, which are based on the SST k-w turbulence model and sliding mesh technique provided by CFX, are executed on the 25 different volute configurations. The hydraulic performance, pressure pulsation and unsteady radial force inside the pump at design condition are obtained and analyzed. It has been found that volute geometrical parameters D3 and A8 are major influence factors on hydrodynamic characteristics of the pump, while 0, 0 and Rt are minor influence factors. The minimum contribution from both D3 and A8 is 58% on head, and maximum contribution from both D3 and A8 is 90% on pressure pulsation. Regarding the pressure pulsation intensity, two peaks can be found. One is in the tongue area and the other is in the diffusor area. The contributions are around 60% from tongue and 25% from diffusor, respectively. The amplitude of pressure pulsation has a quadratic polynomial functional relationship with respect toD3/D2 and A8/A10, and fluctuating level of radial force has a quadratic polynomial functional relationship with respect toD3/D2. While for the other volute parameters 0, 0 and Rt, no special function has been found related to pressure pulsation and radial force. The presented work could be a useful guideline in engineering practice when designing a circulator pump with low hydrodynamic force.
Improper design of volute geometry can be the main cause that leads to unsteady pressure pulsation and radial force in pumps. Therefore, it is important to understand the influence of volute geometrical parameters on hydrodynamic characteristics of pump and the mechanism. However, the existing studies are limited to investigate the influence of only one or two volute geometrical parameters each time, and a systematic study of the influence of the combinations of different volute geometrical parameters on the pumps hydrodynamic characteristics is missing. In this paper, a study on the understanding of the influence of volute geometrical variations on hydrodynamic characteristics of a high speed circulator pump by using computational fluid dynamics(CFD) technology is presented. Five main volute geometrical parameters D3, A8, 0, 0 and Rt are selected and 25 different volute configurations are generated by using design of experiments(DOE) method. The 3D unsteady flow numerical simulations, which are based on the SST k-w turbulence model and sliding mesh technique provided by CFX, are executed on the 25 different volute configurations. The hydraulic performance, pressure pulsation and unsteady radial force inside the pump at design condition are obtained and analyzed. It has been found that volute geometrical parameters D3 and A8 are major influence factors on hydrodynamic characteristics of the pump, while 0, 0 and Rt are minor influence factors. The minimum contribution from both D3 and A8 is 58% on head, and maximum contribution from both D3 and A8 is 90% on pressure pulsation. Regarding the pressure pulsation intensity, two peaks can be found. One is in the tongue area and the other is in the diffusor area. The contributions are around 60% from tongue and 25% from diffusor, respectively. The amplitude of pressure pulsation has a quadratic polynomial functional relationship with respect toD3/D2 and A8/A10, and fluctuating level of radial force has a quadratic polynomial functional relationship with respect toD3/D2. While for the other volute parameters 0, 0 and Rt, no special function has been found related to pressure pulsation and radial force. The presented work could be a useful guideline in engineering practice when designing a circulator pump with low hydrodynamic force.
2016, 30(2): 325-331.
doi: 10.3901/CJME.2015.1028.128
Abstract:
The need to continuously separate multiple microparticles is required for the recent development of lab-on-chip technology.Dielectrophoresis(DEP)-based separation device is extensively used in kinds of microfluidic applications. However, such conventional DEP-based device is relatively complicated and difficult for fabrication. A concise microfluidic device is presented for effective continuous separation of multiple size particle mixtures. A pair of acupuncture needle electrodes are creatively employed and embedded in a PDMS(poly-dimethylsiloxane) hurdle for generating non-uniform electric field thereby achieving a continuous DEP separation. The separation mechanism is that the incoming particle samples with different sizes experience different negative DEP(nDEP) forces and then they can be transported into different downstream outlets. The DEP characterizations of particles are calculated, and their trajectories are numerically predicted by considering the combined action of the incoming laminar flow and the nDEP force field for guiding the separation experiments. The device performance is verified by successfully separating a three-sized particle mixture, including polystyrene microspheres with diameters of 3 m, 10 m and 25 m. The separation purity is below 70% when the flow rate ratio is less than 3.5 or more than 5.1, while the separation purity can be up to more than 90% when the flow rate ratio is between 3.5 and 5.1 and meanwhile ensure the voltage output falls in between 120 V and 150 V. Such simple DEP-based separation device has extensive applications in future microfluidic systems.
The need to continuously separate multiple microparticles is required for the recent development of lab-on-chip technology.Dielectrophoresis(DEP)-based separation device is extensively used in kinds of microfluidic applications. However, such conventional DEP-based device is relatively complicated and difficult for fabrication. A concise microfluidic device is presented for effective continuous separation of multiple size particle mixtures. A pair of acupuncture needle electrodes are creatively employed and embedded in a PDMS(poly-dimethylsiloxane) hurdle for generating non-uniform electric field thereby achieving a continuous DEP separation. The separation mechanism is that the incoming particle samples with different sizes experience different negative DEP(nDEP) forces and then they can be transported into different downstream outlets. The DEP characterizations of particles are calculated, and their trajectories are numerically predicted by considering the combined action of the incoming laminar flow and the nDEP force field for guiding the separation experiments. The device performance is verified by successfully separating a three-sized particle mixture, including polystyrene microspheres with diameters of 3 m, 10 m and 25 m. The separation purity is below 70% when the flow rate ratio is less than 3.5 or more than 5.1, while the separation purity can be up to more than 90% when the flow rate ratio is between 3.5 and 5.1 and meanwhile ensure the voltage output falls in between 120 V and 150 V. Such simple DEP-based separation device has extensive applications in future microfluidic systems.
2016, 30(2): 332-341.
doi: 10.3901/CJME.2015.1225.155
Abstract:
Optimization of a manufacturing process results in higher productivity and reduced wastes. Production parameters of a local steel bar manufacturing industry of Pakistan is optimized by using six Sigma-Define, Measure, Analyze, Improve, and Control- methodology. Production data is collected and analyzed. After analysis, experimental design result is used to identify significant factors affecting process performance. The significant factors are controlled to optimized level using two-level factorial design method. A regression model is developed that helps in the estimation of response under multi variable input values. Model is tested, verified, and validated by using industrial data collected at a local steel bar manufacturing industry of Peshawar(Khyber Pakhtunkhwa, Pakistan). The sigma level of the manufacturing process is improved to 4.01 from 3.58. The novelty of the research is the identification of the significant factors along with the optimum levels that affects the process yield, and the methodology to optimize the steel bar manufacturing process.
Optimization of a manufacturing process results in higher productivity and reduced wastes. Production parameters of a local steel bar manufacturing industry of Pakistan is optimized by using six Sigma-Define, Measure, Analyze, Improve, and Control- methodology. Production data is collected and analyzed. After analysis, experimental design result is used to identify significant factors affecting process performance. The significant factors are controlled to optimized level using two-level factorial design method. A regression model is developed that helps in the estimation of response under multi variable input values. Model is tested, verified, and validated by using industrial data collected at a local steel bar manufacturing industry of Peshawar(Khyber Pakhtunkhwa, Pakistan). The sigma level of the manufacturing process is improved to 4.01 from 3.58. The novelty of the research is the identification of the significant factors along with the optimum levels that affects the process yield, and the methodology to optimize the steel bar manufacturing process.
2016, 30(2): 342-350.
doi: 10.3901/CJME.2015.0824.106
Abstract:
Flexible roll forming is a promising manufacturing method for the production of variable cross section products. Considering the large plastic strain in this forming process which is much larger than that of uniform deformation phase of uniaxial tensile test, the widely adopted method of simulating the forming processes with non-supplemented material data from uniaxial tensile test will certainly lead to large error. To reduce this error, the material data is supplemented based on three constitutive models. Then a finite element model of a six passes flexible roll forming process is established based on the supplemented material data and the original material data from the uniaxial tensile test. The flexible roll forming experiment of a B pillar reinforcing plate is carried out to verify the proposed method. Final cross section shapes of the experimental and the simulated results are compared. It is shown that the simulation calculated with supplemented material data based on Swift model agrees well with the experimental results, while the simulation based on original material data could not predict the actual deformation accurately. The results indicate that this material supplement method is reliable and indispensible, and the simulation model can well reflect the real metal forming process. Detailed analysis of the distribution and history of plastic strain at different positions are performed. A new material data supplement method is proposed to tackle the problem which is ignored in other roll forming simulations, and thus the forming process simulation accuracy can be greatly improved.
Flexible roll forming is a promising manufacturing method for the production of variable cross section products. Considering the large plastic strain in this forming process which is much larger than that of uniform deformation phase of uniaxial tensile test, the widely adopted method of simulating the forming processes with non-supplemented material data from uniaxial tensile test will certainly lead to large error. To reduce this error, the material data is supplemented based on three constitutive models. Then a finite element model of a six passes flexible roll forming process is established based on the supplemented material data and the original material data from the uniaxial tensile test. The flexible roll forming experiment of a B pillar reinforcing plate is carried out to verify the proposed method. Final cross section shapes of the experimental and the simulated results are compared. It is shown that the simulation calculated with supplemented material data based on Swift model agrees well with the experimental results, while the simulation based on original material data could not predict the actual deformation accurately. The results indicate that this material supplement method is reliable and indispensible, and the simulation model can well reflect the real metal forming process. Detailed analysis of the distribution and history of plastic strain at different positions are performed. A new material data supplement method is proposed to tackle the problem which is ignored in other roll forming simulations, and thus the forming process simulation accuracy can be greatly improved.
2016, 30(2): 351-356.
doi: 10.3901/CJME.2015.1104.131
Abstract:
Welding polarity has influence on welding stability to some extent, but the specific relationship between welding polarity and weld quality has not been found, especially under the hyperbaric environment. Based on a hyperbaric dry welding experiment system, gas metal arc welding(GMAW) experiments with direct current electrode positive(DCEP) and direct current electrode negative(DCEN) operations are carried out under the ambient pressures of 0.1 MPa, 0.4 MPa, 0.7 MPa and 1.0 MPa to find the influence rule of different welding polarities on welding spatters and weld bead geometry. The effects of welding polarities on the weld bead geometry such as the reinforcement, the weld width and the penetration are discussed. The experimental results show that the welding spatters gradually grow in quantity and size for GMAW with DCEP, while GMAW with DCEN can produce fewer spatters comparatively with the increase of the ambient pressure. Compared with DCEP, the welding current and arc voltage waveforms for DCEN is more stable and the distribution of welding current probability density for DCEN is more concentrated under the hyperbaric environment. When the ambient pressure is increased from 0.1 MPa to 1.0 MPa, the effects of welding polarities on the reinforcement, the weld width and the penetration are as follows: an increase of 0.8 mm for the weld reinforcement is produced by GMAW with DCEN and 1.3 mm by GMAW with DCEP, a decrease of 7.2 mm for the weld width is produced by DCEN and 6.1 mm by DCEP; and an increase of 3.9 mm for the penetration is produced by DCEN and 1.9 mm by DCEP. The proposed research indicates that the desirable stability in the welding procedure can be achieved by GMAW with DCEN operation under the hyperbaric environment.
Welding polarity has influence on welding stability to some extent, but the specific relationship between welding polarity and weld quality has not been found, especially under the hyperbaric environment. Based on a hyperbaric dry welding experiment system, gas metal arc welding(GMAW) experiments with direct current electrode positive(DCEP) and direct current electrode negative(DCEN) operations are carried out under the ambient pressures of 0.1 MPa, 0.4 MPa, 0.7 MPa and 1.0 MPa to find the influence rule of different welding polarities on welding spatters and weld bead geometry. The effects of welding polarities on the weld bead geometry such as the reinforcement, the weld width and the penetration are discussed. The experimental results show that the welding spatters gradually grow in quantity and size for GMAW with DCEP, while GMAW with DCEN can produce fewer spatters comparatively with the increase of the ambient pressure. Compared with DCEP, the welding current and arc voltage waveforms for DCEN is more stable and the distribution of welding current probability density for DCEN is more concentrated under the hyperbaric environment. When the ambient pressure is increased from 0.1 MPa to 1.0 MPa, the effects of welding polarities on the reinforcement, the weld width and the penetration are as follows: an increase of 0.8 mm for the weld reinforcement is produced by GMAW with DCEN and 1.3 mm by GMAW with DCEP, a decrease of 7.2 mm for the weld width is produced by DCEN and 6.1 mm by DCEP; and an increase of 3.9 mm for the penetration is produced by DCEN and 1.9 mm by DCEP. The proposed research indicates that the desirable stability in the welding procedure can be achieved by GMAW with DCEN operation under the hyperbaric environment.
2016, 30(2): 357-364.
doi: 10.3901/CJME.2016.0105.002
Abstract:
In practical engineering, finite element(FE) modeling for weld seam is commonly simplified by neglecting its inhomogeneous mechanical properties. This will cause a significant loss in accuracy of FE forming analysis, in particular, for friction stir welded(FSW) blanks due to the large width and good formability of its weld seam. The inhomogeneous mechanical properties across weld seam need to be well characterized for an accurate FE analysis. Based on a similar AA5182 FSW blank, the metallographic observation and micro-Vickers hardness analysis upon the weld cross-section are performed to identify the interfaces of different sub-zones, i.e., heat affected zone (HAZ), thermal-mechanically affected zone (TMAZ) and weld nugget (WN). Based on the rule of mixture and hardness distribution, a constitutive model is established for each sub-zone to characterize the inhomogeneous mechanical properties across the weld seam. Uniaxial tensile tests of the AA5182 FSW blank are performed with the aid of digital image correlation(DIC) techniques. Experimental local stress-strain curves are obtained for different weld sub-zones. The experimental results show good agreement with those derived from the constitutive models, which demonstrates the feasibility and accuracy of these models. The proposed research gives an accurate characterization of inhomogeneous mechanical properties across the weld seam produced by FSW, which provides solutions for improving the FE simulation accuracy of FSW sheet forming.
In practical engineering, finite element(FE) modeling for weld seam is commonly simplified by neglecting its inhomogeneous mechanical properties. This will cause a significant loss in accuracy of FE forming analysis, in particular, for friction stir welded(FSW) blanks due to the large width and good formability of its weld seam. The inhomogeneous mechanical properties across weld seam need to be well characterized for an accurate FE analysis. Based on a similar AA5182 FSW blank, the metallographic observation and micro-Vickers hardness analysis upon the weld cross-section are performed to identify the interfaces of different sub-zones, i.e., heat affected zone (HAZ), thermal-mechanically affected zone (TMAZ) and weld nugget (WN). Based on the rule of mixture and hardness distribution, a constitutive model is established for each sub-zone to characterize the inhomogeneous mechanical properties across the weld seam. Uniaxial tensile tests of the AA5182 FSW blank are performed with the aid of digital image correlation(DIC) techniques. Experimental local stress-strain curves are obtained for different weld sub-zones. The experimental results show good agreement with those derived from the constitutive models, which demonstrates the feasibility and accuracy of these models. The proposed research gives an accurate characterization of inhomogeneous mechanical properties across the weld seam produced by FSW, which provides solutions for improving the FE simulation accuracy of FSW sheet forming.
2016, 30(2): 365-371.
doi: 10.3901/CJME.2015.1023.126
Abstract:
To address the difficulty in testing and calibrating the stress gradient in the depth direction of mechanical components, a new technology of nondestructive testing and characterization of the residual stress gradient field by ultrasonic method is proposed based on acoustoelasticity theory. By carrying out theoretical analysis, the sensitivity coefficients of different types of ultrasonic are obtained by taking the low carbon steel(12%C) as a research object. By fixing the interval distance between sending and receiving transducers, the mathematical expressions of the change of stress and the variation of time are established. To design one sending-one receiving and oblique incidence ultrasonic detection probes, according to Snell law, the critically refracted longitudinal wave (LCR wave) is excited at a certain depth of the fixed distance of the tested components. Then, the relationship between the depth of LCR wave detection and the center frequency of the probe in Q235 steel is obtained through experimental study. To detect the stress gradient in the depth direction, a stress gradient LCR wave detection model is established, through which the stress gradient formula is derived by the relationship between center frequency and detecting depth. A C-shaped stress specimen of Q235 steel is designed to conduct stress loading tests, and the stress is measured with the five group probes at different center frequencies. The accuracy of ultrasonic testing is verified by X-ray stress analyzer. The stress value of each specific depth is calculated using the stress gradient formula. Accordingly, the ultrasonic characterization of residual stress field is realized. Characterization results show that the stress gradient distribution is consistent with the simulation in ANSYS. The new technology can be widely applied in the detection of the residual stress gradient field caused by mechanical processing, such as welding and shot peening.
To address the difficulty in testing and calibrating the stress gradient in the depth direction of mechanical components, a new technology of nondestructive testing and characterization of the residual stress gradient field by ultrasonic method is proposed based on acoustoelasticity theory. By carrying out theoretical analysis, the sensitivity coefficients of different types of ultrasonic are obtained by taking the low carbon steel(12%C) as a research object. By fixing the interval distance between sending and receiving transducers, the mathematical expressions of the change of stress and the variation of time are established. To design one sending-one receiving and oblique incidence ultrasonic detection probes, according to Snell law, the critically refracted longitudinal wave (LCR wave) is excited at a certain depth of the fixed distance of the tested components. Then, the relationship between the depth of LCR wave detection and the center frequency of the probe in Q235 steel is obtained through experimental study. To detect the stress gradient in the depth direction, a stress gradient LCR wave detection model is established, through which the stress gradient formula is derived by the relationship between center frequency and detecting depth. A C-shaped stress specimen of Q235 steel is designed to conduct stress loading tests, and the stress is measured with the five group probes at different center frequencies. The accuracy of ultrasonic testing is verified by X-ray stress analyzer. The stress value of each specific depth is calculated using the stress gradient formula. Accordingly, the ultrasonic characterization of residual stress field is realized. Characterization results show that the stress gradient distribution is consistent with the simulation in ANSYS. The new technology can be widely applied in the detection of the residual stress gradient field caused by mechanical processing, such as welding and shot peening.
2016, 30(2): 372-377.
doi: 10.3901/CJME.2015.1119.136
Abstract:
Metal magnetic memory(MMM) testing has been widely used to detect welded joints. However, load levels, environmental magnetic field, and measurement noises make the MMM data dispersive and bring difficulty to quantitative evaluation. In order to promote the development of quantitative MMM reliability assessment, a new MMM model is presented for welded joints. Steel Q235 welded specimens are tested along the longitudinal and horizontal lines by TSC-2M-8 instrument in the tensile fatigue experiments. The X-ray testing is carried out synchronously to verify the MMM results. It is found that MMM testing can detect the hidden crack earlier than X-ray testing. Moreover, the MMM gradient vector sum Kvs is sensitive to the damage degree, especially at early and hidden damage stages. Considering the dispersion of MMM data, the Kvs statistical law is investigated, which shows that Kvs obeys Gaussian distribution. So Kvs is the suitable MMM parameter to establish reliability model of welded joints. At last, the original quantitative MMM reliability model is first presented based on the improved stress strength interference theory. It is shown that the reliability degree R gradually decreases with the decreasing of the residual life ratio T, and the maximal error between prediction reliability degree R1 and verification reliability degree R2 is 9.15%. This presented method provides a novel tool of reliability testing and evaluating in practical engineering for welded joints.
Metal magnetic memory(MMM) testing has been widely used to detect welded joints. However, load levels, environmental magnetic field, and measurement noises make the MMM data dispersive and bring difficulty to quantitative evaluation. In order to promote the development of quantitative MMM reliability assessment, a new MMM model is presented for welded joints. Steel Q235 welded specimens are tested along the longitudinal and horizontal lines by TSC-2M-8 instrument in the tensile fatigue experiments. The X-ray testing is carried out synchronously to verify the MMM results. It is found that MMM testing can detect the hidden crack earlier than X-ray testing. Moreover, the MMM gradient vector sum Kvs is sensitive to the damage degree, especially at early and hidden damage stages. Considering the dispersion of MMM data, the Kvs statistical law is investigated, which shows that Kvs obeys Gaussian distribution. So Kvs is the suitable MMM parameter to establish reliability model of welded joints. At last, the original quantitative MMM reliability model is first presented based on the improved stress strength interference theory. It is shown that the reliability degree R gradually decreases with the decreasing of the residual life ratio T, and the maximal error between prediction reliability degree R1 and verification reliability degree R2 is 9.15%. This presented method provides a novel tool of reliability testing and evaluating in practical engineering for welded joints.
2016, 30(2): 378-385.
doi: 10.3901/CJME.2015.1216.149
Abstract:
Conventional servomotor and stepping motor face challenges in nanometer positioning stages due to the complex structure, motion transformation mechanism, and slow dynamic response, especially directly driven by linear motor. A new butterfly-shaped linear piezoelectric motor for linear motion is presented. A two-degree precision position stage driven by the proposed linear ultrasonic motor possesses a simple and compact configuration, which makes the system obtain shorter driving chain. Firstly, the working principle of the linear ultrasonic motor is analyzed. The oscillation orbits of two driving feet on the stator are produced successively by using the anti-symmetric and symmetric vibration modes of the piezoelectric composite structure, and the slider pressed on the driving feet can be propelled twice in only one vibration cycle. Then with the derivation of the dynamic equation of the piezoelectric actuator and transient response model, start-upstart-up and settling state characteristics of the proposed linear actuator is investigated theoretically and experimentally, and is applicable to evaluate step resolution of the precision platform driven by the actuator. Moreover the structure of the two-degree position stage system is described and a special precision displacement measurement system is built. Finally, the characteristics of the two-degree position stage are studied. In the closed-loop condition the positioning accuracy of plus or minus 0.5 m is experimentally obtained for the stage propelled by the piezoelectric motor. A precision position stage based the proposed butterfly-shaped linear piezoelectric is theoretically and experimentally investigated.
Conventional servomotor and stepping motor face challenges in nanometer positioning stages due to the complex structure, motion transformation mechanism, and slow dynamic response, especially directly driven by linear motor. A new butterfly-shaped linear piezoelectric motor for linear motion is presented. A two-degree precision position stage driven by the proposed linear ultrasonic motor possesses a simple and compact configuration, which makes the system obtain shorter driving chain. Firstly, the working principle of the linear ultrasonic motor is analyzed. The oscillation orbits of two driving feet on the stator are produced successively by using the anti-symmetric and symmetric vibration modes of the piezoelectric composite structure, and the slider pressed on the driving feet can be propelled twice in only one vibration cycle. Then with the derivation of the dynamic equation of the piezoelectric actuator and transient response model, start-upstart-up and settling state characteristics of the proposed linear actuator is investigated theoretically and experimentally, and is applicable to evaluate step resolution of the precision platform driven by the actuator. Moreover the structure of the two-degree position stage system is described and a special precision displacement measurement system is built. Finally, the characteristics of the two-degree position stage are studied. In the closed-loop condition the positioning accuracy of plus or minus 0.5 m is experimentally obtained for the stage propelled by the piezoelectric motor. A precision position stage based the proposed butterfly-shaped linear piezoelectric is theoretically and experimentally investigated.
2016, 30(2): 386-395.
doi: 10.3901/CJME.2015.1211.145
Abstract:
Intake system of diesel engine is a strong nonlinear system, and it is difficult to establish accurate model of intake system; and bias fault and precision degradation fault of MAP of diesel engine cant be diagnosed easily using model-based methods. Thus, a fault diagnosis method based on Elman neural network observer is proposed. By comparing simulation results of intake pressure based on BP network and Elman neural network, lower sampling error magnitude is gained using Elman neural network, and the error is less volatile. Forecast accuracy is between 0.015-0.017 5 and sample error is controlled within 0-0.07. Considering the output stability and complexity of solving comprehensively, Elman neural network with a single hidden layer and with 44 nodes is presented as intake system observer. By comparing the relations of confidence intervals of the residual value between the measured and predicted values, error variance and failures in various fault types. Then four typical MAP faults of diesel engine can be diagnosed: complete failure fault, bias fault, precision degradation fault and drift fault. The simulation results show: intake pressure is observable and selection of diagnostic strategy parameter reasonably can increase the accuracy of diagnosis；the proposed fault diagnosis method only depends on data and structural parameters of observer, not depends on the nonlinear model of air intake system. A fault diagnosis method is proposed not depending system model to observe intake pressure, and bias fault and precision degradation fault of MAP of diesel engine can be diagnosed based on residuals.
Intake system of diesel engine is a strong nonlinear system, and it is difficult to establish accurate model of intake system; and bias fault and precision degradation fault of MAP of diesel engine cant be diagnosed easily using model-based methods. Thus, a fault diagnosis method based on Elman neural network observer is proposed. By comparing simulation results of intake pressure based on BP network and Elman neural network, lower sampling error magnitude is gained using Elman neural network, and the error is less volatile. Forecast accuracy is between 0.015-0.017 5 and sample error is controlled within 0-0.07. Considering the output stability and complexity of solving comprehensively, Elman neural network with a single hidden layer and with 44 nodes is presented as intake system observer. By comparing the relations of confidence intervals of the residual value between the measured and predicted values, error variance and failures in various fault types. Then four typical MAP faults of diesel engine can be diagnosed: complete failure fault, bias fault, precision degradation fault and drift fault. The simulation results show: intake pressure is observable and selection of diagnostic strategy parameter reasonably can increase the accuracy of diagnosis；the proposed fault diagnosis method only depends on data and structural parameters of observer, not depends on the nonlinear model of air intake system. A fault diagnosis method is proposed not depending system model to observe intake pressure, and bias fault and precision degradation fault of MAP of diesel engine can be diagnosed based on residuals.
2016, 30(2): 396-405.
doi: 10.3901/CJME.2015.1214. 147
Abstract:
The high accurate classification ability of an intelligent diagnosis method often needs a large amount of training samples with high-dimensional eigenvectors, however the characteristics of the signal need to be extracted accurately. Although the existing EMD(empirical mode decomposition) and EEMD(ensemble empirical mode decomposition) are suitable for processing non-stationary and non-linear signals, but when a short signal, such as a hydraulic impact signal, is concerned, their decomposition accuracy become very poor. An improve EEMD is proposed specifically for short hydraulic impact signals. The improvements of this new EEMD are mainly reflected in four aspects, including self-adaptive de-noising based on EEMD, signal extension based on SVM(support vector machine), extreme center fitting based on cubic spline interpolation, and pseudo component exclusion based on cross-correlation analysis. After the energy eigenvector is extracted from the result of the improved EEMD, the fault pattern recognition based on SVM with small amount of low-dimensional training samples is studied. At last, the diagnosis ability of improved EEMD+SVM method is compared with the EEMD+SVM and EMD+SVM methods, and its diagnosis accuracy is distinctly higher than the other two methods no matter the dimension of the eigenvectors are low or high. The improved EEMD is very propitious for the decomposition of short signal, such as hydraulic impact signal, and its combination with SVM has high ability for the diagnosis of hydraulic impact faults.
The high accurate classification ability of an intelligent diagnosis method often needs a large amount of training samples with high-dimensional eigenvectors, however the characteristics of the signal need to be extracted accurately. Although the existing EMD(empirical mode decomposition) and EEMD(ensemble empirical mode decomposition) are suitable for processing non-stationary and non-linear signals, but when a short signal, such as a hydraulic impact signal, is concerned, their decomposition accuracy become very poor. An improve EEMD is proposed specifically for short hydraulic impact signals. The improvements of this new EEMD are mainly reflected in four aspects, including self-adaptive de-noising based on EEMD, signal extension based on SVM(support vector machine), extreme center fitting based on cubic spline interpolation, and pseudo component exclusion based on cross-correlation analysis. After the energy eigenvector is extracted from the result of the improved EEMD, the fault pattern recognition based on SVM with small amount of low-dimensional training samples is studied. At last, the diagnosis ability of improved EEMD+SVM method is compared with the EEMD+SVM and EMD+SVM methods, and its diagnosis accuracy is distinctly higher than the other two methods no matter the dimension of the eigenvectors are low or high. The improved EEMD is very propitious for the decomposition of short signal, such as hydraulic impact signal, and its combination with SVM has high ability for the diagnosis of hydraulic impact faults.
2016, 30(2): 406-420.
doi: 10.3901/CJME.2015.1217.150
Abstract:
Traditional modular design methods lead to product maintenance problems, because the module form of a system is created according to either the function requirements or the manufacturing considerations. For solving these problems, a new modular design method is proposed with the considerations of not only the traditional function related attributes, but also the maintenance related ones. First, modularity parameters and modularity scenarios for product modularity are defined. Then the reliability and economic assessment models of product modularity strategies are formulated with the introduction of the effective working age of modules. A mathematical model used to evaluate the difference among the modules of the product so that the optimal module of the product can be established. After that, a multi-objective optimization problem based on metrics for preventive maintenance interval different degrees and preventive maintenance economics is formulated for modular optimization. Multi-objective GA is utilized to rapidly approximate the Pareto set of optimal modularity strategy trade-offs between preventive maintenance cost and preventive maintenance interval difference degree. Finally, a coordinate CNC boring machine is adopted to depict the process of product modularity. In addition, two factorial design experiments based on the modularity parameters are constructed and analyzed. These experiments investigate the impacts of these parameters on the optimal modularity strategies and the structure of module. The research proposes a new modular design method, which may help to improve the maintainability of product in modular design.
Traditional modular design methods lead to product maintenance problems, because the module form of a system is created according to either the function requirements or the manufacturing considerations. For solving these problems, a new modular design method is proposed with the considerations of not only the traditional function related attributes, but also the maintenance related ones. First, modularity parameters and modularity scenarios for product modularity are defined. Then the reliability and economic assessment models of product modularity strategies are formulated with the introduction of the effective working age of modules. A mathematical model used to evaluate the difference among the modules of the product so that the optimal module of the product can be established. After that, a multi-objective optimization problem based on metrics for preventive maintenance interval different degrees and preventive maintenance economics is formulated for modular optimization. Multi-objective GA is utilized to rapidly approximate the Pareto set of optimal modularity strategy trade-offs between preventive maintenance cost and preventive maintenance interval difference degree. Finally, a coordinate CNC boring machine is adopted to depict the process of product modularity. In addition, two factorial design experiments based on the modularity parameters are constructed and analyzed. These experiments investigate the impacts of these parameters on the optimal modularity strategies and the structure of module. The research proposes a new modular design method, which may help to improve the maintainability of product in modular design.
2016, 30(2): 421-429.
doi: 10.3901/CJME.2015.1221.152
Abstract:
The current mathematical models for the storage assignment problem are generally established based on the traveling salesman problem(TSP), which has been widely applied in the conventional automated storage and retrieval system(AS/RS). However, the previous mathematical models in conventional AS/RS do not match multi-tier shuttle warehousing systems(MSWS) because the characteristics of parallel retrieval in multiple tiers and progressive vertical movement destroy the foundation of TSP. In this study, a two-stage open queuing network model in which shuttles and a lift are regarded as servers at different stages is proposed to analyze system performance in the terms of shuttle waiting period (SWP) and lift idle period (LIP) during transaction cycle time. A mean arrival time difference matrix for pair wise stock keeping units(SKUs) is presented to determine the mean waiting time and queue length and to optimize the storage assignment problem on the basis of SKU correlation. The decomposition method is applied to analyze the interactions among outbound task time, SWP, and LIP. The ant colony clustering algorithm is designed to determine storage partitions using clustering items. In addition, goods are assigned for storage according to the rearranging permutation and the combination of storage partitions in a 2D plane. This combination is derived based on the analysis results of the queuing network model and on three basic principles. The storage assignment method and its entire optimization algorithm method as applied in a MSWS are verified through a practical engineering project conducted in the tobacco industry. The applying results show that the total SWP and LIP can be reduced effectively to improve the utilization rates of all devices and to increase the throughput of the distribution center.
The current mathematical models for the storage assignment problem are generally established based on the traveling salesman problem(TSP), which has been widely applied in the conventional automated storage and retrieval system(AS/RS). However, the previous mathematical models in conventional AS/RS do not match multi-tier shuttle warehousing systems(MSWS) because the characteristics of parallel retrieval in multiple tiers and progressive vertical movement destroy the foundation of TSP. In this study, a two-stage open queuing network model in which shuttles and a lift are regarded as servers at different stages is proposed to analyze system performance in the terms of shuttle waiting period (SWP) and lift idle period (LIP) during transaction cycle time. A mean arrival time difference matrix for pair wise stock keeping units(SKUs) is presented to determine the mean waiting time and queue length and to optimize the storage assignment problem on the basis of SKU correlation. The decomposition method is applied to analyze the interactions among outbound task time, SWP, and LIP. The ant colony clustering algorithm is designed to determine storage partitions using clustering items. In addition, goods are assigned for storage according to the rearranging permutation and the combination of storage partitions in a 2D plane. This combination is derived based on the analysis results of the queuing network model and on three basic principles. The storage assignment method and its entire optimization algorithm method as applied in a MSWS are verified through a practical engineering project conducted in the tobacco industry. The applying results show that the total SWP and LIP can be reduced effectively to improve the utilization rates of all devices and to increase the throughput of the distribution center.
2016, 30(2): 430-438.
doi: 10.3901/CJME.2016.0106.003
Abstract:
Product variation reduction is critical to improve process efficiency and product quality, especially for multistage machining process (MMP). However, due to the variation accumulation and propagation, it becomes quite difficult to predict and reduce product variation for MMP. While the method of statistical process control can be used to control product quality, it is used mainly to monitor the process change rather than to analyze the cause of product variation. In this paper, based on a differential description of the contact kinematics of locators and part surfaces, and the geometric constraints equation defined by the locating scheme, an improved analytical variation propagation model for MMP is presented. In which the influence of both locator position and machining error on part quality is considered while, in traditional model, it usually focuses on datum error and fixture error. Coordinate transformation theory is used to reflect the generation and transmission laws of error in the establishment of the model. The concept of deviation matrix is heavily applied to establish an explicit mapping between the geometric deviation of part and the process error sources. In each machining stage, the part deviation is formulized as three separated components corresponding to three different kinds of error sources, which can be further applied to fault identification and design optimization for complicated machining process. An example part for MMP is given out to validate the effectiveness of the methodology. The experiment results show that the model prediction and the actual measurement match well. This paper provides a method to predict part deviation under the influence of fixture error, datum error and machining error, and it enriches the way of quality prediction for MMP.
Product variation reduction is critical to improve process efficiency and product quality, especially for multistage machining process (MMP). However, due to the variation accumulation and propagation, it becomes quite difficult to predict and reduce product variation for MMP. While the method of statistical process control can be used to control product quality, it is used mainly to monitor the process change rather than to analyze the cause of product variation. In this paper, based on a differential description of the contact kinematics of locators and part surfaces, and the geometric constraints equation defined by the locating scheme, an improved analytical variation propagation model for MMP is presented. In which the influence of both locator position and machining error on part quality is considered while, in traditional model, it usually focuses on datum error and fixture error. Coordinate transformation theory is used to reflect the generation and transmission laws of error in the establishment of the model. The concept of deviation matrix is heavily applied to establish an explicit mapping between the geometric deviation of part and the process error sources. In each machining stage, the part deviation is formulized as three separated components corresponding to three different kinds of error sources, which can be further applied to fault identification and design optimization for complicated machining process. An example part for MMP is given out to validate the effectiveness of the methodology. The experiment results show that the model prediction and the actual measurement match well. This paper provides a method to predict part deviation under the influence of fixture error, datum error and machining error, and it enriches the way of quality prediction for MMP.
2016, 30(2): 439-444.
doi: 10.3901/CJME.2015.1028.129
Abstract:
The performance of a lubricant largely depends on the additives it involves. However, currently used additives cause severe pollution if they are burned and exhausted. Therefore, it is necessary to develop a new generation of green additives. Graphene oxide (GO) consists of only C, H and O and thus is considered to be environmentally friendly. So the tribological properties of the few-layer GO sheet as an additive in hydrocarbon base oil are investigated systematically. It is found that, with the addition of GO sheets, both the coefficient of friction (COF) and wear are decreased and the working temperature range of the lubricant is expanded in the positive direction. Moreover, GO sheets has better performance under higher sliding speed and the optimized concentration of GO sheets is determined to be 0.5wt%. After rubbing, GO is detected on the wear scars through Raman spectroscopy. And it is believed that, during the rubbing, GO sheets adhere to the sliding surfaces, behaving like protective films and preventing the sliding surfaces from contacting with each other directly. This paper proves that the GO sheet is an effective lubricant additive, illuminates the lubrication mechanism, and provides some critical parameters for the practical application of GO sheets in lubrication.
The performance of a lubricant largely depends on the additives it involves. However, currently used additives cause severe pollution if they are burned and exhausted. Therefore, it is necessary to develop a new generation of green additives. Graphene oxide (GO) consists of only C, H and O and thus is considered to be environmentally friendly. So the tribological properties of the few-layer GO sheet as an additive in hydrocarbon base oil are investigated systematically. It is found that, with the addition of GO sheets, both the coefficient of friction (COF) and wear are decreased and the working temperature range of the lubricant is expanded in the positive direction. Moreover, GO sheets has better performance under higher sliding speed and the optimized concentration of GO sheets is determined to be 0.5wt%. After rubbing, GO is detected on the wear scars through Raman spectroscopy. And it is believed that, during the rubbing, GO sheets adhere to the sliding surfaces, behaving like protective films and preventing the sliding surfaces from contacting with each other directly. This paper proves that the GO sheet is an effective lubricant additive, illuminates the lubrication mechanism, and provides some critical parameters for the practical application of GO sheets in lubrication.
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