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Machines
Volume 8
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Machines, Volume 8, Issue 2 (June 2020) – 19 articles

Cover Story (view full-size image): The power density and efficiency of electric machines used for automotive traction continues to improve. The designs used in recent vehicles are converging on interior permanent magnet machine topology, where substantial innovations in rotor and stator design have evolved over the years. There is also an increasing trend toward the reduction of rare-earth permanent magnet content in these machines and this will continue to inspire new topologies of machines. Resurgence of research into traditional topologies such as switched reluctance and synchronous reluctance machines may also be expected. This paper provides an overview of present trends towards high specific power density machines for traction drive systems, with a focus on technology used in recent vehicles and trends that are likely to be pursued in the near future. View this paper
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17 pages, 3205 KiB  
Article
Practical Classification and Evaluation of Optically Recorded Food Data by Using Various Big-Data Analysis Technologies
by Tim Jarschel, Christoph Laroque, Ronny Maschke and Peter Hartmann
Machines 2020, 8(2), 34; https://doi.org/10.3390/machines8020034 - 16 Jun 2020
Cited by 1 | Viewed by 3202
Abstract
An increasing shortening of product life cycles, as well as the trend towards highly individualized food products, force manufacturers to digitize their own production chains. Especially the collection, monitoring, and evaluation of food data will have a major impact in the future on [...] Read more.
An increasing shortening of product life cycles, as well as the trend towards highly individualized food products, force manufacturers to digitize their own production chains. Especially the collection, monitoring, and evaluation of food data will have a major impact in the future on how the manufacturers will satisfy constantly growing customer demands. For this purpose, an automated system for collecting and analyzing food data was set up to promote advanced production technologies in the food industry. Based on the technique of laser triangulation, various types of food were measured three-dimensionally and examined for their chromatic composition. The raw data can be divided into individual data groups using clustering technologies. Subsequent indexing of the data in a big data architecture set the ground for setting up real-time data visualizations. The cluster-based back-end system for data processing can also be used as an organization-wide communication network for more efficient monitoring of companies’ production data flows. The results not only describe the procedure for digitization of food data, they also provide deep insights into the practical application of big data analytics while helping especially small- and medium-sized enterprises to find a good introduction to this field of research. Full article
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25 pages, 5282 KiB  
Article
A Self-triggered Position Based Visual Servoing Model Predictive Control Scheme for Underwater Robotic Vehicles
by Shahab Heshmati-alamdari, Alina Eqtami, George C. Karras, Dimos V. Dimarogonas and Kostas J. Kyriakopoulos
Machines 2020, 8(2), 33; https://doi.org/10.3390/machines8020033 - 11 Jun 2020
Cited by 26 | Viewed by 3304
Abstract
An efficient position based visual sevroing control approach for Autonomous Underwater Vehicles (AUVs) by employing Non-linear Model Predictive Control (N-MPC) is designed and presented in this work. In the proposed scheme, a mechanism is incorporated within the vision-based controller that determines when the [...] Read more.
An efficient position based visual sevroing control approach for Autonomous Underwater Vehicles (AUVs) by employing Non-linear Model Predictive Control (N-MPC) is designed and presented in this work. In the proposed scheme, a mechanism is incorporated within the vision-based controller that determines when the Visual Tracking Algorithm (VTA) should be activated and new control inputs should be calculated. More specifically, the control loop does not close periodically, i.e., between two consecutive activations (triggering instants), the control inputs calculated by the N-MPC at the previous triggering time instant are applied to the underwater robot in an open-loop mode. This results in a significantly smaller number of requested measurements from the vision tracking algorithm, as well as less frequent computations of the non-linear predictive control law. This results in a reduction in processing time as well as energy consumption and, therefore, increases the accuracy and autonomy of the Autonomous Underwater Vehicle. The latter is of paramount importance for persistent underwater inspection tasks. Moreover, the Field of View constraints (FoV), control input saturation, the kinematic limitations due to the underactuated degree of freedom in sway direction, and the effect of the model uncertainties as well as external disturbances have been considered during the control design. In addition, the stability and convergence of the closed-loop system has been guaranteed analytically. Finally, the efficiency and performance of the proposed vision-based control framework is demonstrated through a comparative real-time experimental study while using a small underwater vehicle. Full article
(This article belongs to the Special Issue Intelligent Mechatronics Systems)
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13 pages, 3415 KiB  
Article
An Analytical Method for Generating Determined Torque Ripple in Synchronous Machines with Surface Magnets by Harmonic Current Injection
by Matthias Vollat, Daniel Hartmann and Frank Gauterin
Machines 2020, 8(2), 32; https://doi.org/10.3390/machines8020032 - 08 Jun 2020
Cited by 3 | Viewed by 2283
Abstract
In this paper, we present a new analytical method to calculate the required amplitudes and phase angles of the injected harmonic currents, to generate a determined torque ripple for synchronous machines with surface-mounted permanent magnets. First, we described the machine equations as a [...] Read more.
In this paper, we present a new analytical method to calculate the required amplitudes and phase angles of the injected harmonic currents, to generate a determined torque ripple for synchronous machines with surface-mounted permanent magnets. First, we described the machine equations as a function of the phase current and the back electromotive force. We then introduced a new asymmetrical power system. After combining the equations, we established a linear system of equations. The solution of the equation system yielded the amplitudes and phase angles of the harmonic currents to be injected. Finally, we validated the method with several finite element method simulations. With this method, a previously defined torque ripple could be generated very accurately for synchronous machines with surface magnets. Full article
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28 pages, 1991 KiB  
Review
Condition-Based Maintenance—An Extensive Literature Review
by Elena Quatrini, Francesco Costantino, Giulio Di Gravio and Riccardo Patriarca
Machines 2020, 8(2), 31; https://doi.org/10.3390/machines8020031 - 08 Jun 2020
Cited by 54 | Viewed by 6636
Abstract
This paper presents an extensive literature review on the field of condition-based maintenance (CBM). The paper encompasses over 4000 contributions, analysed through bibliometric indicators and meta-analysis techniques. The review adopts Factor Analysis as a dimensionality reduction, concerning the metric of the co-citations of [...] Read more.
This paper presents an extensive literature review on the field of condition-based maintenance (CBM). The paper encompasses over 4000 contributions, analysed through bibliometric indicators and meta-analysis techniques. The review adopts Factor Analysis as a dimensionality reduction, concerning the metric of the co-citations of the papers. Four main research areas have been identified, able to delineate the research field synthetically, from theoretical foundations of CBM; (i) towards more specific implementation strategies (ii) and then specifically focusing on operational aspects related to (iii) inspection and replacement and (iv) prognosis. The data-driven bibliometric results have been combined with an interpretative research to extract both core and detailed concepts related to CBM. This combined analysis allows a critical reflection on the field and the extraction of potential future research directions. Full article
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20 pages, 2033 KiB  
Article
Research on Recommendation Method of Product Design Scheme Based on Multi-Way Tree and Learning-to-Rank
by Boyang Chen, Xiaobing Hu, Yunliang Huo and Xi Deng
Machines 2020, 8(2), 30; https://doi.org/10.3390/machines8020030 - 05 Jun 2020
Cited by 5 | Viewed by 2214
Abstract
A product is composed of several components, and the number, type, and combination of components plays a crucial role in the process of product design. It is difficult to get an optimized scheme in a short time. In order to improve the efficiency [...] Read more.
A product is composed of several components, and the number, type, and combination of components plays a crucial role in the process of product design. It is difficult to get an optimized scheme in a short time. In order to improve the efficiency of product design, a product design scheme recommendation algorithm based on multi-way tree and learning-to-rank is proposed. Firstly, the product solution model, whose nodes are obtained by mapping the product attributes, is generated according to the design process, and the alternative scheme is obtained by traversing the multi-tree model. Secondly, considering users’ cognition of the importance of each product attribute, the analytic hierarchy process (AHP) is applied to assign weight to the product attribute, and then similarity to ideal solution (TOPSIS) method based on AHP is used to rank alternative solutions. Furthermore, according to users’ preference for parts’ supplier information, the learning-to-rank algorithm is used to optimize the list of alternative schemes twice. Finally, taking the design of the hoist as an example, it was verified that the proposed method had higher efficiency and better recommendation effect than the traditional parametric design method. Full article
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19 pages, 4294 KiB  
Article
Performance Analysis of Low-Cost Tracking System for Mobile Robots
by Andrea Botta and Giuseppe Quaglia
Machines 2020, 8(2), 29; https://doi.org/10.3390/machines8020029 - 02 Jun 2020
Cited by 5 | Viewed by 4137
Abstract
This paper proposes a reliable and straightforward approach to mobile robots (or moving objects in general) indoor tracking, in order to perform a preliminary study on their dynamics. The main features of this approach are its minimal and low-cost setup and a user-friendly [...] Read more.
This paper proposes a reliable and straightforward approach to mobile robots (or moving objects in general) indoor tracking, in order to perform a preliminary study on their dynamics. The main features of this approach are its minimal and low-cost setup and a user-friendly interpretation of the data generated by the ArUco library. By using a commonly available camera, such as a smartphone one or a webcam, and at least one marker for each object that has to be tracked, it is possible to estimate the pose of these markers, with respect to a reference conveniently placed in the environment, in order to produce results that are easily interpretable by a user. This paper presents a simple extension to the ArUco library to generate such user-friendly data, and it provides a performance analysis of this application with static and moving objects, using a smartphone camera to highlight the most notable feature of this solution, but also its limitations. Full article
(This article belongs to the Special Issue Selected Papers from Advances of Japanese Machine Design)
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22 pages, 2936 KiB  
Article
Simulation of Subcritical Vibrations of a Large Flexible Rotor with Varying Spherical Roller Bearing Clearance and Roundness Profiles
by Emil Kurvinen, Raine Viitala, Tuhin Choudhury, Janne Heikkinen and Jussi Sopanen
Machines 2020, 8(2), 28; https://doi.org/10.3390/machines8020028 - 29 May 2020
Cited by 11 | Viewed by 3347
Abstract
In large rotor-bearing systems, the rolling element bearings act as a considerable source of subcritical vibration excitation. Simulation of such rotor bearing systems contains major sources of uncertainty contributing to the excitation, namely the roundness profile of the bearing inner ring and the [...] Read more.
In large rotor-bearing systems, the rolling element bearings act as a considerable source of subcritical vibration excitation. Simulation of such rotor bearing systems contains major sources of uncertainty contributing to the excitation, namely the roundness profile of the bearing inner ring and the clearance of the bearing. In the present study, a simulation approach was prepared to investigate carefully the effect of varying roundness profile and clearance on the subcritical vibration excitation. The FEM-based rotor-bearing system simulation model included a detailed description of the bearings and asymmetricity of the rotor. The simulation results were compared to measured responses for validation. The results suggest that the simulation model was able to capture the response of the rotor within a reasonable accuracy compared to the measured responses. The bearing clearance was observed to have a major effect on the subcritical resonance response amplitudes. In addition, the simulation model confirmed that the resonances of the 3rd and 4th harmonic vibration components in addition to the well-known 2nd harmonic resonance (half-critical resonance) can be significantly high and should thus be taken into account already in the design phase of large subcritical rotors. Full article
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16 pages, 11709 KiB  
Article
Local Motion Planner for Autonomous Navigation in Vineyards with a RGB-D Camera-Based Algorithm and Deep Learning Synergy
by Diego Aghi, Vittorio Mazzia and Marcello Chiaberge
Machines 2020, 8(2), 27; https://doi.org/10.3390/machines8020027 - 25 May 2020
Cited by 42 | Viewed by 5410
Abstract
With the advent of agriculture 3.0 and 4.0, in view of efficient and sustainable use of resources, researchers are increasingly focusing on the development of innovative smart farming and precision agriculture technologies by introducing automation and robotics into the agricultural processes. Autonomous agricultural [...] Read more.
With the advent of agriculture 3.0 and 4.0, in view of efficient and sustainable use of resources, researchers are increasingly focusing on the development of innovative smart farming and precision agriculture technologies by introducing automation and robotics into the agricultural processes. Autonomous agricultural field machines have been gaining significant attention from farmers and industries to reduce costs, human workload, and required resources. Nevertheless, achieving sufficient autonomous navigation capabilities requires the simultaneous cooperation of different processes; localization, mapping, and path planning are just some of the steps that aim at providing to the machine the right set of skills to operate in semi-structured and unstructured environments. In this context, this study presents a low-cost, power-efficient local motion planner for autonomous navigation in vineyards based only on an RGB-D camera, low range hardware, and a dual layer control algorithm. The first algorithm makes use of the disparity map and its depth representation to generate a proportional control for the robotic platform. Concurrently, a second back-up algorithm, based on representations learning and resilient to illumination variations, can take control of the machine in case of a momentaneous failure of the first block generating high-level motion primitives. Moreover, due to the double nature of the system, after initial training of the deep learning model with an initial dataset, the strict synergy between the two algorithms opens the possibility of exploiting new automatically labeled data, coming from the field, to extend the existing model’s knowledge. The machine learning algorithm has been trained and tested, using transfer learning, with acquired images during different field surveys in the North region of Italy and then optimized for on-device inference with model pruning and quantization. Finally, the overall system has been validated with a customized robot platform in the appropriate environment. Full article
(This article belongs to the Special Issue Latest Trends of Autonomous Aerial and Terrestrial Vehicles for Service Robotics Applications)
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16 pages, 4682 KiB  
Article
Virtual Testing of Counterbalance Forklift Trucks: Implementation and Experimental Validation of a Numerical Multibody Model
by Alberto Martini, Giovanni Paolo Bonelli and Alessandro Rivola
Machines 2020, 8(2), 26; https://doi.org/10.3390/machines8020026 - 14 May 2020
Cited by 17 | Viewed by 4287
Abstract
This study investigates the dynamic behavior of a recently developed counterbalance forklift truck. The final objective is creating virtual testing tools based on numerical multibody models to evaluate the dynamic stresses experienced by the forklift family of interest during a reference operating cycle, [...] Read more.
This study investigates the dynamic behavior of a recently developed counterbalance forklift truck. The final objective is creating virtual testing tools based on numerical multibody models to evaluate the dynamic stresses experienced by the forklift family of interest during a reference operating cycle, defined by the manufacturer’s testing protocols. This work aims at defining sufficiently accurate and easy-to-implement modelling approaches and validation procedures. It focuses on a specific test, namely the passage of a speed-bump-like obstacle at high velocity, which represents one of the most severe conditions within the reference cycle. Indeed, unlike most of the other wheeled vehicles, forklifts typically do not have advanced suspension systems and their dynamic response is significantly affected by ground irregularities. To this end, a preliminary model of the complete forklift, featuring rigid bodies and a simplified tire–ground contact model, is implemented with a commercial software. Experimental tests are conducted on the forklift to measure the vehicle vibrations when running on the obstacle, for model validation purposes. After model updating, the results provided by the numerical simulations match the experimental data satisfactorily. Hence, the modelling and validation strategies are proven viable and effective. Full article
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29 pages, 10365 KiB  
Review
Review of Multiaxial Testing for Very High Cycle Fatigue: From ‘Conventional’ to Ultrasonic Machines
by Pedro Costa, Richard Nwawe, Henrique Soares, Luís Reis, Manuel Freitas, Yong Chen and Diogo Montalvão
Machines 2020, 8(2), 25; https://doi.org/10.3390/machines8020025 - 13 May 2020
Cited by 18 | Viewed by 5382
Abstract
Fatigue is one of the main causes for in service failure of mechanical components and structures. With the development of new materials, such as high strength aluminium or titanium alloys with different microstructures from steels, materials no longer have a fatigue limit in [...] Read more.
Fatigue is one of the main causes for in service failure of mechanical components and structures. With the development of new materials, such as high strength aluminium or titanium alloys with different microstructures from steels, materials no longer have a fatigue limit in the classical sense, where it was accepted that they would have ‘infinite life’ from 10 million (107) cycles. The emergence of new materials used in critical mechanical parts, including parts obtained from metal additive manufacturing (AM), the need for weight reduction and the ambition to travel greater distances in shorter periods of time, have brought many challenges to design engineers, since they demand predictability of material properties and that they are readily available. Most fatigue testing today still uses uniaxial loads. However, it is generally recognised that multiaxial stresses occur in many full-scale structures, being rare the occurrence of pure uniaxial stress states. By combining both Ultrasonic Fatigue Testing with multiaxial testing through Single-Input-Multiple-Output Modal Analysis, the high costs of both equipment and time to conduct experiments have seen a massive improvement. It is presently possible to test materials under multiaxial loading conditions and for a very high number of cycles in a fraction of the time compared to non-ultrasonic fatigue testing methods (days compared to months or years). This work presents the current status of ultrasonic fatigue testing machines working at a frequency of 20 kHz to date, with emphasis on multiaxial fatigue and very high cycle fatigue. Special attention will be put into the performance of multiaxial fatigue tests of classical cylindrical specimens under tension/torsion and flat cruciform specimens under in-plane bi-axial testing using low cost piezoelectric transducers. Together with the description of the testing machines and associated instrumentation, some experimental results of fatigue tests are presented in order to demonstrate how ultrasonic fatigue testing can be used to determine the behaviour of a steel alloy from a railway wheel at very high cycle fatigue regime when subjected to multiaxial tension/torsion loadings. Full article
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16 pages, 4625 KiB  
Article
Design of a Motorcycle Steering Damper for a Safer Ride
by Simone Piantini, Alessandro Giorgetti, Niccolò Baldanzini, Cosimo Monti and Marco Pierini
Machines 2020, 8(2), 24; https://doi.org/10.3390/machines8020024 - 10 May 2020
Cited by 5 | Viewed by 6055
Abstract
Powered-two-wheelers (PTWs) are increasingly popular because of their lower cost compared to cars, and therefore the riders’ exposure risk is increasing. Due to their complex dynamics characterized by high non-linearity and inherent instability, PTWs are more difficult to control compared to four-wheeled vehicles. [...] Read more.
Powered-two-wheelers (PTWs) are increasingly popular because of their lower cost compared to cars, and therefore the riders’ exposure risk is increasing. Due to their complex dynamics characterized by high non-linearity and inherent instability, PTWs are more difficult to control compared to four-wheeled vehicles. Wobble is a high-frequency instability mode affecting the steering assembly of the PTW, and which often causes the rider to lose control and crash when it occurs. In this paper, we present the design of a new motorcycle semi-active steering damper integrated into the steering column and utilizing a magnetorheological fluid (MRF) for variable damping torque. An analytical model of the concept was first used to perform the preliminary sizing, followed by concept validation using a 3D FE multiphysics magnetic-fluid analysis. The final innovative design offers several advantages compared to traditional steering dampers: (i) a wide range of adjustable damping torque values, with a multiplication factor up to 10 with a maximum electrical current of 2 A; (ii) total integration into the motorcycle steering column enabled by its axial design and limited radius; (iii) a simple chamber geometry that allows for easy manufacture; (iv) longer seal life due to the absence of direct contact between seals and the MRF. Full article
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15 pages, 6521 KiB  
Article
Kineto-Static Analysis of a Wrist Rehabilitation Robot with Compliance and Passive Joints for Joint Misalignment Compensation
by Ying-Chi Liu and Yukio Takeda
Machines 2020, 8(2), 23; https://doi.org/10.3390/machines8020023 - 02 May 2020
Cited by 9 | Viewed by 3342
Abstract
In this paper, we present a kineto-static analysis on a wrist rehabilitation robot to compensate for joint misalignment between human and robot joints. Since joint misalignment has proved to generate user–device interaction forces, which reduce the comfort and safety of the wearable devices [...] Read more.
In this paper, we present a kineto-static analysis on a wrist rehabilitation robot to compensate for joint misalignment between human and robot joints. Since joint misalignment has proved to generate user–device interaction forces, which reduce the comfort and safety of the wearable devices and limit the user’s willingness to use it. The use of compliance and the addition of passive joints for joint misalignment compensation are discussed. In order to study the effect of the initial offset, we find that the initial offset in the direction perpendicular to the forearm causes a larger unwanted force. In addition, the use of the softest compliance can minimize unwanted force by 38% compared to the case without compliance. Furthermore, the effect of the addition of passive joints to the exoskeleton is investigated. From the analysis results, the soft part of the human being is regarded as a passive joint with the ability to compensate for joint misalignment. Moreover, the influence of the soft characteristics of human limbs should be considered when designing a wearable robot. This soft property, causing the movement of the braces, results in reducing the angular range of the wrist. Through the analysis results, we provide effective ideas for joint misalignment compensation to fulfill a comfortable and safer robot design. Full article
(This article belongs to the Special Issue Selected Papers from Advances of Japanese Machine Design)
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21 pages, 9856 KiB  
Article
Fault Tolerant Control Based on an Observer on PI Servo Design for a High-Speed Automation Machine
by Prathan Chommuangpuck, Thanasak Wanglomklang, Suradet Tantrairatn and Jiraphon Srisertpol
Machines 2020, 8(2), 22; https://doi.org/10.3390/machines8020022 - 01 May 2020
Cited by 4 | Viewed by 2352
Abstract
The fault tolerant control (FTC) technique is widely used in many industries to provide tolerance to systems so that they can operate when a system fault occurs. This paper presents a technique for FTC based on the observer signal application, which is used [...] Read more.
The fault tolerant control (FTC) technique is widely used in many industries to provide tolerance to systems so that they can operate when a system fault occurs. This paper presents a technique for FTC based on the observer signal application, which is used for a high-speed auto core adhesion mounting machine. The utilization of the observer signal information of the linear encoder fault is employed to adjust the gain parameters to achieve the appropriate gain value while maintaining the required performance of the system. The dynamic modeling of the servo motor system design utilizing a pole placement technique was designed to support the proposed method. A scaling gain fault step size adjustment from −1% to 1% with increments of 0.2% is used to simulate the fault conditions of the linear encoder. The statistical mean value of the observer error signal is used to train the artificial neural network (ANN) model. The results showed that the control system design successfully tracked the dynamic response. Furthermore, the ANN model, with more than 98% confidence, was satisfactory in classifying the linear encoder fault condition. The gain compensation was successful in reducing position error by more than 95% compared with the system without compensated gain. Full article
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28 pages, 12113 KiB  
Article
Calculation of the Incompressible Viscous Fluid Flow in Piston Seals of Piston Hybrid Power Machines
by Viktor Shcherba, Viktor Shalai, Nikolay Pustovoy, Evgeniy Pavlyuchenko, Sergey Gribanov and Egor Dorofeev
Machines 2020, 8(2), 21; https://doi.org/10.3390/machines8020021 - 24 Apr 2020
Cited by 5 | Viewed by 3503
Abstract
The article considers the calculation of the flow of a viscous incompressible fluid in piston seals of piston hybrid power machines. The most widely used and effective seals are considered: a smooth gap seal and a step-type gap seal, and—based on the references [...] Read more.
The article considers the calculation of the flow of a viscous incompressible fluid in piston seals of piston hybrid power machines. The most widely used and effective seals are considered: a smooth gap seal and a step-type gap seal, and—based on the references analyses—the initial boundary conditions for their calculation are determined. The laminar and turbulent flows in gap seals are calculated based on the well-known analytical relationships, experimental studies and flow models, including the k-ε, Menter’s Shear StressTransport (SST) and Reynolds Stress (RSM) turbulence models. The effectiveness of using each model to determine average velocities, flow rates, and velocity plots in the cross section of a gap seal, as well as the adequacy of the description of known physical laws, is estimated. The results proved that the RSM turbulence model is better for the gap seals of different types under different modes of motion. Full article
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16 pages, 4644 KiB  
Review
An Overview of Electric Machine Trends in Modern Electric Vehicles
by Emmanuel Agamloh, Annette von Jouanne and Alexandre Yokochi
Machines 2020, 8(2), 20; https://doi.org/10.3390/machines8020020 - 17 Apr 2020
Cited by 90 | Viewed by 28748
Abstract
Electric machines are critical components of the drivetrains of electric vehicles. Over the past few years the majority of traction drive systems have converged toward containing some form of a permanent magnet machine. There is increasing tendency toward the improvement of power density [...] Read more.
Electric machines are critical components of the drivetrains of electric vehicles. Over the past few years the majority of traction drive systems have converged toward containing some form of a permanent magnet machine. There is increasing tendency toward the improvement of power density and efficiency of traction machines, thereby giving rise to innovative designs and improvements of basic machine topologies and the emergence of new classes of machines. This paper provides an overview of present trends toward high specific power density machines for traction drive systems. The focus will be on current technology and the trends that are likely to be pursued in the near future to achieve the high specific power goals set for the industry. The paper discusses machines that are applied in both hybrid and battery electric drivetrains without distinction and does not discuss the associated power electronic inverters. Future electric machine trends that are likely to occur are also projected. Full article
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14 pages, 3370 KiB  
Article
Disturbance Simulation in the Packaging Process of Confectionary Using Virtual Commissioning
by Johanna Wolf, Sebastian Carsch, Clemens Troll and Jens-Peter Majschak
Machines 2020, 8(2), 19; https://doi.org/10.3390/machines8020019 - 16 Apr 2020
Cited by 2 | Viewed by 2593
Abstract
Operator assistance systems can help to reduce disturbance-related machine downtime in food production and packaging processes, especially when combined with machine learning algorithms. These assistance systems analyze the available sensor signals of the process control over time to help operators identify the causes [...] Read more.
Operator assistance systems can help to reduce disturbance-related machine downtime in food production and packaging processes, especially when combined with machine learning algorithms. These assistance systems analyze the available sensor signals of the process control over time to help operators identify the causes of disturbances. Training such systems requires sufficient test data, which often are hardly available. Thus, this paper presents a study to investigate how test data for teaching machine learning algorithms can be generated by numerical simulation. The potential of using virtual commissioning (VC) software for simulating disturbances of discrete processes is examined, considering the example of a friction and collision-afflicted sub-process from an intermitting wrapping machine for confectionary. In this study the software industrialPhysics (iP) is analyzed regarding accuracy of static and dynamic friction and restitution. The values are verified by setting up virtual substitute tests and comparing the results with analytically determined values. Subsequently, prerecorded disturbances are classified, and seven selected elements are simulated in VC software, recording visual effects and switching the characteristics of sensors. The verification shows that VC software is generally adequate for the assigned task. Restrictions occur regarding the computing power required of the built-in physics engine and the resulting reduction of the machine to be simulated. Full article
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21 pages, 14201 KiB  
Article
A Power Recirculating Test Rig for Ball Screws: A New Perspective for Endurance Tests
by Hermes Giberti, Marco Carnevale and Marco Bocciolone
Machines 2020, 8(2), 18; https://doi.org/10.3390/machines8020018 - 16 Apr 2020
Viewed by 3578
Abstract
Ball screw mechanisms are commonly designed and adopted to work for a high number of cycles, so that one of their most relevant characteristics is mechanical endurance. State-of-art experimental setups designed to characterize these mechanisms under operational load conditions require a layout able [...] Read more.
Ball screw mechanisms are commonly designed and adopted to work for a high number of cycles, so that one of their most relevant characteristics is mechanical endurance. State-of-art experimental setups designed to characterize these mechanisms under operational load conditions require a layout able to withstand high loads and a relevant power to actuate the ball screw, therefore, being rather complex and expensive. To overcome these issues, this paper proposes an innovative test bench exploiting the recirculating power principle, designed for testing a ball screw under operational loads. It enables (at the same time) a reduction of loads on the test rig frame and a reduction of the mechanical power required to actuate the screw. The concept and the design of the proposed test bench are presented, as well as a simplified model to calculate the motor torque and the forces transmitted at the supports. An experimental setup is then realized and tested under actual loads for endurance tests. The results show that the use of the recirculating principle is promising to realize a test rig for endurance tests on a ball screw, thanks to the effectiveness of the solution and the simplicity of the realization of the system even under heavy loads. Among all the measuring instruments adopted (accelerometers, strain gauges, thermocouples and laser sensors for distance measurement on the test bench), the adoption of accelerometers on the nuts seems to be the most promising for condition monitoring, allowing to detect an incipient fault before a macroscopic failure of the ball screw system occurs. Full article
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18 pages, 2957 KiB  
Article
ADRC-Based Robust and Resilient Control of a 5-Phase PMSM Driven Electric Vehicle
by Abir Hezzi, Seifeddine Ben Elghali, Yemna Bensalem, Zhibin Zhou, Mohamed Benbouzid and Mohamed Naceur Abdelkrim
Machines 2020, 8(2), 17; https://doi.org/10.3390/machines8020017 - 16 Apr 2020
Cited by 30 | Viewed by 3827
Abstract
The selection of electric machines for an Electric Vehicle (EV) is mainly based on reliability, efficiency, and robustness, which makes the 5-phase Permanent Magnet Synchronous Motor (PMSM) among the best candidates. However, control performance of any motor drive can be deeply affected by [...] Read more.
The selection of electric machines for an Electric Vehicle (EV) is mainly based on reliability, efficiency, and robustness, which makes the 5-phase Permanent Magnet Synchronous Motor (PMSM) among the best candidates. However, control performance of any motor drive can be deeply affected by both: (1) internal disturbances caused by parametric variations and model uncertainties and (2) external disturbances related to sensor faults or unexpected speed or torque variation. To ensure stability under those conditions, an Active Disturbance Rejection Controller (ADRC) based on an online dynamic compensation of estimated internal and external disturbances, and a Linear ADRC (LADRC) are investigated in this paper. The control performance was compared with traditional controller and evaluated by considering parametric variation, unmodeled disturbances, and speed sensor fault. The achieved results clearly highlight the effectiveness and high control performance of the proposed ADRC-based strategies. Full article
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Article
Measurement Method for Quality Control of Cylinders in Roll-to-Roll Printing Machines
by Diego Scaccabarozzi, Marianna Magni, Bortolino Saggin, Marco Tarabini, Carmine Cioffi and Simone Nasatti
Machines 2020, 8(2), 16; https://doi.org/10.3390/machines8020016 - 10 Apr 2020
Cited by 2 | Viewed by 3541
Abstract
This paper describes a measurement method for the quality control of cylinders for printing machines based on roll-to-roll presses. If the surface finishing of the cylinders is not adequate, the printing is unacceptable, and the defective cylinders must be reworked. The performed quality [...] Read more.
This paper describes a measurement method for the quality control of cylinders for printing machines based on roll-to-roll presses. If the surface finishing of the cylinders is not adequate, the printing is unacceptable, and the defective cylinders must be reworked. The performed quality check of the cylinder surface roughness by means of contact methods was unable to identify the cylinder defects, and acceptance of the manufactured cylinders before integration was demanded to the visual inspection performed by trained operators. In this work a contactless measurement method based on the eddy current displacement sensor was proposed and validated as a tool for quality check as an alternative to optical roughness measurements. A test bench for the characterization of printer cylinders was designed and manufactured, allowing for the validation of the proposed method on different batches of cylinders and the identification of a threshold to guide the acceptance of tested cylinders prior to mounting on the roll-to-roll press. Full article
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