Improving robotic machining accuracy through experimental error investigation and modular compensation

Machining using industrial robots is currently limited to applications with low geometrical accuracies and soft materials. This paper analyzes the sources of errors in robotic machining and characterizes them in amplitude and frequency. Experiments under different conditions represent a typical set of industrial applications and allow a qualified evaluation. Based on this analysis, a modular approach is proposed to overcome these obstacles, applied both during program generation (offline) and execution (online). Predictive offline compensation of machining errors is achieved by means of an innovative programming system, based on kinematic and dynamic robot models. Real-time adaptive machining error compensation is also provided by sensing the real robot positions with an innovative tracking system and corrective feedback to both the robot and an additional high-dynamic compensation mechanism on piezo-actuator basis

Improving Dynamics Estimations and Low Level Torque Control Through Inertial Sensing

In 1996, professors J. Edward Colgate and Michael Peshkin invented the cobots as robotic equipment safe enough for interacting with human workers. Twenty years later, collaborative robots are highly demanded in the packaging industry, and have already been massively adopted by companies facing issues for meeting customer demands. Meantime, cobots are still making they way into environments where value-added tasks require more complex interactions between robots and human operators. For other applications like a rescue mission in a disaster scenario, robots have to deal with highly dynamic environments and uneven terrains. All these applications require robust, fine and fast control of the interaction forces, specially in the case of locomotion on uneven terrains in an environment where unexpected events can occur. Such interaction forces can only be modulated through the control of joint internal torques in the case of under-actuated systems which is typically the case of mobile robots. For that purpose, an efficient low level joint torque control is one of the critical requirements, and motivated the research presented here. This thesis addresses a thorough model analysis of a typical low level joint actuation sub-system, powered by a Brushless DC motor and suitable for torque control. It then proposes procedure improvements in the identification of model parameters, particularly challenging in the case of coupled joints, in view of improving their control. Along with these procedures, it proposes novel methods for the calibration of inertial sensors, as well as the use of such sensors in the estimation of joint torques

Generalized thick strip modelling for vortex-induced vibration of long flexible cylinders

We propose a generalized strip modelling method that is computationally efficient for the VIV prediction of long flexible cylinders in three-dimensional incompressible flow. In order to overcome the shortcomings of conventional strip-theory-based 2D models, the fluid domain is divided into “thick” strips, which are sufficiently thick to locally resolve the small scale turbulence effects and three dimensionality of the flow around the cylinder. An attractive feature of the model is that we independently construct a three-dimensional scale resolving model for individual strips, which have local spanwise scale along the cylinder's axial direction and are only coupled through the structural model of the cylinder. Therefore, this approach is able to cover the full spectrum for fully resolved 3D modelling to 2D strip theory. The connection between these strips is achieved through the calculation of a tensioned beam equation, which is used to represent the dynamics of the flexible body. In the limit, however, a single “thick” strip would fill the full 3D domain. A parallel Fourier spectral/hp element method is employed to solve the 3D flow dynamics in the strip-domain, and then the VIV response prediction is achieved through the strip-structure interactions. Numerical tests on both laminar and turbulent flows as well as the comparison against the fully resolved DNS are presented to demonstrate the applicability of this approach

Study and Development of Mechatronic Devices and Machine Learning Schemes for Industrial Applications

Obiettivo del presente progetto di dottorato è lo studio e sviluppo di sistemi meccatronici e di modelli machine learning per macchine operatrici e celle robotizzate al fine di incrementarne le prestazioni operative e gestionali. Le pressanti esigenze del mercato hanno imposto lavorazioni con livelli di accuratezza sempre più elevati, tempi di risposta e di produzione ridotti e a costi contenuti. In questo contesto nasce il progetto di dottorato, focalizzato su applicazioni di lavorazioni meccaniche (e.g. fresatura), che includono sistemi complessi quali, ad esempio, macchine a 5 assi e, tipicamente, robot industriali, il cui utilizzo varia a seconda dell’impiego. Oltre alle specifiche problematiche delle lavorazioni, si deve anche considerare l’interazione macchina-robot per permettere un’efficiente capacità e gestione dell’intero impianto. La complessità di questo scenario può evidenziare sia specifiche problematiche inerenti alle lavorazioni (e.g. vibrazioni) sia inefficienze più generali che riguardano l’impianto produttivo (e.g. asservimento delle macchine con robot, consumo energetico). Vista la vastità della tematica, il progetto si è suddiviso in due parti, lo studio e sviluppo di due specifici dispositivi meccatronici, basati sull’impiego di attuatori piezoelettrici, che puntano principalmente alla compensazione di vibrazioni indotte dal processo di lavorazione, e l’integrazione di robot per l’asservimento di macchine utensili in celle robotizzate, impiegando modelli di machine learning per definire le traiettorie ed i punti di raggiungibilità del robot, al fine di migliorarne l’accuratezza del posizionamento del pezzo in diverse condizioni. In conclusione, la presente tesi vuole proporre soluzioni meccatroniche e di machine learning per incrementare le prestazioni di macchine e sistemi robotizzati convenzionali. I sistemi studiati possono essere integrati in celle robotizzate, focalizzandosi sia su problematiche specifiche delle lavorazioni in macchine operatrici sia su problematiche a livello di impianto robot-macchina. Le ricerche hanno riguardato un’approfondita valutazione dello stato dell’arte, la definizione dei modelli teorici, la progettazione funzionale e l’identificazione delle criticità del design dei prototipi, la realizzazione delle simulazioni e delle prove sperimentali e l’analisi dei risultati.The aim of this Ph.D. project is the study and development of mechatronic systems and machine learning models for machine tools and robotic applications to improve their performances. The industrial demands have imposed an ever-increasing accuracy and efficiency requirement whilst constraining the cost. In this context, this project focuses on machining processes (e.g. milling) that include complex systems such as 5-axes machine tool and industrial robots, employed for various applications. Beside the issues related to the machining process itself, the interaction between the machining centre and the robot must be considered for the complete industrial plant’s improvement. This scenario´s complexity depicts both specific machining problematics (e.g. vibrations) and more general issues related to the complete plant, such as machine tending with an industrial robot and energy consumption. Regarding the immensity of this area, this project is divided in two parts, the study and development of two mechatronic devices, based on piezoelectric stack actuators, for the active vibration control during the machining process, and the robot machine tending within the robotic cell, employing machine learning schemes for the trajectory definition and robot reachability to improve the corresponding positioning accuracy. In conclusion, this thesis aims to provide a set of solutions, based on mechatronic devices and machine learning schemes, to improve the conventional machining centre and the robotic systems performances. The studied systems can be integrated within a robotic cell, focusing on issues related to the specific machining process and to the interaction between robot-machining centre. This research required a thorough study of the state-of-the-art, the formulation of theoretical models, the functional design development, the identification of the critical aspects in the prototype designs, the simulation and experimental campaigns, and the analysis of the obtained results

Structure-thermal coupling in viscoelastic material in rubber bushing of vehicle system

The objective of this research is to utilize the frequency-dependent viscoelastic material model and characterize the dynamic response of rubber bushing under external excitation. Furthermore, with appropriate modeling, two heat generation mechanisms of rubber bushing are explored and their thermal fields are investigated. Due to the nonlinear force-deflection relationship of the viscoelastic material, finding satisfactory mechanical properties of rubber components still poses a great challenge. However, industry nowadays is in urgent demand for precise finite element analysis (FEA) modeling of rubber components. For example, a proper constitutive relationship of rubber components is critical to providing a reliable and trustable simulation of vehicle suspension systems. As for current FEA commercial software, the frequency-dependent modulus of viscoelastic material hasn\u27t been presented well and they have failed to provide satisfactory results. Therefore, two approaches, FEA and the multi-body dynamic analysis have been selected together to give a more comprehensive and credible prediction of suspension system\u27s performance in different working conditions. The FEA approach evaluated the stability of rubber bushing in view of the dynamic response and temperature distribution under high frequency excitation. With these results, the life prediction of rubber bushing becomes more feasible. The multi-body dynamic analysis explores the structure instability of rubber bushing when exposed to extremely high frequency and estimates the energy dissipation in the rubber core.^ The key innovations of this paper can be classified into four aspects. The first one is the application of multi-body dynamics in the dynamic analysis of rubber bushing. Based on experimental modal analysis, the sandwich cylindrical rubber bushing is treated as multi-body. With the multi-body model, the transfer function of the rubber bushing is calculated in order to estimate the dynamic response. The second innovation comes from the development of the FORTRAN program to solve the system transfer function of the structure made of viscoelastic material. Since the geometry and boundary conditions are amenable in FEA compared with the experimental modal testing, this approach is not just applicable in rubber bushing dynamic analysis, but also useful in dynamic analysis of different rubber components. The third innovative contribution of this research is connecting the multi-body analysis with continuum mechanics to evaluate the mechanical properties of rubber bushing. The last innovation is the structure-thermal coupling of rubber bushing to predict its temperature distribution based on the heat source calculated from the FEA simulation. The finite volume method (FVM) is applied using MATLAB in the simulation of temperature distribution. In this research, the classical standard linear model is applied in the FEA program to characterize the variation of viscoelastic material in the frequency domain. The three parameters of this model have been identified with the batch data measurement using dynamic mechanical analysis equipment (DMA). Specially, two heat generation mechanisms are explored to emphasize the friction-induced hysteresis damping except for the commonly discussed viscous damping. As complementation of FORTRAN program simulation in the frequency domain, the multi-physics commercial software COMSOL is employed to estimate the dynamic response of rubber bushing and temperature distribution in the time domain. To verify the results of FEA and multi-body dynamic approach in the dynamic and thermal analysis of rubber bushing, dynamic tests have been carried out using torsion and tensile testing machines. The experimental temperature distribution is in good agreement with the simulation results, which indicated the feasibility of the FEA method.^ However, due to the limited experience and complicated constitutive relationship of the viscoelastic material, the standard linear viscoelastic model is chosen to simulate the heat dissipation mechanism of rubber core. The high-frequency or high-temperature dynamic testing are almost impossible because of the experiment equipments\u27 range of service. As the first step of predicting the dissipation energy density and temperature distribution of rubber components, the initial explorations are significant and provide a proper guidance for further predictions about life expectation

Tribo-dynamic analysis of hypoid gears in automotive differentials

Torsional vibrations in differentials of Rear Wheel Drive vehicles are of major importance for the automotive industry. Hypoid transmissions, forming the motion transfer mechanism from the driveshaft to the wheels, suffer from severe vibration issues. The latter are attributed to improper mesh between the mating gear flanks due to misalignments, variation of contact load and shifting of the effective mesh position. For certain operating conditions, the gear pair exhibits high amplitude motions accompanied with separation of the mating surfaces. Ultimately, single or even double-sided vibro-impact phenomena evolve, which have been related to noise generation. This thesis attempts to address these issues by effectively analysing the dynamic behaviour of a hypoid gear pair under torsional motion. The case study considered is focused on a commercial light truck. The major difference of the employed mathematical model to prior formulations is the usage of an alternative expression for the dynamic transmission error so that the variation of contact radii and transmission error can be accounted for. This approach combined to a correlation of the resistive torque in terms of the angular velocity of the differential enables the achievement of steady state, stable periodic solutions. The dynamic complexity of systems with gears necessitates the identification of the various response regimes. A solution continuation method (software AUTO) is employed to determine the stable/unstable branches over the operating range of the differential. The ensuing parametric studies convey the importance of the main system parameters on the dynamic behaviour of the transmission yielding crucial design guidelines. A tribo-dynamic investigation aims at expanding the dynamic model from pure dry conditions to a more integrated elastohydrodynamic (EHL) approach. Analytical and extrapolated solutions are applied for the derivation of the film thickness magnitude based on the kinematic and loading characteristics of the dynamic model. The temperature rise is governed mainly by conduction due to the thin lubricant films. The generated friction is also computed as a function of the viscous shear and asperity interactions. The effective lubricant viscosity is greatly affected by the pressure increase due to the resonant behaviour of the contact load. The final part of this work is involved with a feasibility study concerning the application of Nonlinear Energy Sinks (NES) as vibration absorbers, exploiting their ability for broadband frequency interaction. Response regimes associated with effective energy absorption are identified and encouraging results are obtained, showing the potential of the method

A differential-based parallel force/velocity actuation concept : theory and experiments

textRobots are now moving from their conventional confined habitats such as factory floors to human environments where they assist and physically interact with people. The requirement for inherent mechanical safety is overarching in such human-robot interaction systems. We propose a dual actuator called Parallel Force/Velocity Actuator (PFVA) that combines a Force Actuator (FA) (low velocity input) and a Velocity Actuator (VA) (high velocity input) using a differential gear train. In this arrangement mechanical safety can be achieved by limiting the torque on the FA and thus making it a backdriveable input. In addition, the kinematic redundancy in the drive can be used to control output velocity while satisfying secondary operational objectives. Our research focus was on three areas: (i) scalable parametric design of the PFVA, (ii) analytical modeling of the PFVA and experimental testing on a single-joint prototype, and (iii) generalized model formulation for PFVA-driven serial robot manipulators. In our analysis, the ratio of velocity ratios between the FA and the VA, called the relative scale factor, emerged as a purely geometric and dominant design parameter. Based on a dimensionless parametric design of PFVAs using power-flow and load distributions between the inputs, a prototype was designed and built using commercial-off-the-shelf components. Using controlled experiments, two performance-limiting phenomena in our prototype, friction and dynamic coupling between the two inputs, were identified. Two other experiments were conducted to characterize the operational performance of the actuator in velocity-mode and in what we call ‘torque-limited’ mode (i.e. when the FA input can be backdriven). Our theoretical and experimental results showed that the PFVA can be mechanical safe to both slow collisions and impacts due to the backdriveability of the FA. Also, we show that its kinematic redundancy can be effectively utilized to mitigate low-velocity friction and backlash in geared mechanisms. The implication at the system level of our actuator level analytical and experimental work was studied using a generalized dynamic modeling framework based on kinematic influence coefficients. Based on this dynamic model, three design case studies for a PFVA-driven serial planar 3R manipulator were presented. The major contributions of this research include (i) mathematical models and physical understanding for over six fundamental design and operational parameters of the PFVA, based on which approximately ten design and five operational guidelines were laid out, (ii) analytical and experimental proof-of-concept for the mechanical safety feature of the PFVA and the effective utilization of its kinematic redundancy, (iii) an experimental methodology to characterize the dynamic coupling between the inputs in a differential-summing mechanism, and (iv) a generalized dynamic model formulation for PFVA-driven serial robot manipulators with emphasis on distribution of output loads between the FA and VA input-sets.Mechanical Engineerin

Instationary modal Analysis for Impulse-type stimulated structures

In order to determine modal parameters, classical experimental modal analysis can be used in engineering application. This method finds a system frequency response function using fast Fourier Transform (FFT). The Fourier Transform is one type of global data analysis method. The frequency resolution is equal to the reciprocal of the total sample time. So applying the FFT is not suitable for any transient signal to reveal local characteristics. However, in modern manufacturing industries, processing forces are rapidly changing. The dynamic behavior may vary rapidly in a short time due to variations in the machining parameters and changes in boundary conditions. These nonlinear and non-stationary dynamic parameters are not constant during machining operations identification using FFT. In this research, an innovative transient signal analysis approach has been developed, which is based on an application of the least squares estimation. The proposed method provides transient information with high resolution and to identify the time-varying modal parameters during machining. Least squares estimation can be augmented with a sliding-window operation (SWLSE) to reveal the actual system dynamic behavior at any moment. The accuracy of this method depends on the window size, the noise ratio and the sampling rate etc. The estimation accuracy of modal parameters is discussed in this work. To examine the efficiency of the SWLSE method experimental tests are performed on a laboratory beam system and the results are compared with the classical experimental modal analysis (CEMA) method. The laboratory beam system is designed and assembled that the stiffness and damping ratio of the structure can be adjusted. Additionally, the proposed method is applied to the identification of the actual modal parameters of machine tools during machining operations. In another application, the proposed method provides also the process varied damping information in a process monitoring

An Assessment on the Non-Invasive Methods for Condition Monitoring of Induction Motors

The ability to forecast motor mechanical faults at incipient stages is vital to reducing maintenance costs, operation downtime and safety hazards. This paper synthesized the progress in the research and development in condition monitoring and fault diagnosis of induction motors. The motor condition monitoring techniques are mainly classified into two categories that are invasive and non-invasive techniques. The invasive techniques are very basic, but they have some implementation difficulties and high cost. The non-invasive methods, namely MCSA, PVA and IPA, overcome the disadvantages associated to invasive methods. This book chapter reviews the various non-invasive condition monitoring methods for diagnosis of mechanical faults in induction motor and concludes that the instantaneous power analysis (IPA) and Park vector analysis (PVA) methods are best suitable for the diagnosis of small fault signatures associated to mechanical faults. Recommendations for the future research in these areas are also presented

Advances of Italian Machine Design

This 2028 Special Issue presents recent developments and achievements in the field of Mechanism and Machine Science coming from the Italian community with international collaborations and ranging from theoretical contributions to experimental and practical applications. It contains selected contributions that were accepted for presentation at the Second International Conference of IFToMM Italy, IFIT2018, that has been held in Cassino on 29 and 30 November 2018. This IFIT conference is the second event of a series that was established in 2016 by IFToMM Italy in Vicenza. IFIT was established to bring together researchers, industry professionals and students, from the Italian and the international community in an intimate, collegial and stimulating environment