31 research outputs found

    Computer aided design of horizontal axis turbine

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    This paper presents a computer-based method for modelling the blades of horizontal axis turbines using B-spline surfaces. The method uses common design parameters for the geometry of this type of turbine and produces a final set of B-spline surfaces for the geometry of the blades that can be used for the visualisation, calculations and construction of the rotor surface. The method begins with the creation of a 3D set of offsets that constitute the rotor blades based on a 2D definition of the airfoils, which is normally used in the design of different stations along the rotor blade. It also uses geometrical parameters such as the skew and rake or coning distribution. The method stresses the fitting of the blade?s leading edge, which has a significant impact on the properties of the rotor and separately models the trailing edge of the blades. B-spline curves and surfaces are used in this method because they are widely used in CAD-CAM software products and can be easily exported to other programs

    Clothoid-Based Three-Dimensional Curve for Attitude Planning

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    Interest in flying robots, also known as unmanned aerial vehicles (UAVs), has grown during last years in both military and civil fields [1, 2]. The same happens to autonomous underwater vehicles (AUVs) [3]. These vehicles, UAVs and AUVs, offer a wide variety of possible applications and challenges, such as control, guidance or navigation [2, 3]. In this sense, heading and attitude control in UAVs is very important [4], particularly relevant in airplanes (fixed-wing flying vehicles), because they are strongly non-linear, coupled, and tend to be underactuated systems with non-holonomic constraints. Hence, designing a good attitude controller is a difficult task [5, 6, 7, 8, 9], where stability must be taken into account by the controller [10]. Indeed, if the reference is too demanding for the controller or non-achievable because its dynamics is too fast, the vehicle might become unstable. In order to address this issue, autonomous navigation systems usually include a high-level path planner to generate smooth reference trajectories to be followed by the vehicle using a low-level controller. Usually a set of waypoints is given in GPS coordinates, normally from a map, in order to apply a smooth point-to-point control trajectory [11, 12]

    The Construction of Optimized High-Order Surface Meshes by Energy-Minimization

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    Despite the increasing popularity of high-order methods in computational fluid dynamics, their application to practical problems still remains challenging. In order to exploit the advantages of high-order methods with geometrically complex computational domains, coarse curved meshes are necessary, i.e. high-order representations of the geometry. This dissertation presents a strategy for the generation of curved high-order surface meshes. The mesh generation method combines least-squares fitting with energy functionals, which approximate physical bending and stretching energies, in an incremental energy-minimizing fitting strategy. Since the energy weighting is reduced in each increment, the resulting surface representation features high accuracy. Nevertheless, the beneficial influence of the energy-minimization is retained. The presented method aims at enabling the utilization of the superior convergence properties of high-order methods by facilitating the construction of coarser meshes, while ensuring accuracy by allowing an arbitrary choice of geometric approximation order. Results show surface meshes of remarkable quality, even for very coarse meshes representing complex domains, e.g. blood vessels

    Toolpath interpolation and smoothing for computer numerical control machining of freeform surfaces : a review

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    Driven by the ever increasing demand in function integration, more and more next generation high value-added products, such as head-up displays, solar concentrators and intra-ocular-lens, etc., are designed to possess freeform (i.e., non-rotational symmetric) surfaces. The toolpath, composed of high density of short linear and circular segments, is generally used in computer numerical control (CNC) systems to machine those products. However, the discontinuity between toolpath segments leads to high-frequency fluctuation of feedrate and acceleration, which will decrease the machining efficiency and product surface finish. Driven by the ever-increasing need for high-speed high-precision machining of those products, many novel toolpath interpolation and smoothing approaches have been proposed in both academia and industry, aiming to alleviate the issues caused by the conventional toolpath representation and interpolation methods. This paper provides a comprehensive review of the state-of-the-art toolpath interpolation and smoothing approaches with systematic classifications. The advantages and disadvantages of these approaches are discussed. Possible future research directions are also offered

    Novel control approaches for the next generation computer numerical control (CNC) system for hybrid micro-machines

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    It is well-recognised that micro-machining is a key enabling technology for manufacturing high value-added 3D micro-products, such as optics, moulds/dies and biomedical implants etc. These products are usually made of a wide range of engineering materials and possess complex freeform surfaces with tight tolerance on form accuracy and surface finish.In recent years, hybrid micro-machining technology has been developed to integrate several machining processes on one platform to tackle the manufacturing challenges for the aforementioned micro-products. However, the complexity of system integration and ever increasing demand for further enhanced productivity impose great challenges on current CNC systems. This thesis develops, implements and evaluates three novel control approaches to overcome the identified three major challenges, i.e. system integration, parametric interpolation and toolpath smoothing. These new control approaches provide solid foundation for the development of next generation CNC system for hybrid micro-machines.There is a growing trend for hybrid micro-machines to integrate more functional modules. Machine developers tend to choose modules from different vendors to satisfy the performance and cost requirements. However, those modules often possess proprietary hardware and software interfaces and the lack of plug-and-play solutions lead to tremendous difficulty in system integration. This thesis proposes a novel three-layer control architecture with component-based approach for system integration. The interaction of hardware is encapsulated into software components, while the data flow among different components is standardised. This approach therefore can significantly enhance the system flexibility. It has been successfully verified through the integration of a six-axis hybrid micro-machine. Parametric curves have been proven to be the optimal toolpath representation method for machining 3D micro-products with freeform surfaces, as they can eliminate the high-frequency fluctuation of feedrate and acceleration caused by the discontinuity in the first derivatives along linear or circular segmented toolpath. The interpolation for parametric curves is essentially an optimization problem, which is extremely difficult to get the time-optimal solution. This thesis develops a novel real-time interpolator for parametric curves (RTIPC), which provides a near time-optimal solution. It limits the machine dynamics (axial velocities, axial accelerations and jerk) and contour error through feedrate lookahead and acceleration lookahead operations. Experiments show that the RTIPC can simplify the coding significantly, and achieve up to ten times productivity than the industry standard linear interpolator. Furthermore, it is as efficient as the state-of-the-art Position-Velocity-Time (PVT) interpolator, while achieving much smoother motion profiles.Despite the fact that parametric curves have huge advantage in toolpath continuity, linear segmented toolpath is still dominantly used on the factory floor due to its straightforward coding and excellent compatibility with various CNC systems. This thesis presents a new real-time global toolpath smoothing algorithm, which bridges the gap in toolpath representation for CNC systems. This approach uses a cubic B-spline to approximate a sequence of linear segments. The approximation deviation is controlled by inserting and moving new control points on the control polygon. Experiments show that the proposed approach can increase the productivity by more than three times than the standard toolpath traversing algorithm, and 40% than the state-of-the-art corner blending algorithm, while achieving excellent surface finish.Finally, some further improvements for CNC systems, such as adaptive cutting force control and on-line machining parameters adjustment with metrology, are discussed in the future work section.It is well-recognised that micro-machining is a key enabling technology for manufacturing high value-added 3D micro-products, such as optics, moulds/dies and biomedical implants etc. These products are usually made of a wide range of engineering materials and possess complex freeform surfaces with tight tolerance on form accuracy and surface finish.In recent years, hybrid micro-machining technology has been developed to integrate several machining processes on one platform to tackle the manufacturing challenges for the aforementioned micro-products. However, the complexity of system integration and ever increasing demand for further enhanced productivity impose great challenges on current CNC systems. This thesis develops, implements and evaluates three novel control approaches to overcome the identified three major challenges, i.e. system integration, parametric interpolation and toolpath smoothing. These new control approaches provide solid foundation for the development of next generation CNC system for hybrid micro-machines.There is a growing trend for hybrid micro-machines to integrate more functional modules. Machine developers tend to choose modules from different vendors to satisfy the performance and cost requirements. However, those modules often possess proprietary hardware and software interfaces and the lack of plug-and-play solutions lead to tremendous difficulty in system integration. This thesis proposes a novel three-layer control architecture with component-based approach for system integration. The interaction of hardware is encapsulated into software components, while the data flow among different components is standardised. This approach therefore can significantly enhance the system flexibility. It has been successfully verified through the integration of a six-axis hybrid micro-machine. Parametric curves have been proven to be the optimal toolpath representation method for machining 3D micro-products with freeform surfaces, as they can eliminate the high-frequency fluctuation of feedrate and acceleration caused by the discontinuity in the first derivatives along linear or circular segmented toolpath. The interpolation for parametric curves is essentially an optimization problem, which is extremely difficult to get the time-optimal solution. This thesis develops a novel real-time interpolator for parametric curves (RTIPC), which provides a near time-optimal solution. It limits the machine dynamics (axial velocities, axial accelerations and jerk) and contour error through feedrate lookahead and acceleration lookahead operations. Experiments show that the RTIPC can simplify the coding significantly, and achieve up to ten times productivity than the industry standard linear interpolator. Furthermore, it is as efficient as the state-of-the-art Position-Velocity-Time (PVT) interpolator, while achieving much smoother motion profiles.Despite the fact that parametric curves have huge advantage in toolpath continuity, linear segmented toolpath is still dominantly used on the factory floor due to its straightforward coding and excellent compatibility with various CNC systems. This thesis presents a new real-time global toolpath smoothing algorithm, which bridges the gap in toolpath representation for CNC systems. This approach uses a cubic B-spline to approximate a sequence of linear segments. The approximation deviation is controlled by inserting and moving new control points on the control polygon. Experiments show that the proposed approach can increase the productivity by more than three times than the standard toolpath traversing algorithm, and 40% than the state-of-the-art corner blending algorithm, while achieving excellent surface finish.Finally, some further improvements for CNC systems, such as adaptive cutting force control and on-line machining parameters adjustment with metrology, are discussed in the future work section

    Isogeometric Analysis: Fundamentals and details of implementation. From first steps to two-dimensional non-linear problems

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    Isogeometric analysis (IGA) is a computational analysis technique that can serve as an alternative to the traditional finite element method (FEM) in approximating solutions to differential equations. IGA is not necessarily more efficient that traditional FEM, but because of its nature, can naturally handle a greater variety of complex geometries. IGA is based on the use of NURBS (non-uniform rational B-splines), mathematical descriptions of geometry which are the standard of representing geometry in computer aided design (CAD) modeling software. IGA therefore links the CAD world to the world of analysis. Traditional FEM was developed before NURBS, in the 1950s and therefore developed quite separately. This project focuses on the fundamentals and implementation of IGA for problems, including one-dimensional, two-dimensional scalar, two-dimensional vector-valued and simple non-linear problems. For each new problem, the underlying mathematics is developed and the implementation is discussed in detail. One of the major contributions of this project is considered to be the detail in which the implementation of the Neumann boundary condition is described. There is none of this level of detail in any of the available literature. All problems solved are demonstrative and was written in a modular way that is easy to read and understand. Furthermore, how to extract NURBS data from CAD software is discussed, which would prove useful for future problems with more complex geometry. While the work done in this project is not considered novel, the thoroughness in which the project was approached is hoped to be useful for future projects. From this project, the work can be expanded to more complex geometries, multi-patch problems with the help of CAD programs or more complex non-linear problems

    Annales Mathematicae et Informaticae 2010

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    Annales Mathematicae et Informaticae (37.)

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