On systematic approaches for interpreted information transfer of inspection data from bridge models to structural analysis

In conjunction with the improved methods of monitoring damage and degradation processes, the interest in reliability assessment of reinforced concrete bridges is increasing in recent years. Automated imagebased inspections of the structural surface provide valuable data to extract quantitative information about deteriorations, such as crack patterns. However, the knowledge gain results from processing this information in a structural context, i.e. relating the damage artifacts to building components. This way, transformation to structural analysis is enabled. This approach sets two further requirements: availability of structural bridge information and a standardized storage for interoperability with subsequent analysis tools. Since the involved large datasets are only efficiently processed in an automated manner, the implementation of the complete workflow from damage and building data to structural analysis is targeted in this work. First, domain concepts are derived from the back-end tasks: structural analysis, damage modeling, and life-cycle assessment. The common interoperability format, the Industry Foundation Class (IFC), and processes in these domains are further assessed. The need for usercontrolled interpretation steps is identified and the developed prototype thus allows interaction at subsequent model stages. The latter has the advantage that interpretation steps can be individually separated into either a structural analysis or a damage information model or a combination of both. This approach to damage information processing from the perspective of structural analysis is then validated in different case studies

3D Innovations in Personalized Surgery

Current practice involves the use of 3D surgical planning and patient-specific solutions in multiple surgical areas of expertise. Patient-specific solutions have been endorsed for several years in numerous publications due to their associated benefits around accuracy, safety, and predictability of surgical outcome. The basis of 3D surgical planning is the use of high-quality medical images (e.g., CT, MRI, or PET-scans). The translation from 3D digital planning toward surgical applications was developed hand in hand with a rise in 3D printing applications of multiple biocompatible materials. These technical aspects of medical care require engineers’ or technical physicians’ expertise for optimal safe and effective implementation in daily clinical routines.The aim and scope of this Special Issue is high-tech solutions in personalized surgery, based on 3D technology and, more specifically, bone-related surgery. Full-papers or highly innovative technical notes or (systematic) reviews that relate to innovative personalized surgery are invited. This can include optimization of imaging for 3D VSP, optimization of 3D VSP workflow and its translation toward the surgical procedure, or optimization of personalized implants or devices in relation to bone surgery

Mechatronics Methods for Mitigating Undesirable Effects of Pre-motion Friction in Nanopositioning Stages with Mechanical Bearings

Nanopositioning (NP) stages are used to for precise positioning in a wide range of nanotech processes, ranging from substrate patterning to micro additive manufacturing. They are often used for point-to-point (P2P) motions, where the stage is commanded to travel to and settle within a pre-specified window of the target position, and for tracking motions, where the stage is commanded to follow a reference trajectory. The settling time, in-position stability and tracking accuracy of NP stages directly affects productivity and quality of the associated processes or manufactured products. NP stages can be constructed using flexure, fluidic, magnetic or mechanical bearings (i.e., sliding and, especially, rolling-element bearings). Of these choices, mechanical bearings are the most cost-effective, and are currently the only commercially viable option for a growing number of NP applications that must be performed in high vacuum environments. However, mechanical-bearing-guided NP stages experience nonlinear pre-motion (i.e., pre-sliding/pre-rolling) friction which adversely affects their precision and speed. Control-based compensation methods, commonly used to address this problem, often suffer from poor robustness and limited practicality due to the complexity and extreme variability of friction dynamics at the micro scale. Therefore, this dissertation proposes three novel mechatronics methods, featuring a combination of mechanical design and control strategy, as more effective and robust solutions to mitigate the undesirable effects of pre-motion friction. The first approach is vibration assisted nanopositioning (VAN), which utilizes high frequency vibration (i.e., dither) to mitigate the low speed (slow settling) of mechanical-bearing-guided NP stages during P2P motions. VAN allows the use of dither to mitigate pre-motion friction while maintaining nanometer-level positioning precision. P2P positioning experiments on an in-house built VAN stage demonstrates up to 66% reductions in the settling time, compared to a conventional mechanical bearing NP stage. A major shortcoming of VAN is that it increases the cost of NP stages. To address this limitation, a friction isolator (FI) is proposed as a simple and more cost-effective method for mitigating pre-motion friction. The idea of FI is to connect the mechanical bearing to the NP stage using a joint that is very compliant in the motion direction, thus effectively isolating the stage from bearing friction. P2P positioning tests on a NP stage equipped with FI prototypes demonstrate up to 84% reductions in the settling time. The introduction of FI also enables accurate and robust reductions of motion errors during circular tracking tests, using feedforward compensation with a simple friction model. One pitfall of FI is that it causes increased error of the stage during in position. Therefore, a semi-active isolator (SAI) is proposed to mitigate the slow settling problem using the FI, while maintaining the benefits of friction on in-position stability. The proposed SAI, which connects the bearing and NP stage, is equipped with solenoids to switch its stiffness from low, during settling, to high once the stage gets into position. P2P experiments demonstrate up to 81% improvements in the settling time without sacrificing in-position stability. The proposed mechatronics methods are compared and FI stands out as a result of its simplicity, cost-effectiveness and robust performance. Therefore, the influence of design parameters on the effectiveness of FI are investigated to provide design guidelines. It is recommended that the FI should be designed with the smallest stiffness in the motion direction, while satisfying other requirements such as in-position stability and off-axis rigidity.PHDMechanical EngineeringUniversity of Michigan, Horace H. Rackham School of Graduate Studieshttps://deepblue.lib.umich.edu/bitstream/2027.42/155296/1/terrydx_1.pd

Design, Development and Implementation of the Position Estimator Algorithm for Harmonic Motion on the XY Flexural Mechanism for High Precision Positioning

This article presents a novel concept of the position estimator algorithm for voice coil actuators used in precision scanning applications. Here, a voice coil motor was used as an actuator and a sensor using the position estimator algorithm, which was derived from an electro-mechanical model of a voice coil motor. According to the proposed algorithm, the position of coil relative to the fixed magnet position depends on the current drawn, voltage across coil and motor constant of the voice coil motor. This eliminates the use of a sensor that is an integral part of all feedback control systems. Proposed position estimator was experimentally validated for the voice coil actuator in integration with electro-mechanical modeling of the flexural mechanism. The experimental setup consisted of the flexural mechanism, voice coil actuator, current and voltage monitoring circuitry and its interfacing with PC via a dSPACE DS1104 R&D microcontroller board. Theoretical and experimental results revealed successful implementation of the proposed novel algorithm in the feedback control system with positioning resolution of less than ±5 microns at the scanning speed of more than 5 mm/s. Further, proportional-integral-derivative (PID) control strategy was implemented along with developed algorithm to minimize the error. The position determined by the position estimator algorithm has an accuracy of 99.4% for single direction motion with the experimentally observed position at those instantaneous states

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

Advanced Motor Control for Improving the Trajectory Tracking Accuracy of a Low-Cost Mobile Robot

This research was funded by the Grant PID2019-111278RB-C21 funded by MCIN/AEI/ 10.13039/501100011033 and “ERDF A way of making Europe”.Peer reviewedPublisher PD

Semiautonomous Robotic Manipulator for Minimally Invasive Aortic Valve Replacement

Aortic valve surgery is the preferred procedure for replacing a damaged valve with an artificial one. The ValveTech robotic platform comprises a flexible articulated manipulator and surgical interface supporting the effective delivery of an artificial valve by teleoperation and endoscopic vision. This article presents our recent work on force-perceptive, safe, semiautonomous navigation of the ValveTech platform prior to valve implantation. First, we present a force observer that transfers forces from the manipulator body and tip to a haptic interface. Second, we demonstrate how hybrid forward/inverse mechanics, together with endoscopic visual servoing, lead to autonomous valve positioning. Benchtop experiments and an artificial phantom quantify the performance of the developed robot controller and navigator. Valves can be autonomously delivered with a 2.0±0.5 mm position error and a minimal misalignment of 3.4±0.9°. The hybrid force/shape observer (FSO) algorithm was able to predict distributed external forces on the articulated manipulator body with an average error of 0.09 N. FSO can also estimate loads on the tip with an average accuracy of 3.3%. The presented system can lead to better patient care, delivery outcome, and surgeon comfort during aortic valve surgery, without requiring sensorization of the robot tip, and therefore obviating miniaturization constraints.</p

Design, control and error analysis of a fast tool positioning system for ultra-precision machining of freeform surfaces

This thesis was previously held under moratorium from 03/12/19 to 03/12/21Freeform surfaces are widely found in advanced imaging and illumination systems, orthopaedic implants, high-power beam shaping applications, and other high-end scientific instruments. They give the designers greater ability to cope with the performance limitations commonly encountered in simple-shape designs. However, the stringent requirements for surface roughness and form accuracy of freeform components pose significant challenges for current machining techniques—especially in the optical and display market where large surfaces with tens of thousands of micro features are to be machined. Such highly wavy surfaces require the machine tool cutter to move rapidly while keeping following errors small. Manufacturing efficiency has been a bottleneck in these applications. The rapidly changing cutting forces and inertial forces also contribute a great deal to the machining errors. The difficulty in maintaining good surface quality under conditions of high operational frequency suggests the need for an error analysis approach that can predict the dynamic errors. The machining requirements also impose great challenges on machine tool design and the control process. There has been a knowledge gap on how the mechanical structural design affects the achievable positioning stability. The goal of this study was to develop a tool positioning system capable of delivering fast motion with the required positioning accuracy and stiffness for ultra-precision freeform manufacturing. This goal is achieved through deterministic structural design, detailed error analysis, and novel control algorithms. Firstly, a novel stiff-support design was proposed to eliminate the structural and bearing compliances in the structural loop. To implement the concept, a fast positioning device was developed based on a new-type flat voice coil motor. Flexure bearing, magnet track, and motor coil parameters were designed and calculated in detail. A high-performance digital controller and a power amplifier were also built to meet the servo rate requirement of the closed-loop system. A thorough understanding was established of how signals propagated within the control system, which is fundamentally important in determining the loop performance of high-speed control. A systematic error analysis approach based on a detailed model of the system was proposed and verified for the first time that could reveal how disturbances contribute to the tool positioning errors. Each source of disturbance was treated as a stochastic process, and these disturbances were synthesised in the frequency domain. The differences between following error and real positioning error were discussed and clarified. The predicted spectrum of following errors agreed with the measured spectrum across the frequency range. It is found that the following errors read from the control software underestimated the real positioning errors at low frequencies and overestimated them at high frequencies. The error analysis approach thus successfully revealed the real tool positioning errors that are mingled with sensor noise. Approaches to suppress disturbances were discussed from the perspectives of both system design and control. A deterministic controller design approach was developed to preclude the uncertainty associated with controller tuning, resulting in a control law that can minimize positioning errors. The influences of mechanical parameters such as mass, damping, and stiffness were investigated within the closed-loop framework. Under a given disturbance condition, the optimal bearing stiffness and optimal damping coefficients were found. Experimental positioning tests showed that a larger moving mass helped to combat all disturbances but sensor noise. Because of power limits, the inertia of the fast tool positioning system could not be high. A control algorithm with an additional acceleration-feedback loop was then studied to enhance the dynamic stiffness of the cutting system without any need for large inertia. An analytical model of the dynamic stiffness of the system with acceleration feedback was established. The dynamic stiffness was tested by frequency response tests as well as by intermittent diamond-turning experiments. The following errors and the form errors of the machined surfaces were compared with the estimates provided by the model. It is found that the dynamic stiffness within the acceleration sensor bandwidth was proportionally improved. The additional acceleration sensor brought a new error source into the loop, and its contribution of errors increased with a larger acceleration gain. At a certain point, the error caused by the increased acceleration gain surpassed other disturbances and started to dominate, representing the practical upper limit of the acceleration gain. Finally, the developed positioning system was used to cut some typical freeform surfaces. A surface roughness of 1.2 nm (Ra) was achieved on a NiP alloy substrate in flat cutting experiments. Freeform surfaces—including beam integrator surface, sinusoidal surface, and arbitrary freeform surface—were successfully machined with optical-grade quality. Ideas for future improvements were proposed in the end of this thesis.Freeform surfaces are widely found in advanced imaging and illumination systems, orthopaedic implants, high-power beam shaping applications, and other high-end scientific instruments. They give the designers greater ability to cope with the performance limitations commonly encountered in simple-shape designs. However, the stringent requirements for surface roughness and form accuracy of freeform components pose significant challenges for current machining techniques—especially in the optical and display market where large surfaces with tens of thousands of micro features are to be machined. Such highly wavy surfaces require the machine tool cutter to move rapidly while keeping following errors small. Manufacturing efficiency has been a bottleneck in these applications. The rapidly changing cutting forces and inertial forces also contribute a great deal to the machining errors. The difficulty in maintaining good surface quality under conditions of high operational frequency suggests the need for an error analysis approach that can predict the dynamic errors. The machining requirements also impose great challenges on machine tool design and the control process. There has been a knowledge gap on how the mechanical structural design affects the achievable positioning stability. The goal of this study was to develop a tool positioning system capable of delivering fast motion with the required positioning accuracy and stiffness for ultra-precision freeform manufacturing. This goal is achieved through deterministic structural design, detailed error analysis, and novel control algorithms. Firstly, a novel stiff-support design was proposed to eliminate the structural and bearing compliances in the structural loop. To implement the concept, a fast positioning device was developed based on a new-type flat voice coil motor. Flexure bearing, magnet track, and motor coil parameters were designed and calculated in detail. A high-performance digital controller and a power amplifier were also built to meet the servo rate requirement of the closed-loop system. A thorough understanding was established of how signals propagated within the control system, which is fundamentally important in determining the loop performance of high-speed control. A systematic error analysis approach based on a detailed model of the system was proposed and verified for the first time that could reveal how disturbances contribute to the tool positioning errors. Each source of disturbance was treated as a stochastic process, and these disturbances were synthesised in the frequency domain. The differences between following error and real positioning error were discussed and clarified. The predicted spectrum of following errors agreed with the measured spectrum across the frequency range. It is found that the following errors read from the control software underestimated the real positioning errors at low frequencies and overestimated them at high frequencies. The error analysis approach thus successfully revealed the real tool positioning errors that are mingled with sensor noise. Approaches to suppress disturbances were discussed from the perspectives of both system design and control. A deterministic controller design approach was developed to preclude the uncertainty associated with controller tuning, resulting in a control law that can minimize positioning errors. The influences of mechanical parameters such as mass, damping, and stiffness were investigated within the closed-loop framework. Under a given disturbance condition, the optimal bearing stiffness and optimal damping coefficients were found. Experimental positioning tests showed that a larger moving mass helped to combat all disturbances but sensor noise. Because of power limits, the inertia of the fast tool positioning system could not be high. A control algorithm with an additional acceleration-feedback loop was then studied to enhance the dynamic stiffness of the cutting system without any need for large inertia. An analytical model of the dynamic stiffness of the system with acceleration feedback was established. The dynamic stiffness was tested by frequency response tests as well as by intermittent diamond-turning experiments. The following errors and the form errors of the machined surfaces were compared with the estimates provided by the model. It is found that the dynamic stiffness within the acceleration sensor bandwidth was proportionally improved. The additional acceleration sensor brought a new error source into the loop, and its contribution of errors increased with a larger acceleration gain. At a certain point, the error caused by the increased acceleration gain surpassed other disturbances and started to dominate, representing the practical upper limit of the acceleration gain. Finally, the developed positioning system was used to cut some typical freeform surfaces. A surface roughness of 1.2 nm (Ra) was achieved on a NiP alloy substrate in flat cutting experiments. Freeform surfaces—including beam integrator surface, sinusoidal surface, and arbitrary freeform surface—were successfully machined with optical-grade quality. Ideas for future improvements were proposed in the end of this thesis

High-Performance Tracking for Piezoelectric Actuators Using Super-Twisting Algorithm Based on Artificial Neural Networks

Piezoelectric actuators (PEA) are frequently employed in applications where nano-Micr-odisplacement is required because of their high-precision performance. However, the positioning is affected substantially by the hysteresis which resembles in an nonlinear effect. In addition, hysteresis mathematical models own deficiencies that can influence on the reference following performance. The objective of this study was to enhance the tracking accuracy of a commercial PEA stack actuator with the implementation of a novel approach which consists in the use of a Super-Twisting Algorithm (STA) combined with artificial neural networks (ANN). A Lyapunov stability proof is bestowed to explain the theoretical solution. Experimental results of the proposed method were compared with a proportional-integral-derivative (PID) controller. The outcomes in a real PEA reported that the novel structure is stable as it was proved theoretically, and the experiments provided a significant error reduction in contrast with the PID.This research was funded by Basque Government and UPV/EHU projects