Mechatronic design, actuator optimization, and control of a long stroke linear nano-positioner

The final publication is available at Elsevier via https://dx.doi.org/10.1016/j.precisioneng.2018.01.007 © 2018. This manuscript version is made available under the CC-BY-NC-ND 4.0 license https://creativecommons.org/licenses/by-nc-nd/4.0/In this paper, mechatronic design, actuator optimization and controls of a long-stroke (20 mm) linear nano-positioner are presented. The mechatronic design is described in terms of the stage's most prominent features regarding mechanical design, assembly, actuator configuration, and power supply. A novel air-bearing/bushing arrangement has been used in which the commonly employed double shaft arrangement is replaced with a single shaft supported by an air bearing from the bottom to constrain the roll motion. The assembly is greatly simplified by exploiting the self-aligning property of the air-bushings which are held in the housings by O-rings. Also, the footprint of the stage is reduced. Voice coil actuators (VCA) in moving magnet mode have been used in complementary double configuration for uniformity of force response. The performance objectives of previously optimized VCA's as standalone actuators are re-evaluated in this configuration. It is observed that while the performance objectives decrease a bit, the desirability of the design point is still retained. Controller design has been made for the current control and position control loops. Heydemann's method for the compensation of encoder quadrature detection errors is implemented. The positioning resolution of the stage as measured from the sensor output is experimentally determined to be +/-5 nm. Dynamic Error Budgeting (DEB) method has been used to analyze the contributing factors to the positioning error, and sensor broadband noise is determined to be the major contributor. The actual positioning accuracy of the stage is estimated by DEB to be 0.682 nm root-mean-square (RMS). The trajectory following accuracy is determined to be +/-15 nm. It is expected that trajectory following accuracy can substantially improve if more advanced compensation methods for encoder quadrature errors are implemented.Natural Sciences and Engineering Research Council of Canada [RGPIN-03879]Engage grant EGP [436910-12

Towards self-powered sensing using nanogenerators for automotive systems

The final publication is available at Elsevier via https://dx.doi.org/10.1016/j.nanoen.2018.09.032 © 2018. This manuscript version is made available under the CC-BY-NC-ND 4.0 license https://creativecommons.org/licenses/by-nc-nd/4.0/Harvesting energy from the working environment of vehicles is important for wirelessly monitoring their operation conditions and safety. This review aims at reporting different sensory and energy harvesting technologies developed for automotive and active safety systems. A few dominant sensing and power harvesting mechanisms in automotive systems are illustrated, then, triboelectric, piezoelectric and pyroelectric nanogenerators, and their potential for utilization in automotive systems are discussed considering their high power density, flexibility, different operating modes, and cost in comparison with other mechanisms. Various ground vehicles’ sensing mechanisms including position, thermal, pressure, chemical and gas composition, and pressure sensors are presented. A few novel types self-powered sensing mechanisms are presented for each of the abovementioned sensor categories using nanogenerators. The last section includes the automotive systems and subsystems, which have the potential to be used for energy harvesting, such as suspension and tires. The potential of nanogenerators for developing new self-powered sensors for automotive applications, which in the near future, will be an indispensable part of the active safety systems in production cars, is also discussed in this review article

A flexible hybridized electromagnetic-triboelectric multi-purpose self-powered sensor

The final publication is available at Elsevier via https://dx.doi.org/10.1016/j.nanoen.2018.01.011 © 2018. This manuscript version is made available under the CC-BY-NC-ND 4.0 license https://creativecommons.org/licenses/by-nc-nd/4.0/This paper presents a novel hybridized flexible electromagnetic-triboelectric generator that consists of a round/square shaped coil and magnet, and also, highly flexible, mechanically and thermally durable, and cost-effective polymeric materials. The reported hybridized nano generator is capable of converting external mechanical load to electricity. Using a systematic optimization approach results in an optimal configuration and size for the electromagnetic components of the self-powered sensor. Combination of the electromagnetic and triboelectric components provides several advantages for the proposed self-powered device including high resolution and power density even in low frequency and small amplitude of the excitations. We probe the sensitivity of the fabricated self-powered sensor considering different amplitude and frequency of excitations as well as external resistors. After providing a general performance analysis for the proposed self powered sensor, we show its potential for different specific applications including human motion based energy harvesting and sensing, tire condition monitoring, and pressure sensing. The utilization of the proposed self-powered sensor can provide a sustainable energy source for wireless sensor nodes, and also overcomes the battery capacity limitation that restricts the life time durability of mobile electrical devices

A flexible tube-based triboelectric-electromagnetic sensor for knee rehabilitation assessment

The final publication is available at Elsevier via https://dx.doi.org/10.1016/j.sna.2018.05.016 © 2018. This manuscript version is made available under the CC-BY-NC-ND 4.0 license https://creativecommons.org/licenses/by-nc-nd/4.0/This paper reports a novel hybridized flexible electromagnetic-triboelectric generator for vibration/deflection monitoring as it is implemented in a cantilever or clamped-clamped configuration. The proposed self-powered sensor operates based on the concepts of electromagnetism and triboelectricity. The fabricated device consists of a stack of magnets and coils, a flexible tube as the main body, and also, highly flexible, mechanically and thermally durable, and cost-effective polymeric materials. The configuration of the electromagnetic component is optimized based on the magnetization direction of the utilized magnets. The device can effectively convert the shear force and bending moment to electrical voltage through the hybridized system with exerting an external force. The performance of the self-powered sensor is investigated for different cases including a single stack and also a double stack of magnetic components. The design of the triboelectric component of the device is based on the vertical contact separation mode. Results of the paper show how the change of configuration of the magnetic components alters the electrical output of the sensor. A detailed experimental analysis is provided to show the capability of the device under different excitation conditions for both triboelectric nanogenerator (TENG) and electromagnetic generator (EMG) components of the sensor. As the experimental analysis shows, the proposed self-powered system has the potential to be utilized for knee rehabilitation, as it shows explicit results under periodical bending load with different frequencies and amplitudes of excitation

Development and Analysis of a Novel Magnetic Levitation System with a Feedback Controller for Additive Manufacturing Applications

The primary goal of this study is to create a magnetic levitation system for additive manufacturing (AM) applications. The emphasis of this research is placed on Laser Directed Energy Deposition via Powder Feeding (LDED-PF). The primary benefit of using a magnetic levitation system for AM applications is that the levitated geometry is expected to be a portion of the final part manufactured, thus eliminating the need for a substrate and reducing the post-processing operation requirement. Two novel levitation systems were designed, optimized, and manufactured. The design, optimization, and analysis were first conducted in the simulation environment using ANSYS Maxwell and then tested with experiments. The newly developed systems depicted a much-improved performance compared to the first prototype developed in a previous article written by the authors. The newly developed systems had an increase in levitation height, the surface area for powder deposition activities, the time available for AM operations, and the ability to support additional mass within the limits of allowable inputs. The compatibility of the levitation system with AM applications was also verified by testing the impact of powder deposition and the ability of the levitated disc to support added mass as a function of time with minimal loss in performance. This article also highlights the development of a novel feedback PID controller for the levitation system. To improve the overall performance of the controller, a feedforward controller was added in conjunction with the PID controller. Finally, the levitation system was shown to highlight control over levitation height and maintain constant levitation height with the addition of an added mass using the feedback controller

A Novel Wrench–Current Decoupling Strategy to Extend the Use of Small Lookup Data for a Long-Range Maglev Planar Motor

The maglev planar motor is one of the most promising industrial applications. The planar motor can increase flexibility in modern manufacturing with the multidirectional motion of the mover. In levitation control, the decoupling matrix is used to decouple the strong cross-coupling effect. The Lorentz force-based wrench matrices can be precomputed and stored in the lookup table. However, the motion range is restricted by the data range. This paper presents a wrench–current decoupling strategy to extend the use of small lookup data for long-range planar motion. The horizontal data range is 40 mm by 40 mm, which is determined from the minimally repetitive area of the planar coil array. The quadrant symmetry transformation is used to estimate the data for other areas. The experiment results demonstrated the accomplishment of the developed technique for long-range motion with a maximum motion stroke of 380 mm. The disc-magnet movers can levitate with a large air gap of 30 mm and have a total roll and pitch rotation range of 20 degrees

Electrodynamic Concentration of Non-ferrous Metallic Particles in the Moving Gas-powder Stream: Mathematical Modeling and Analysis

This paper presents theory, modeling, and analysis of a novel electrodynamic concentration approach for submillimeter-sized conductive metal particles focusing in moving gas-powder stream. Such method is of particular interest in blown-powder feeding fabrication industry (e.g., powder-fed additive manufacturing) to generate a tightly focused powder stream. Conceptual design of a concentration generator is proposed with two different configurations: The doublet Halbach permanent magnet quadrupoles (doublet-Halbach-PMQs) and the doublet electromagnet quadrupoles (doublet-EMQs). Analytical models for magnetic forces and concentration angles were built. Numerical calculations were conducted for pure aluminum particles with a radius of 50150 μm . The particles with a radius of Rp = 300 μm can be concentrated with more than 15∘ angle at the frequency of 600 kHz . Therefore, the proposed doublet-EMQs configuration has a great potential to generate a narrowed and finely focused powder stream in the blown-powder feeding fabrication process

Design of a Compact Planar Magnetic Levitation System with Wrench–Current Decoupling Enhancement

Magnetic levitation technology has promising applications in modern manufacturing, especially for fine-motion stage and long-range omnidirectional planar motors. This paper presents the development of a compact planar maglev prototype with the potential to achieve both applications to increase flexibility for the manufacturing system. The planar stator is designed by using optimized square coils arranged in the zigzag configuration, which provides a better uniform magnetic flux density compared with another configuration. The stator is a compact and portable module with built-in current amplifier units. The single-disc magnet mover is deployed with five controllable degrees of freedom. The cross-coupling effect is decoupled by a precomputed Lorentz force based wrench—current transformation matrix stored in the lookup table. A 2-D linear interpolation is implemented to enhance decoupling effectiveness which is offered via discrete lookup data. Experiments with motion-tracking cameras and a basic controller demonstrate the results of fine step motion of 10 and 20 µm and rotation steps of 0.5 and 1.0 mrad. The potential for multidirectional material handling is represented by a total horizontal translation range of 20 mm by 20 mm with a maximum air gap of 26 mm and a total rotation range of 20 degrees for both roll and pitch