Re-Design of a Packaging Machine Employing Linear Servomotors: a Description of Modelling Methods and Engineering Tools

open4noPosition-controlled servo-systems mostly make use of electric rotary motors and gearboxes and, if necessary, a transmission mechanism to convert rotary into linear motion. Even so, especially in the field of automatic machines for packaging, it should be highlighted that most of the required movements are usually linear, so that Linear Electric Motors (LEM) should somehow represent a more convenient solution for designers. LEM can directly generate the required trajectory avoiding any intermediate mechanism, thus potentially minimizing the number of linkages/mechanical parts and, therefore, the undesired backlash and compliance that come along. On the other hand, particularly within small-medium enterprises, LEM may be rarely employed despite obvious advantages, mostly due to their high-cost as compared to rotary actuators and the lack of knowledge of the achievable performance. In light of these considerations, the present paper reports an industrial case study where an automatic machine for packaging, comprising distributed actuation and several tasks requiring a linear motion, has been completely redesigned employing different kind of LEM (i.e. iron-core and iron-less). Such machine architecture is compared to a “traditional” design where brushless gear-motors are coupled to linkage systems. The paper mainly focuses on the selection criteria for the LEM system and on the engineering tools employed during the different design stages. Qualitative and quantitative conclusions are finally drawn, which may provide useful hints for designers that are willing to actually employ LEM-based solutions in an industrial scenarioopenBerselli, Giovanni; Bilancia, Pietro; Bruzzone, Luca; Fanghella, PietroBerselli, Giovanni; Bilancia, Pietro; Bruzzone, Luca; Fanghella, Pietr

Analysis of a Reduced-Order Approximate Deconvolution Model and its interpretation as a Navier-Stokes-Voigt regularization

We study mathematical and physical properties of a family of recently introduced, reduced-order approximate deconvolution models. We first show a connection between these models and the NS-Voigt model, and that NS-Voigt can be re-derived in the approximate deconvolution framework. We then study the energy balance and spectra of the model, and provide results of some turbulent flow computations that backs up the theory. Analysis of global attractors for the model is also provided, as is a detailed analysis of the Voigt model's treatment of pulsatile flow

Compliant actuation based on dielectric elastomers for a force-feedback device: modeling and experimental evaluation

Thanks to their large power densities, low costs and shock-insensitivity, Dielectric Elastomers (DE)seem to be a promising technology for the implementation of light and compact force-feedback devices such as,for instance, haptic interfaces. Nonetheless, the development of these kinds of DE-based systems is not trivialowing to the relevant dissipative phenomena that affect the DE when subjected to rapidly changingdeformations. In this context, the present paper addresses the development of a force feedback controller foran agonist-antagonist linear actuator composed of a couple of conically-shaped DE films and a compliantmechanism behaving as a negative-rate bias spring. The actuator is firstly modeled accounting for the viscohyperelasticnature of the DE material. The model is then linearized and employed for the design of a forcecontroller. The controller employs a position sensor, which determines the actuator configuration, and a forcesensor, which measures the interaction force that the actuator exchanges with the environment. In addition, anoptimum full-state observer is also implemented, which enables both accurate estimation of the time-dependentbehavior of the elastomeric material and adequate suppression of the sensor measurement noise. Preliminaryexperimental results are provided to validate the proposed actuator-controller architectur

Virtual Prototyping of a Flexure-based RCC Device for Automated Assembly

The actual use of Industrial Robots (IR) for assembly systems requires the exertion of suitable strategies allowing to overcome shortcomings about IR poor precision and repeatability. In this paper, the practical issues that emerge during common \ue2\u80\u9cpeg-in-hole\ue2\u80\u9d assembly procedures are discussed. In particular, the use of passive Remote Center of Compliance (RCC) devices, capable of compensating the IR non-optimal performance in terms of repeatability, is investigated. The focus of the paper is the design and simulation of a flexure-based RCC that allows the prevention of jamming, due to possible positioning inaccuracies during peg insertion. The proposed RCC architecture comprises a set of flexural hinges, whose behavior is simulated via a CAE tool that provides built-in functions for modelling the motion of compliant members. For given friction coefficients of the contact surfaces, these numerical simulations allow to determine the maximum lateral and angular misalignments effectively manageable by the RCC device

Smart actuation for helicopter rotorblades

Successful rotorcrafts were only achieved when the differences between hovering flight conditions and a stable forward flight were understood. During hovering, the air speed on all helicopter blades is linearly distributed along each blade and is the same for each. However, during forward flight, the forward motion of the helicopter in the air creates an unbalance. The airspeed is increased for the blade passing in the advancing side of the helicopter, while it is reduced in the retreating side. Moreover, when each blade enters the retreating side of the helicopter, a reverse flow occurs around the profile where the blade speed is lower than the forward speed of the helicopter. The balance of a rotorcraft is solved by a cyclic pitch control, but trade-offs are made on the blade design to cope with the great variety of aerodynamic conditions. A smart blade that would adapt its characteristics to this large set of conditions would improve rotorcrafts energy efficiency while providing vibration and noise control.\ud Smart rotor blades systems are studied to adapt the aerodynamic characteristics of the blade during its revolution and to improve the overall performances. An increase in the lift over drag ratio on the retreating side has been studied to design a blade with better aerodynamic efficiency and better stall performances in the low-speed region. The maximum speed of a rotorcraft is limited by the angle of attack that the profile can sustain on the retreating side before stall. Therefore, increasing the maximum angle of attack that a profile geometry can sustain increases the rotorcraft flight envelope. Flow asymmetry and aerodynamic interaction between successive blades are also investigated to actively reduce vibrations and limit noise.\ud These improvements can be achieved by deploying flaps, by using flow control devices or by morphing the full shape of the profile at a specific places during the blade revolution. Each of the listed methods has advantages and disadvantages as well as various degrees of feasibility and integrability inside helicopter blades. They all modify the aerodynamic characteristics of the profile. Their leverage on the various aerodynamic effects depends on the control strategy chosen for actuation. Harmonic actuation is therefore studied for active noise and vibration control whereas stepped deployment is foreseen to modify the stall behaviour of the retreating side of the helicopter.\ud Helicopter blades are subjected to various force constraints such as the loads from the complex airflow and the centrifugal forces. Furthermore, any active system embedded inside a rotor blade needs to comply with the environmental constraints to which a helicopter will be subjected  during its life-span. Other concerns, like the power consumption and the data transfer for blade control, play an important role as well. Finally, such a system must have a life-time exceeding the life-time of a rotor blade and meet the same criteria in toughness, reliability and ease of maintenance.\ud Smart system is an interplay of aerodynamics, rotor-mechanics, material science and control, thus a multidisciplinary approach is essential. A large part of the work consists in building processes to integrate these domains for investigating, designing and testing smart components.\ud Piezoelectric actuators are a promising technology to bring adaptability to rotor blades. They can be used directly on the structure to actively modify its geometry, stiffness and aerodynamic behaviour or be integrated to mechanisms for the deployment of flaps. Their large specific work, toughness, reliability and small form factor make them suitable components for integration within a rotor blade. The main disadvantage of piezoelectric actuators is the small displacement and strain available. Amplification mechanisms must be optimised to produce sufficient displacement in morphing applications.\ud Smart actuation systems placed inside rotor blades have the potential to improve the efficiency and the performances of tomorrow's helicopters. Piezoelectric materials can address many of the challenges of integrating smart components inside helicopter blades. The key aspect remains the collaboration between various domains, skills and expertise to successfully implement these new technologies

Path Approximation Strategies for Robot Manufacturing: A Preliminary Experimental Evaluation

Industrial Robots (IRs) are increasingly adopted for material subtraction or deposition functions owing to their advantages over machine tools, like cost-effectiveness and versatility. Unfortunately, the development of efficient robot manufacturing processes still faces unsolved issues related to the IRs poor positioning accuracy and to the tool path generation process. Novel engineering methods and tools are needed for CAD based programming of accurate paths and continuous robot motions to obtain the required manufacturing quality and tolerances. Within this context, to achieve smoothness along the tool path formed by linear G-code segments, the IR controllers’ approximation strategies, summarily reported in the manufacturer’s manuals, must be considered. The aim of this paper is to present the preliminary work carried out to identify the approximation algorithms of a Kuka IR when executing linear moves. An experimental study is conducted by varying the controller settings and the maximum translational velocity. The robot behavior has been acquired thanks to the controller tracing function and then processed to yield relations readily employable for the interpretation of G-Code commands and the subsequent generation of proper robot motion instructions. The obtained formulas allow to accurately predict the robot geometric path and kinematics within the corner transition between two linear segments

Global regularity criterion for the 3D Navier-Stokes equations involving one entry of the velocity gradient tensor

In this paper we provide a sufficient condition, in terms of only one of the nine entries of the gradient tensor, i.e., the Jacobian matrix of the velocity vector field, for the global regularity of strong solutions to the three-dimensional Navier-Stokes equations in the whole space, as well as for the case of periodic boundary conditions

An elementary proof of uniqueness of the particle trajectories for solutions of a class of shear-thinning non-Newtonian 2D fluids

We prove some regularity results for a class of two dimensional non-Newtonian fluids. By applying results from [Dashti and Robinson, Nonlinearity, 22 (2009), 735-746] we can then show uniqueness of particle trajectories

A Modular Regularized Variational Multiscale Proper Orthogonal Decomposition for Incompressible Flows

In this paper, we propose, analyze and test a post-processing implementation of a projection-based variational multiscale (VMS) method with proper orthogonal decomposition (POD) for the incompressible Navier-Stokes equations. The projection-based VMS stabilization is added as a separate post-processing step to the standard POD approximation, and since the stabilization step is completely decoupled, the method can easily be incorporated into existing codes, and stabilization parameters can be tuned independent from the time evolution step. We present a theoretical analysis of the method, and give results for several numerical tests on benchmark problems which both illustrate the theory and show the proposed method's effectiveness