Two improved scanning path planning algorithms and a 3D printing control system with circular motion controller

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Dier Wang ◽  
Jun Zhang
Keyword(s):  
Control System ◽  
3D Printing ◽  
Optimization Method ◽  
Orthogonal Decomposition ◽  
Circular Motion ◽  
Motion Controller ◽  
Content Type ◽  
Scanning Path ◽  
Scanning Path Planning

Purpose This paper aims to improve the infilling efficiency and the quality of parts forming. It proposes two improved scanning path planning algorithm based on velocity orthogonal decomposition. Design/methodology/approach The algorithms this paper proposes replace empty paths and corners with circular segments, driving each axis synchronously according to the SIN or COS velocity curve to make the extruder always moves at a constant speed at maximum during the infilling process. Also, to support the improved algorithms, a three-dimensional (3D) printing control system based on circular motion controller is also designed. Findings The simulation and experiment results show that the improved algorithms are effective, and the printing time is shortened more significantly, especially in the case of small or complex models. What’s more, the optimized algorithm is not only compact in shape but also not obvious in edge warping. Research limitations/implications The algorithms in this paper are not applicable to traditional motion controllers. Practical implications The algorithms in this paper improve the infilling efficiency and the quality of parts forming. Social implications There are no social implications in this paper. Originality/value The specific optimization method of parallel-line scanning algorithm based on velocity orthogonal decomposition is replacing the empty paths with arc corners. And the specific optimization method of contour offsetting algorithm based on velocity orthogonal decomposition is to add connection paths between adjacent contours and turn all straight corners into arcs. What’s more, the 3D printing control system based on the circular motion controller can achieve multi-axis parallel motion to support these two improved path scanning algorithms.

The Laser Focus Position Control System Based on Motion Controller

2014 ◽  
Vol 644-650 ◽  
pp. 636-638
Author(s):  
Yun Li Zhang
Keyword(s):  
Control System ◽  
Laser Cutting ◽  
Position Control ◽  
Tracking System ◽  
Displacement Sensor ◽  
Focus Position ◽  
Motion Controller ◽  
Automatic Tracking ◽  
Laser Focus

Laser cutting focus position automatic tracking system of control precision directly affects the quality of laser cutting processing. There is a low anti-jamming capability, poor quality,poorer openness and poorer dynamic response short comings in the inductive sensor or the capacitive sensor and constitute of the single chip microcomputer control system. This paper introduces a laser focus automatic tracking system based on motion controller, using optical encoder as displacement sensor, use the motion controller of master-slave tracking (electronic gear) function implementation focus position error compensation quickly. Improve the quality of system control, openness, the stability and reliability.

scholarly journals A flash-based thermal simulation of scanning paths in LPBF additive manufacturing

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Kamel Ettaieb ◽  
Sylvain Lavernhe ◽  
Christophe Tournier
Keyword(s):  
High Performance ◽  
Laser Scanning ◽  
Thermal Field ◽  
Computational Cost ◽  
Three Dimensional ◽  
Three Dimensional Model ◽  
Content Type ◽  
Proposed Model ◽  
Scanning Path

Purpose This paper aims to propose an analytical thermal three-dimensional model that allows an efficient evaluation of the thermal effect of the laser-scanning path. During manufacturing by laser powder bed fusion (LPBF), the laser-scanning path influences the thermo-mechanical behavior of parts. Therefore, it is necessary to validate the path generation considering the thermal behavior induced by this process to improve the quality of parts. Design/methodology/approach The proposed model, based on the effect of successive thermal flashes along the scanning path, is calibrated and validated by comparison with thermal results obtained by FEM software and experimental measurements. A numerical investigation is performed to compare different scanning path strategies on the Ti6Al4V material with different stimulation parameters. Findings The simulation results confirm the effectiveness of the approach to simulate the thermal field to validate the scanning strategy. It suggests a change in the scale of simulation thanks to high-performance computing resources. Originality/value The flash-based approach is designed to ensure the quality of the simulated thermal field while minimizing the computational cost.

Method for characterization and enhancement of 3D printing by binder jetting applied to the textures quality

2017 ◽  
Vol 37 (2) ◽  
pp. 162-169 ◽  
Author(s):  
Julien Gardan
Keyword(s):  
Image Processing ◽  
3D Printing ◽  
Computer Aided Design ◽  
Product Life Cycle ◽  
Content Type ◽  
Powder Bed ◽  
3D Printed ◽  
Aided Design ◽  
Binder Jetting

Purpose This paper aims to present a technical approach to evaluate the quality of textures obtained by an inkjet during binder jetting in 3D printing on a powder bed through contours detection to improve the quality of the surface printed according to the result of the assembly between the inkjet and a granular product. Design/methodology/approach The manufacturing process is based on the use of computer-aided design and a 3D printer via binder jetting. Image processing measures the edge deviation of a texture on the granular surface with the possibility of implementing a correction in an active assembly through a “design for manufacturing” (DFM) approach. Example application is presented through first tests. Findings This approach observes a shape alteration of the printed image on a 3D printed product, and the work used the image processing method to improve the model according to the DFM approach. Originality/value This paper introduces a solution for improving the texture quality on 3D printed products realized via binder jetting. The DFM approach proposes an active assembly by compensating the print errors in upstream of a product life cycle.

Co-designed of network scheduling and sliding mode control for underwater shuttle based on adaptive genetic algorithm

2018 ◽  
Vol 38 (5) ◽  
pp. 635-644 ◽  
Author(s):  
Zeyu Li ◽  
Weidong Liu ◽  
Le Li ◽  
Zhi Liu ◽  
Feihu Zhang
Keyword(s):  
Genetic Algorithm ◽  
Control System ◽  
Time Delay ◽  
Sliding Mode ◽  
Transmission Time ◽  
Adaptive Genetic Algorithm ◽  
Control Performance ◽  
Network Scheduling ◽  
Content Type

Purpose Underwater shuttle is widely used in scenarios of deep sea transportation and observation. As messages are transmitted via the limited network, high transmission time-delay often leads to information congestion, worse control performance and even system crash. Moreover, due to the nonlinear issues with respect to shuttle’s heading motion, the delayed transmission also brings extra challenges. Hence, this paper aims to propose a co-designed method, for the purpose of network scheduling and motion controlling. Design/methodology/approach First, the message transmission scheduling is modeled as an optimization problem via adaptive genetic algorithm. The initial transmission time and the genetic operators are jointly encoded and adjusted to balance the payload in network. Then, the heading dynamic model is compensated for the delayed transmission, in which the parameters are unknown. Therefore, the adaptive sliding mode controller is designed to online estimate the parameters, for enhancing control precision and anti-interference ability. Finally, the method is evaluated by simulation. Findings The messages in network are well scheduled and the time delay is thus reduced, which increases the quality of service in network. The unknown parameters are estimated online, and the quality of control is enhanced. The control performance of the shuttle control system is thus increased. Originality/value The paper is the first to apply co-design method of message scheduling and attitude controlling for the underwater unmanned vehicle, which enhaces the control performance of the network control system.

Robot path optimization for laser cladding forming

2019 ◽  
Vol 46 (2) ◽  
pp. 281-289 ◽  
Author(s):  
Huadong Zheng ◽  
Ming Cong ◽  
Dong Liu ◽  
Hang Dong ◽  
Yi Liu
Keyword(s):  
Laser Cladding ◽  
Pso Algorithm ◽  
Optimization Method ◽  
Path Optimization ◽  
Stl Model ◽  
Content Type ◽  
Laser Cladding Process ◽  
Before And After ◽  
Manufacturing Techniques

Purpose The purpose of this paper is to provide an optimization method of robot cladding path, which is helpful to solve the problem of path under-optimization in laser cladding forming (LCF) based on robot. Design/methodology/approach First, the error influence parameters need setting before the cladding path generation, and the model of seeking appropriate error influence parameters is established based on the particle swarm optimization (PSO). Second, to solve the problem of collapse during the LCF process, the reason for collapse is analyzed and a robot cladding path error optimization method based on the layer path interpolation is proposed. Finally, the simulation and experiments are carried out. Findings Under the premise of giving the expected error of stereo lithography (STL) model, the optimal range of the chord height and the angle control can be quickly found by using PSO algorithm. Aiming at the collapse problem in the laser cladding process, a robot cladding path optimization method based on the layer path interpolation is proposed. A four-layer path interpolation simulation and the contrast experiments before and after the path optimization are completed; the results show that the robot cladding path optimization method can solve the problem of the collapse in laser cladding. Practical implications Robot cladding path optimization is one of the key technologies of LCF, and the quality of the robot cladding path is affected by STL model error and the path optimization method. This paper proposed a robot cladding path optimization method for LCF. This method can be used in other additive manufacturing techniques. Originality/value The quality of cladding path is important for LCF; this paper first proposed the optimization method of the robot cladding path for LCF to solve the collapse problem.

A coiling robot for elevator compensation chain

2016 ◽  
Vol 43 (4) ◽  
pp. 403-408
Author(s):  
Xianchuan Shi ◽  
Liang Gao ◽  
Lei Qian ◽  
Mingya Cheng ◽  
Kyle Jiang
Keyword(s):  
Control System ◽  
Servo Control ◽  
Original Position ◽  
Content Type ◽  
Servo Control System ◽  
And Control ◽  
System Designs ◽  
Practical Implications ◽  
Analog Output

Purpose The purpose of this paper is to develop a coiling robot in the production of coated elevator compensation chains to replace the manual coiling operations and improve the quality of compensation chains. Design/methodology/approach This paper introduces both mechanical and servo control system designs of the coiling robot. The structure of two friction wheels stabilizes the conveying speed of compensation chain, so the chain speed matches with the car speed. A centering mechanism pushes the chain to its original position. Seven servo motors are integrated into the system, and they are controlled by a servo control system based on programmable logic controller, positioning controller, analog output block and touch screen. Findings The results of the project show that the coiling robot can both greatly reduce the number of workers and the intensity of the work and improve the quality of the chain. The chain lid by the robot is not only neat, but also uniform in its inner stress. Research limitations/implications When the output speed of the compensation chain from the rear friction wheel does not match the coiling speed, the coiling operation has to be halted. Then, the operator adjusts the chain speed and restarts the coiling operation. Practical implications The coiling robot is proven working. It has been adopted by a leading company manufacturing compensation chains. Originality/value This is the first coiling robot which is practically used in a production line of compensation chains. Its design, mechanism and control systems are of great reference values to people.

Case study of the additive manufacturing application in the supersonic flow researches

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Jefte da Silva Guimarães ◽  
Valéria Serrano Faillace Oliveira Leite ◽  
Marco Antonio Sala Minucci ◽  
Dermeval Carinhana
Keyword(s):  
Additive Manufacturing ◽  
Supersonic Flow ◽  
3D Printing ◽  
Dimensional Change ◽  
Supersonic Combustion ◽  
Measuring System ◽  
Content Type ◽  
Before And After ◽  
New Perspective

Purpose The purpose of this paper is to demonstrate the aerodynamic behavior of a supersonic combustion test bench (SCTB) components, as the transition piece and the combustor of a scramjet (supersonic combustion ramjet), manufactured by 3D printing or additive manufacturing (AM). Design/methodology/approach For the dimensional and structural analysis of the manufactured models, a portable 3D scanner was used to generate the mesh of its dimensions, and to compare them before and after the experiments, a roughness measuring system was also used to verify the roughness inside the models before and after the tests, as roughness is an important parameter because it directly affects the boundary layer. For the visualization of the flow, the non-intrusive schlieren optical technique was used. Findings The experiments were carried out on the SCBT for Mach 2 flows, using the manufactured prototypes and showed that there was no structural and dimensional change of the model after the test batteries. It was found that the roughness presented by the material did not affect the quality of the flow generated. This shows that the investigated material can also be applied in experiments with supersonic flow. Originality/value This paper presents that it is possible to use in ground test facilities, for the studies of supersonic flow (in cold condition), pieces and models manufactured by 3D printing without affecting the quality of the flow generated during the experiments. This study presents a new perspective to approach AM applied in the studies of supersonic flows.

Modified shuffled frog leaping algorithm for optimization of UAV flight controller

2011 ◽  
Vol 4 (1) ◽  
pp. 25-39 ◽  
Author(s):  
Huangzhong Pu ◽  
Ziyang Zhen ◽  
Daobo Wang
Keyword(s):  
Particle Swarm Optimization ◽  
Control System ◽  
Flight Control ◽  
Attitude Control ◽  
Optimization Method ◽  
Flight Control System ◽  
Shuffled Frog Leaping Algorithm ◽  
Swarm Optimization ◽  
Content Type ◽  
Shuffled Frog Leaping

PurposeAttitude control of unmanned aerial vehicle (UAV) is the purposeful manipulation of controllable external forces to establish a desired attitude, which is inner‐loop of the autonomous flight control system. In the practical applications, classical control methods such as proportional‐integral‐derivative control are usually selected because of simple and high reliability. However, it is usually difficult to select or optimize the control parameters. The purpose of this paper is to investigate an intelligent algorithm based classical controller of UAV.Design/methodology/approachAmong the many intelligent algorithms, shuffled frog leaping algorithm (SFLA) combines the benefits of the genetic‐based memetic algorithm as well as social behavior based particle swarm optimization. SFLA is a population based meta‐heuristic intelligent optimization method inspired by natural memetics. In order to improve the performance of SFLA, a different dividing method of the memeplexes is presented to make their performance balance; moreover, an evolution mechanism of the best frog is introduced to make the algorithm jump out the local optimum. The modified SFLA is applied to the tuning of the proportional coefficients of pitching and rolling channels of UAV flight control system.FindingsSimulation of a UAV control system in which the nonlinear model is obtained by the wind tunnel experiment show the rapid dynamic response and high control precision by using the modified SFLA optimized attitude controller, which is better than that of the original SFLA and particle swarm optimization method.Originality/valueA modification scheme is presented to improve the global searching capability of SFLA. The modified SFLA based intelligent determination method of the UAV flight controller parameters is proposed, in order to improve the attitude control performance of UAV.

Optimal heat induction treatment of titanium alloys

2020 ◽  
Vol 39 (1) ◽  
pp. 53-65
Author(s):  
Ivan Alexandrovich Smolyanov ◽  
Václav Kotlan ◽  
Ivo Doležel
Keyword(s):  
Heat Treatment ◽  
Control System ◽  
Titanium Alloys ◽  
Temperature Drop ◽  
Industrial Plant ◽  
Induction Treatment ◽  
Temperature Uniformity ◽  
Content Type ◽  
Titanium Alloy Ti6al4v

Purpose This paper aims to propose a number of approaches to reduce the temperature gradient of titanium billets in the heat treatment process. Design/methodology/approach Modeling physical processes in the induction unit is calculated by the finite element method. Required power was calculated based on the fact that all the induced power is allocated in a certain layer and there are loss flows and heating flows. Also, an opportunity is offered to reduce temperature difference using numerical optimization, control system based on proportional-integral regulator and ballast blank. Findings The asymmetry of the magnetic field at the ends of the inductor significantly affects the temperature uniformity along the length of the workpiece. Increasing the length of the workpiece by adding ballast blanks reduces the temperature drop. Also, increasing the non-magnetic gap in some cases it is possible to improve the quality of through heating. Research limitations/implications The results of this study are verified only for a number of titanium alloys. Therefore, this knowledge is appropriate to apply for this type of materials. In future studies, it is possible to expand the possibilities of the considered approaches for other types of materials. Practical implications Part of the study will be used to industrial plant for purpose of heat treatment of titanium alloys workpiece. Especially, control system will be basically made based on the model. Originality/value A novel methodology of induction heating of titanium alloy Ti6Al4V in the form of cylindrical billets is presented that simplifies the process and improves temperature uniformity along the radius and length of the billet by optimizing the shape of the inductor and selecting suitable power modes.

The effects of 3D printing in design thinking and design education

2016 ◽  
Vol 14 (4) ◽  
pp. 752-769 ◽  
Author(s):  
Scott Greenhalgh
Keyword(s):  
3D Printing ◽  
Rapid Prototyping ◽  
Design Process ◽  
Interior Design ◽  
Medium Effect ◽  
Design Technology ◽  
Content Type ◽  
3D Printed ◽  
Design Students

Purpose Rapid prototyping and three-dimensional (3D) printing allows the direct creation of objects from 3D computer-aided design files. To identify the effects 3D printing may have on student experiences and the learning of the design process, students were asked to create a design and create a prototype of that design. Design/methodology/approach This study follows an experimental design involving four total courses of interior design students. After conceptualizing a design, students were randomly selected to either create the prototype by hand or given access to 3D printing equipment. The models were graded by three subject experts using a rubric that focused on three key aspects of the model project, namely, craftsmanship, design quality and scale (proportion). Findings All three measures produced significant mean differences with a medium effect size when comparing the 3D printed models to the traditionally built models. Additional observations provided insights into the design processes approached by students using hand-constructed and 3D printed modeling. The most notable difference was the propensity for curved and rectilinear shapes by available design technologies. Research limitations/implications The experiment showed that the design technology (3D printing) did have an impact on the designs students conceptualized. This suggests that students do connect ideation to implementation, and the availability of enabling technology impacts the design process. This research was conducted in an interior design environment and consists of primarily female students. The experimental research may be limited to design programs with similar student populations and levels of exposure to various design technologies. Practical implications This research is designed to provide instructors and programs valuable information when looking at implementing new design technologies into the curriculum. Instructors are made aware that new design technologies do impact student design strategies. Additionally, although certain design technologies allow for revisions, it was apparent that students continued to be resistant to revise their initial models suggesting instructors prepare to address this issue in instruction. Social implications There is a strong body of research indicating inequality in education where students have differing access to technologies in schools. This research shows that 3D printing, similar to many technologies in education, can impact the cognitive processes of content being learned. Originality/value There is limited research on how design technologies impact design cognition and the experiences of design students. This paper looked specifically at one design technology (3D printing/rapid prototyping) and how it impacts the processes and quality of design, in addition to the quality of design products (prototypes or models). Research such as this provides instructors and faculty members an insight into how design technologies impact their curriculum.

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