Image-Based Versus Signal-Based Sensors for Machine Fault Detection and Isolation

This paper presents the results of a comparative study that investigated the use of image-based and signal-based sensors for fault detection and fault isolation of visually-cued faults on an automated assembly machine. The machine assembles 8 mm circular parts, from a bulk-supply, onto continuously moving carriers at a rate of over 100 assemblies per minute. Common faults on the machine include part jams and ejected parts that occur at different locations on the machine. Two sensor systems are installed on the machine for detecting and isolating these faults: an image-based system consisting of a single camera and a signal-based sensor system consisting of multiple greyscale sensors and limit switches. The requirements and performance of both systems are compared for detecting six faults on the assembly machine. It is found that both methods are able to effectively detect the faults but they differ greatly in terms of cost, ease of implementation, detection time and fault isolation capability. The conventional signal-based sensors are low in cost, simple to implement and require little computing power, but the installation is intrusive to the machine and readings from multiple sensors are required for faster fault detection and isolation. The more sophisticated image-based system requires an expensive, high-resolution, high-speed camera and significantly more processing power to detect the same faults; however, the system is not intrusive to the machine, fault isolation becomes a simpler problem with video data, and the single camera is able to detect multiple faults in its field of view.

Drive System Sizing of a 6-DOF Parallel Robotic Platform

In this work, it is considered a 6-DoF robotic device intended to be applied for hardware-in-the-loop (HIL) motion simulation with wind tunnel models. The requirements have led to a 6-PUS parallel robot whose linkages consist of six closed-loop kinematic chains, connecting the fixed base to the mobile platform with the same sequence of joints: actuated Prism (P), Universal (U), and Spherical (S). As is common for parallel kinematic manipulators (PKMs), the actual performances of the robot depend greatly on its dimensions. Therefore, a kinematic synthesis has been performed and several Pareto-optimal solutions have been obtained through a multi-objective optimization of the machine geometric parameters, using a genetic algorithm. In this paper, the inverse dynamic analysis of the robot is presented. Then, the results are used for the mechanical sizing of the drive system, comparing belt- to screw-driven units and selecting the motor-reducer groups. Finally, the best compromise Pareto-optimal solution is definitely chosen.

Preliminary Study on Automated Concrete Bridge Inspection

This work focuses on the development of a methodology for the complete reconstruction of the 3D geometry of a concrete bridge. 3D scanning technology was selected as the most apt to the task as it provides very detailed geometrical informations. A dedicated carriage system for a compact and lightweight laser scanner has been designed and built as a first prototype to be used on laboratory as well as future on-field tests. A first assessment of the design constraints has been carried out, based on the general goal of implementing a system able to be used with existing inspection vehicles with minimal modifications. The specific electronic system for management and control of the carriage system and the management of the associated tracking system has been also designed and realized. Some preliminary tests have been performed at Politecnico di Milano University campus to assess the viability and analyze the performance of the early design choices.

Automobile Driving Control for a Dual Power Electric Vehicle With a Hydrogen Fuel Cell

In this study, we adopt a dual power system for extension (DPES) operation by combining the existing power system of an electric vehicle with a hydrogen fuel cell. This was to enhance the durability of the electric vehicle and reduce the inconvenience of battery charging. The lithium battery acts as the primary power source and has real-time monitoring of its state of charge (SOC), while the hydrogen fuel cells act as the auxiliary power supply. The auxiliary power can be used either directly or for charging the lithium battery while the vehicle is in its idle state. The dual power system is coupled with a dual-mode motor controller and energy management system. This study aims to apply the dual power system on the electric vehicle using hydrogen fuel cells. We designed a simulation platform for real driving conditions using Labview to send and receive control commands. In this study, we simulated the road cycles of the Economic Commission for Europe (ECE-40), Japanese legislative cycle (JP10) and the World-wide Motorcycle Emissions Test Cycle (WMTC), using Proportional-integral Control (PI) for automatic tracking and employing engineering error analysis to determine the most suitable PI parameter values for the simulated system. The results showed that using a fixed 100 W fuel cell could enhance the operation time up to 21 %, 21 %, and 14 % for the road cycles of the ECE-40, JP10, and WMTC, respectively. Due to the required features of an actual vehicle, we also designed an energy limiting system to manage the driver-controlled electronic throttle by controlling the instantaneous and maximum power output of the motor in order to achieve savings in energy consumption, increase its operation time, protect the system, and enhance its durability.

Static Balancing of a Parallel Kinematics Machine With Linear-Delta Architecture

The study deals with the compensation of gravity loads in closed-loop mechanisms as a possible strategy for enhancing their working performance. This work focuses on the Orthoglide 5-axis, a prototypal parallel robot for milling operation, characterized by linear-delta architecture with two further serial DOFs. Starting from a general theory formerly proposed by the authors, gravity compensation of the mechanism is analytically carried out. The statically balanced Orthoglide 5-axis can be obtained by installing on one leg a proper set of extension springs and a simple additional linkage. A feasible design solution for developing the device in practice is presented. The proposed balancing device can be implemented with minor modifications of the original robot design, thus appearing a profitable solution to be possibly extended to other machinery with similar architecture.

CFD Aided Design of Heat Transfer Plates for Gasketed Plate Heat Exchangers

In this study, three-dimensional computational fluid dynamics (CFD) analyses are performed to assess the thermal-hydraulic characteristics of a commercial Gasketed Plate Heat Exchangers (GPHEx) with 30 degrees of chevron angle (Plate1). The results of CFD analyses are compared with a computer program (ETU HEX) previously developed based on experimental results. Heat transfer plate is scanned using photogrammetric scan method to model GPHEx. CFD model is created as two separate flow zones, one for each of hot and cold domains with a virtual plate. Mass flow inlet and pressure outlet boundary conditions are applied. The working fluid is water. Temperature and pressure distributions are obtained for a Reynolds number range of 700–3400 and total temperature difference and pressure drop values are compared with ETU HEX. A new plate (Plate2) with corrugation pattern using smaller amplitude is designed and analyzed. The thermal properties are in good agreement with experimental data for the commercial plate. For the new plate, the decrease of the amplitude leads to a smaller enlargement factor which causes a low heat transfer rate while the pressure drop remains almost constant.

Applying Novel Future-Internet-Based Supply Chain Control Towers to the Transport and Logistics Domain

Competing supply chain networks all around the globe are under scrutiny due to ever-growing demand for service improvement and cost reduction. A major field of action in this respect is the realization of real-time monitoring means for supply chain processes including a constant comparison of the respective progress status with the planning guidelines and the best possible management of deviations and exceptions. Control towers have been named as the future tool of supply chain monitoring for quite a while. They are defined as decision-support systems merging different data streams from various subordinate levels and displaying the consolidated information at a higher level for the purpose of monitoring and control of processes while pursuing the goal of optimal process operation. Contrary to the technological constraints of the past which prevented a continuous and fully transparent real-time monitoring of supply chain processes, innovative evolving so-called Future Internet technologies enable genuine transparency and the handling of exceptions in a timely and cost-efficient manner nowadays. With the help of such technologies, newly designed and built control towers are supposed to assist actors on the planning and execution levels of their respective supply chain networks in their decision-making in case of relevant deviations or exceptions. This again raises the market acceptance of such control towers. This paper presents a novel approach to the functional principle of Future-Internet-based control tower solutions and describes the different components therein. Especially, the incorporation of manifold information sources from the Future Internet technologies for the purpose of real-time monitoring and control of supply chain processes is highlighted in the paper.

Microstructure and Hardness of Friction Stir Weld Bead on Steel Plate Using W-25%Re Pin Tool

One of the challenges that impede the use of the relatively new friction stir welding (FSW) process in joining steels and high temperature alloys, as well as dissimilar materials, is the development of the right pin tool material that can stand the severe welding conditions of these alloys. Recent developments in FSW tool materials include tungsten rhenium (W-Re) alloys. The ductile to brittle transition temperature of pure tungsten is reduced by the addition of rhenium (Re).. The addition of Re also improve fracture toughness of the alloy. The major focus of this paper is studying the process of making a friction stir welding bead on mild steel using a proprietary W-25%Re alloy pin tool and investigating the effects of process parameters (i.e. tool rotational and welding speeds) on microstructure, microhardness as well as tool reaction loads. Grain refining of the steel microstructure was observed in all beads. Certain process conditions produced a bead with needle like microstructure with the highest values of hardness. Reaction forces were found to increase with the increase in the tool welding speed and to decrease with the increase of the tool rotational speed. Although the spectroscopic analysis of the beads confirmed the diffusion wear of the tool, the overall tool has shown excellent resistance to mechanical wear.

Friction of Rough Soft Matter Contacts: Local Investigations Through Image Correlation Technique

The friction induced in contacts is a key feature concerning functionality of mechanisms, reliability of systems, energy consumption… Friction on soft matter occurs in many applications (tire/road contacts, touch-sensitive exploration, micro-manipulation of biological items…) as well as in nature. The latter offers various examples of how a topographic surface pattern may control friction. The result is a complex combination of phenomena: adhesion, elastic ratio of bodies in contact, viscous flow, plasticity occurrence, and topography interaction. The role of this latter phenomenon essentially lies in the splitting of the contact area between the two contacting materials and plays an important role on friction response when coupled with adhesion.