Table of Content

10 May 2012, Volume 23 Issue 9

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Determination of Collision-free Tool Orientation for RTCP

ZHANG Yong-Nian, DIAO Dong-Biao, LIU Yong-Hua, LIU Kai

2012, 23(9):  1009-1013. 

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Aiming at reducing the nonlinear errors and preventing angular velocity overrun, a RTCPalgorithm based on angle interpolation was proposed herein. The problems of global interference uring interpolation were analyzed, and then an interpolation error factor formula was derived. Finally, a collision-free region of RTCP algorithm was obtained. The algorithm can reduce thenonlinear errors effectively, ensure the rotation axes movement smoothly, improve the machining efficiency by ensuring that CNC codes need not to be generated by postprocessing software when tool length changes. Simulation results demonstrate the effectiveness of proposed algorithm.

On Monotonic Convergence of Iterative Learning Control for Interval Uncertainty Discrete-time System

LI Hong-Qing, LIU Di, TENG Fu-Lin, HUANG Jia-Cai, ZHANG Jian-Hua

2012, 23(9):  1013-1016. 

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Monotonic convergence of interval iterative learning control for discrete linear time invariant system with interval uncertainty was discussed. For commonly used algorithms of discrete PD iterative learning control, the onotonic convergence condition in the l∞-norm topology was checked specially. Simulation results show that the approach is effective.

#br# Angular Displacement Measurement Method of Optical Platform on Moving Vehicle

LI Yu-Long, HE Zhong-Bei, BAI Hong-Bai, HAO Hui-Rong, DAO Shuai, LIU Shu-Feng

2012, 23(9):  1017-1020,1064. 

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This paper proposed a new real-time measurement method of moving optical platform's 6-DOF liner and ngular displacements by using broadband liner displacement sensors, a theoretical formula of the method was derived. The relationship among the inertial coordinate system, platform coordinate system and sensor ordinate system was established by coordinate transformation,the relation between sensor signals and platform cement was obtained, then the 6-DOF of the platform could be calculated by the displacement signals in real time. And many factors affected on the test accuracy were analyzed. Analyses show that this method can achieve dynamic measurement of many different vibration isolation platforms' 6-DOF displacement under different environments by selecting different frequency bands, different accuracy sensors. This method is simple, convenient, high precision and worth spreading. 

Experimental Research on Dynamic Stiffness of Sliding Guide's Joints

GUO Cheng-Long-1, 2, YUAN Jun-Tang-1, WANG Wei-You-1, JIA Ling-Ling-1, HUANG Dun-1

2012, 23(9):  1021-1025. 

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Based on equivalent single freedom mechanical model,modal experiments with various types of sliding guide of CNC machine tools were completed on the testing system designed by ourselves, then the dynamic stiffness of the sliding joint was obtained, and the law of various factors influence on the stiffness was analyzed. The results show that: increasing of the sliding speed will reduce the dynamic stiffness of the joint; increasing the surface pressure will enhance the dynamic stiffness effectively; adding lubrication oil will increase the joint's stiffness by 20%; the plastic-iron guide can maintain the stability of dynamic characteristic better than the metal slide, ariation of its dynamic stiffness with speed is around 25%.

Calculation Method of Wall Thickness for Hollow Turbine Blades Based on Central Arced Curve

LIU Jin-Gang, BO Hun, YANG Xiao-Ning, CHENG Yun-Yong, DONG Yi-Wei

2012, 23(9):  1025-1028. 

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According to the low-shape accuracy of a hollow turbine blade, a calculation method of wall thickness was presented based on central arced curve. The measurement model of point cloud data was established by processing the CT slice data, and aligning the CAD models. Then, the central arced curve was calculated after extracting and fitting the data points of each section. Meanwhile, the blade thickness was obtained by using the UG secondary development platform. Measurement results show that the wall thickness of hollow turbine blades can be extracted accurately through this method, and the accuracy and reliability of wall thickness are also improved.

Analysis of Forward Kinematics for Bionic and Mobile Robot with AFSA

SONG Meng-Jun, ZHANG Meng-Lu

2012, 23(9):  1029-1036. 

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An improved AFSA for the forward kinematics analysis of a bionic and mobile robot was presented. Parallel mechanism model was constructed when the robot was in a standing state.Degrees of freedom of the parallel mechanism were calculated with screw theory. Forward kinematics model of the bionic and mobile robot was constructed. The improved AFSA was based on the constraint equations of forward kinematics model of the bionic and mobile robot. The mathematical model for the AFSA was constructed and the process of the improved AFSA was presented. Finally, the simulation results show that the optimization performance of the AFSA has a good performance, can meet the requirements to solve forward kinematics of the bionic and mobile robot. 

A High Torque Ultrasonic Motor Structured by Double-stators and Double-rotors

WANG Guang-Qiang-1, DIAO Zhong-Wei-1, GUO Ji-Feng-2

2012, 23(9):  1036-1041. 

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In order to improve the output torque of a single-stator and single-rotor rotary traveling-wave type USM, a method using double-stators and double-rotors to constructure a new type USM with high output torque was proposed. Compared with the traditional USM, the output torque of the new type USM is about two times of the traditional USM only enlarging the length in the axial direction, but the driving power and the stator dimension are not changed. The structural perturbation theory was introduced to modify the modal frequency of the two stators.Experimental results show that the two stators have the same resonant frequency, and the output torque of the new type USM is about 1.1N·m, which demonstrates that the new type USM has good performance and wide application fields.

Simulation on Mixing Process of Pin Extruder Based on Electromagnetic Dynamic Plasticizing Theory

DU Yao-Xue-1, LIU Tian-Lei-1, 2, CHEN Shao-Qing-1

2012, 23(9):  1042-1046. 

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With the CFD software POLYFLOW,this paper built simplified models for a single screw pin unit and a single screw unit based on electromagnetic dynamic plasticizing theory,carried out numerical simulation on them,and finally analysed comparatively the mixing behavior of these two mixing units with and without vibration force field.It is found that the pin unit has longer residence time,smaller segregation scale and higher instantaneous efficiency of stretching than the single screw mixing unit does;by the action of vibration field,the pin mixing element possesses better diffluence and rearrangement,flow state,fluidity andplasticization performance for the polymer melt particles.Meanwhile,experimental study proves the fact that vibration field can reduce the particle size of polymer melt.The results are of great importance for designing new type mixing devices based on electromagnetic dynamic plasticizing theory.

ADR Algorithm Applied in Servo System Driven by DC Torque Motor

LONG Man-Lin-1, 2, FU Yong-Ling-1, LI Guang-Hua-2, CHEN Shuang-Qiao-2

2012, 23(9):  1047-1050. 

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In a servo system driven by DC torque motor,  it is difficult to build models because there are several nonlinear and random factors and it is hard to compensate them, thus the control precision in simulation analysis and practical applications will be reduced. Hence, ADR algorithm was adopted to further improve servo precision for servo system driven by DC torque motor, in which the comprehensive disturbance instead of all factors was observed and compensated simultaneously. Through simulation study by building system model with extreme disturbance condition and comparison of different simulation results, the parameters for ADR algorithm were tuned. Real experiments with well tuned parameters was carried out to verify the validity of the algorithm on flight simulator table inner-axis driven by DC torque motor. The experimental results show that a high dynamic tracking performance is achieved and robustness of ADR algorithm is strong. Thus, to tune parameters of algorithm based on nominal model can be used in practical control systems.  

Study on Two-step Damage Detection Methods of Large and Complex Structures

LI Shi-Long, WANG Tian-Hui, MA Li-Yuan, LI Yong-Jun

2012, 23(9):  1051-1056. 

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A new method for complex structures damage detection was proposed based on model updating and modal flexibility curvature difference techniques herein. The method have two steps. First, the method based on model updating was used for preparatory detection. The detection problem was transformed into an optimization problem in this method.An objective function was defined as an nonlinear least-squares problem with bound-constrains and for detection of the location of structural damage by minimizing the sum of differences between the experimental and analytical modal data. The trust-region approach was then used to solve the minimization problem. The method based on modal flexibility curvature difference was then used for detect the location of structural damage accurately. Finally, the proposed method was applied for damage detection on the frame of a launch platform. The simulation and experimentatal results show that the proposed method is suitable well for damage detection on such complex structures.

Thermo-mechanical Coupling Analysis for a Large Calibre Gun Multiround Continuous Firing Process

WU Feng, ZHENG Jie-Hua, TUN Ku-Chuan, JIE Fang-Qiu

2012, 23(9):  1056-1059. 

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The heat conduction process of a large-caliber artillery firing was simulated by using an one-dimensional two-phase flow interior ballistic model and an one-dimensional tube transient heat transfer model,by which the transient temperature field and thermal stress distribution of the barrel champer of a 155mm gun  were calculated by ABAQUS after twenty shots.The results can provide the important basis to evaluate the fatigue crack propagation and to predict the life of gun barrel.

Research on Smooth NURBS Interpolation Algorithm Based on Feedrate Sensitive Point Identification

LIN Feng-1, ZHANG Zheng-Gong-1, CHEN Qing-2

2012, 23(9):  1060-1064. 

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A Non-uniform rational B-spline (NURBS) interpolation algorithm was proposed herein, which was based on the feedrate sensitive point identification. It was crucial for an advanced CNC system compatible with NURBS. The contour errors during rough interpolating calculation were related to the federate at the current point, so it was possible to indentify the feedrate sensitive points according to the chord error during interpolation approximation. The feedrate profile between any two sensitive points should be designed adaptively according to the distance between them, and the security buffer was used. The whole feedrate profile can be generated by feedrate segments combination. A cubic NURBS curve was used to evaluate the interpolation algorithm, and it was simulated under 3 different feedrate commands. Simulation results show that the algorithm is available and can be implemented flexibly according to the different situations of sensitive points. It is also shown that the proposed algorithm guarantees both the contour precision and feedrate smoothness.

#br# Research on Multi-view BOM Data Management Information System for Automobile Manufacturing Process

ZHANG You-Bing-1, CHEN Yo-Rong-1, YANG E-Hui-1, JIA Feng-Chao-2

2012, 23(9):  1065-1069. 

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According to the state-of-the-arts in informatization of automobile manufacturing enterprises, a BOM data management information system was designed and implemented. The business model was proposed focusing on integrating, managing, controlling, sharing and utilizing the core data based on the product BOM. A multi-view BOM for the automobile manufacturing process was constructed using the business model. After analyzing the product configuration management and construction of the multi-view BOM, the general technical scheme was designed and the system was implemented. The application of the system in the Dongfeng Motor Corporation shows good effects, such as integrating the BOM management platforms distributed in different departments, improving the products development efficiency, satisfying the individuating demands of customers and solving the key problems in the life cycle of products.

Surface Quality Prediction in Precision Cylindrical Grinding of YG3 Cemented Carbide Based on Improved ANFIS

LIU Mao-Fu

2012, 23(9):  1070-1074. 

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For improving the surface integrity and processing quality in the precision cylindrical grinding of cemented carbides, and investigating the prediction technique of the surface quality, a prediction model of the surface roughness in the precision cylindrical grinding of YG3 cemented carbide based on the adaptive network-based fuzzy inference system (ANFIS) was proposed. Then, it was improved by the hybrid Taguchi genetic algorithm (HTGA). At last, the grinding parameters and corresponding surface roughness in the experiments was used as the training and testing samples. Trough the comparative analysis of the prediction results in the BP neural network model, traditional ANFIS model and improved ANFIS model, the effectiveness and prediction accuracy of three models were verified. The results show that the prediction accuracy of the improved ANFIS model was better than that of an other two in the distribution of the relative error Er and the size of mean square error EMSRE, and it is an effective prediction method of the surface quality.

Co-simulation Platform Development for Multi-axle Crane

YANG Yong-1, 2, YI Xiao-Gang-1, 2

2012, 23(9):  1074-1078. 

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This platform was redeveloped on software AMESim,MATLAB/Simulink and ADAMS to set up multi-domain co-simulation analysis platform for suspension system and multi-axle steering system, and we have totally intellectual property rights. The comparisons between the results of analysis and testing validate the platform.

A Hybrid Robust Design Model by DEA for Implicit Function of Quality Characteristics and Its Parameters

LI E-Beng, LIU Sai-Feng, FANG Zhi-Geng, XU Lei, DAO Liang-Pan

2012, 23(9):  1079-1083. 

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This paper introduced a novel model for implicit function of
the quality characteristics and its parameters.The model was established based on the
methods of orthogonal and DEA game cross efficiency.First,we arranged orthogonal
test,considering quality indexes and cost indexes as unknown experimental indexes.
Then,to build the model of hybrid robust design,we had cost indexes and quality indexes
as the inputs and outputs of the model,DEA game cross efficiency,respectively,
by taking each pilot program as a decision making unit.In this way,it can evaluate the
combination of parameters and its tolerances which had the highest efficiency of the quality to the cost.At last,for verification purposes,a case was conducted and analyzed.
The research shows that the engineering applicability of the hybrid robust design model is broader than previous models.

Design and Experiment of a High-performance Coaxial Magnetic Gear

YANG Chao-Jun, LI Zhi-Bao, HU Yu-Gen, LI Zhi-Teng, YANG Qiao-Rong, HU You

2012, 23(9):  1083-1088. 

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In order to improve the torque transmission ability of a magnetic gear, a coaxial magnetic gear of modulating pole-pieces squirrel-cage structure was developed. A finite element model of transient analysis of the magnetic gear was built to obtain the law curve of transmission torque affected by a series of structural parameters, such as air gap, the thickness of permanent magnet and length-diameter ratio, as well as the optimal value of these structural parameters.  The operation of the magnetic gear with these parameters was simulated. An experimental prototyping was designed based on the optimal values and tests. The experimental results show that fixed ratio drive and transmission torque can be achieved using this modulating pole-pieces,and verify that the optimal structural parameters can ensure torque transmission ability of magnetic gear, which indicates high similarity with simulation analyses.

Design of Clamping Components for a Linear Ultrasonic Motor

HU Ning, TAO Zhi-Yuan, DIAO Wen-Chao

2012, 23(9):  1089-1091,1098. 

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A new clamping component was put forward for a linear ultrasonic motor, which had circular flexible hinges on both sides and in the middle. The flexible hinges on both sides acted as the mechanical spring to exert proper pre-pressure; the flexible hinge in the middle was designed to eliminate the subsidiary stress in the stator and to reduce the impact on vibration modal of the stator. The research results show the relationship between the distortion of flexible hinges and the pre-pressure is linear by using finite element method.  Experimental results are found that the displacement of the clamping components is of linear relation with the pre-pressure, which coincides with the calculated results. In conclusion, the two phase modal of the stator assembled by the clamping components coincides well. The stator has no interference modal, and has linear boundary conditions.

Semi-active Control of Automobile Self-adaptive Magnetorheological Suspensions

JIANG Hua-Zheng-1, HU Gong-Sheng-1, 2, SONG Hong-Wei-1, WANG Gui-1

2012, 23(9):  1092-1098. 

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According to the problem of power supply and control for current automobile MR suspensions,a new MR damper was designed to control the vibration of vehicle suspensions,which can isolate vibration intellectually under no-power and no-control device circumstances.A dynamic equation for the new MR damper was derived and a simulation study based on Matlab and PSPICE was conducted to check the ability of harvesting energy.Based on this new MR damper,an automobile self-adaptive MR suspensions semi-active vibration control system was constructed and tested on 1/4 vehicle suspension test rig.The experimental results show that the automobile self-adaptive MR suspensions vibration control system based on the new MR damper is feasible and can improve ride comfort of vehicle effectively.

Research on Foot Force Control for Multi-legged Wall-climbing Robot Based on Optimal Target at Energy Consumption

WEI Wu, CA Zhao-Xiong, DENG Gao-Yan

2012, 23(9):  1099-1104. 

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For the energy consumption problem of a multi-legged wall-climbing robot operating at high altitude, a foot force controlling method for multi-legged wall-climbing robot was proposed based on energy consumption optimization. Taking an eight-legged wall-climbing robot for example, a foot force optimization model of the multi-legged wall-climbing robot was described from the view of security and energy consumption while the robot was in operation, and the conversion between the joint driving force and the plantar contact force of the multi-legged robot was implemented, thus reducing the number of the optimal variables effectively and simplifying the optimization calculation. By analyzing the joint driving force constraints and dynamic constraints, a relationship among the total motor power of the robot and the robotic motive gait and the operational environment (including the climbing angle and the roughness of the adsorbed plane) was established. Considering the specificity of the safety of adsorption for the wall-climbing robot, the plantar contact force of the robot was optimized, and the ability of the robot was improved to adapt to the change of environment and the number of supporting legs. Simultaneously, the energy consumption of the joint driving motor is reduced, and the target to minimize the total consumption of the robotic motor is achieved. The experiments and simulation have proved that the proposed control method is simple and feasible.

Green Innovation Design Method Based on TRIZ and CBR Principles

LIU Zhi-Feng, GAO Xiang, HU Di, ZHANG Jing-Dong

2012, 23(9):  1105-1111,1116. 

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To assist designers to develop green products with better environment-friendly performance, and improve the efficiency of the green product innovation, a product green innovation design method was proposed based on TRIZ and CBR principles. The case representation mechanism of green products was proposed based on ontology, and the ontology database of green products' design cases was constructed, which realized the retrieve, reuse and revise for innovation knowledge of product green design case. To achieve the rapid transformation from green design attributes to TRIZ engineering parameters by building the associated table between TRIZ engineering parameters and green design. Finally, a green innovation design support platform for products was developed based on TRIZ and CBR, and the correctness and feasibility of this method were illustrated in a bottom part design of dishwasher.

Variothermal System Design of Injection Mold for Micro Cell Container

XU Bin-1, GAO Chun-Yu-2, WANG Min-Jie-3, XU Tong-Min-3

2012, 23(9):  1112-1116. 

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Using micro-EDM milling, a three-dimensional mold cavity was machined. The molding process was carried out with polypropylene (PP) by numerical simulation. The results indicate that mold temperature , melt temperature and injection rate play significant role on the filling process. In addition, the simulation shows that the micro cavity can be filled when the mold temperature is up to 120℃.  Therefore ,  variothermal technology with the combination of oil, water and electricity is developed. After testing , variothermal time is about 6 minutes when the cavity temperature is changed from 80℃ to 120℃. After injection experiments,  the results explain that the developed variothermal method is feasible to micro injection molding.  

Investigation on Microstructure and Microhardness of Adiabatic Shear Band of Saw-tooth Chip in Machining TC4 Alloy

WANG Sheng-Beng

2012, 23(9):  1117-1121. 

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Microstructure of ASB of saw-tooth chip produced in different cutting speeds was observed and analyzed by optical microscope and TEM in machining of TC4 alloy. The microhardness of ASB was also measured. Experimental results show that ASB formed at low cutting speed is deformed band, at higher cutting speed, ASB becomes transformed band composed of fine equiaxed grains and martensitic phase that comes from phase transformation β→α″. With the further increase of cutting speed, amorphization that had not been observed before occurence inside ASB. The microhardness of ASB always increases with the increasing of cutting speed whatever the ASB is deformed or transfromed band. According to the law of microstructure evolution and  the increase of microhardness of ASB, the microhardness increase can be divided into three stages: strain-hardening, grain refining and martensitic phase transformation hardening, amorphization hardening.
saw-tooth chip; adiabatic shear band(ASB); titanium alloy; martensitic phase transformation; transmission electron microscope(TEM) analysis

Operation Mode Analysis and Parameter Matching Design of a Novel Hybrid Electric Vehicle

BANG Zhi-Yuan-1, QIN Da-Tong-1, DUAN Zhi-Hui-2, YANG E-Lian-1

2012, 23(9):  1122-1128. 

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In order to reduce production cost and achieve lower fuel and emission, powertrain of a novel hybrid electric vehicle based on planetarygears was proposed. Operation modes and parameters of hybrid power system were analyzed and designed respectively by using a method of dynamic modeling theory combined with numerical model theory of crucial parts such as engine, ISG motor, battery, transmission as well as planetary gears. Performance analysis model of hybrid electric vehicle was built based on system scheme and design parameters, dynamic performance of whole vehicle as well as fuel economy under ECU_EUDC were simulated and analyzed. The simulation results show that the parameters of powertrain are reasonably matched, propulsion performances are excellent, fuel oil consumption is reduced by 36.8% comparing with that of conventional vehicle and it gives theoretical basis to carry out the system schema.

A Novel Method for Tire Footprint Pattern Measurement and Pressure Distribution Data Analysis

LIU Ning, LEI Rong-Qing

2012, 23(9):  1128-1133. 

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The paper presented a technology for inspecting tread wear of tire outer surfaces. Piezoresistive matrix imaging approach was used to measure the transformations of tire footprint patterns under different and specific loads in the aim of finally estimating tire quality and life. On the basis of measurement principle introduction, the paper focused on the illumination of footprint image pattern processing technology and evaluation method. In order to solve the problem of image border determination of contacted footprint pattern between tire tread and ground in addition to the contact area calculation, a circle template rolling method was proposed to extract envelope curve of image pattern. The results show both the convex and the concave patterns can be processed effectively. The outer envelope boundary with indentations is acquired automatically. This method is also proved to be of robustness and high accuracy.