Search results for: five-axis computer numerical control (CNC) machine tools

Authors: Reimund Neugebauer, Welf-Guntram Drossel, Andre Bucht, Christoph Ohsenbrügge

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In this paper the authors propose and verify an approach to control heat flow in machine tool components. Thermal deformations are a main aspect that affects the accuracy of machining. Due to goals of energy efficiency, thermal basic loads should be reduced. This leads to inhomogeneous and time variant temperature profiles. To counteract these negative consequences, material with high melting enthalpy is used as a method for thermal stabilization. The increased thermal capacity slows down the transient thermal behavior. To account for the delayed thermal equilibrium, a control mechanism for thermal flow is introduced. By varying a gap in a heat flow path the thermal resistance of an assembly can be controlled. This mechanism is evaluated in two experimental setups. First to validate the ability to control the thermal resistance and second to prove the possibility of a self-sufficient option based on the selfsensing abilities of thermal shape memory alloys.

Keywords: energy-efficiency, heat transfer path, MT thermal stability, thermal shape memory alloy

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Authors: Guangyu Liu

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In the last decade, energy based control theory has undergone a significant breakthrough in dealing with underactated mechanical systems with two successful and similar tools, controlled Lagrangians and controlled Hamiltanians (IDA-PBC). However, because of the complexity of these tools, successful case studies are lacking, in particular, MIMO cases. The seminal theoretical paper of controlled Lagrangians proposed by Bloch and his colleagues presented a benchmark example–a 4 d.o.f underactuated pendulum on a cart but a detailed and completed design is neglected. To compensate this ignorance, the note revisit their design idea by addressing explicit control functions for a similar device motivated by a vector thrust body hovering in the air. To the best of our knowledge, this system is the first MIMO, underactuated example that is stabilized by using energy based tools at the courtesy of the original design idea. Some observations are given based on computer simulation.

Keywords: Controlled Lagrangian, Energy Shaping, Spherical Inverted Pendulum, Controlled Hamiltonian.

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Authors: Ferenc Kovács, Gábor Hosszú

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The paper presents an advanced control system for tennis ball throwing machines to improve their accuracy according to the ball impact points. A further advantage of the system is the much easier calibration process involving the intelligent solution of the automatic adjustment of the stroking parameters according to the ball elasticity, the self-calibration, the use of the safety margin at very flat strokes and the possibility to placing the machine to any position of the half court. The system applies mathematical methods to determine the exact ball trajectories and special approximating processes to access all points on the aimed half court.

Keywords: Control system, robot programming, robot control, sports equipment, throwing machine.

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Authors: Njiri J. G., Ikua B. W., Nyakoe G. N.

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Optimization of cutting parameters important in precision machining in regards to efficiency and surface integrity of the machined part. Usually productivity and precision in machining is limited by the forces emanating from the cutting process. Due to the inherent varying nature of the workpiece in terms of geometry and material composition, the peak cutting forces vary from point to point during machining process. In order to increase productivity without compromising on machining accuracy, it is important to control these cutting forces. In this paper a fuzzy logic control algorithm is developed that can be applied in the control of peak cutting forces in milling of spherical surfaces using ball end mills. The controller can adaptively vary the feedrate to maintain allowable cutting force on the tool. This control algorithm is implemented in a computer numerical control (CNC) machine. It has been demonstrated that the controller can provide stable machining and improve the performance of the CNC milling process by varying feedrate.

Keywords: Ball-end mill, feedrate, fuzzy logic controller, machining optimization, spherical surface.

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Authors: Shyam S.N. Perera

Abstract:

An optimal control problem for a mathematical model of efficiency of antiviral therapy in hepatitis B virus infections is considered. The aim of the study is to control the new viral production, block the new infection cells and maintain the number of uninfected cells in the given range. The optimal controls represent the efficiency of antiviral therapy in inhibiting viral production and preventing new infections. Defining the cost functional, the optimal control problem is converted into the constrained optimization problem and the first order optimality system is derived. For the numerical simulation, we propose the steepest descent algorithm based on the adjoint variable method. A computer program in MATLAB is developed for the numerical simulations.

Keywords: Virus infection model, Optimal control, Adjoint system, Steepest descent

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Authors: Hossein Shahinzadeh, Ladan Darougaran, Ebrahim Jalili Sani, Hamed Yavari, Mahdi Mozaffari Legha

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This paper present a new method for design of power system stabilizer (PSS) based on sliding mode control (SMC) technique. The control objective is to enhance stability and improve the dynamic response of the multi-machine power system. In order to test effectiveness of the proposed scheme, simulation will be carried out to analyze the small signal stability characteristics of the system about the steady state operating condition following the change in reference mechanical torque and also parameters uncertainties. For comparison, simulation of a conventional control PSS (lead-lag compensation type) will be carried out. The main approach is focusing on the control performance which later proven to have the degree of shorter reaching time and lower spike.

Keywords: Power system stabilizer (PSS), multi-machine power system, sliding mode control

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Authors: Jagdeep Singh, Prem Singh

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Milk is considered as an essential and complete food. The present study was conducted at Milk Plant Mohali especially in reference to the procurement section where the cash inflow was maximum, with the objective to achieve higher productivity and reduce wastage of milk. In milk plant it was observed that during the month of Jan-2014 to March-2014 the average procurement of milk was Rs. 4, 19, 361 liter per month and cost of procurement of milk is Rs 35/- per liter. The total cost of procurement thereby equal to Rs. 1crore 46 lakh per month, but there was mismatch in procurementproduction of milk, which leads to an average loss of Rs. 12, 94, 405 per month. To solve the procurement-production problem Quality Control Tools like brainstorming, Flow Chart, Cause effect diagram and Pareto analysis are applied wherever applicable. With the successful implementation of Quality Control tools an average saving of Rs. 4, 59, 445 per month is done.

Keywords: Milk, Procurement-demand, quality control tools.

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Authors: M. Rychlik, R. Roszak, M. Morzynski, M. Nowak, H. Hausa, K. Kotecki

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Article presents the geometry and structure reconstruction procedure of the aircraft model for flatter research (based on the I22-IRYDA aircraft). For reconstruction the Reverse Engineering techniques and advanced surface modeling CAD tools are used. Authors discuss all stages of data acquisition process, computation and analysis of measured data. For acquisition the three dimensional structured light scanner was used. In the further sections, details of reconstruction process are present. Geometry reconstruction procedure transform measured input data (points cloud) into the three dimensional parametric computer model (NURBS solid model) which is compatible with CAD systems. Parallel to the geometry of the aircraft, the internal structure (structural model) are extracted and modeled. In last chapter the evaluation of obtained models are discussed.

Keywords: computer modeling, numerical simulation, Reverse Engineering, structural model

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Authors: Peter Kostal, Karol Velisek

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Flexible manufacturing system is a system that is able to respond to changed conditions. In general, this flexibility is divided into two key categories and several subcategories. The first category is the so called machine flexibility which enables to make various products by the given machinery. The second category is routing flexibility enabling to execute the same operation by various machines. Flexible manufacturing systems usually consist of three main parts: CNC machine tools, transport system and control system. A higher level of flexible manufacturing systems is represented by the so called intelligent manufacturing systems.

Keywords: drawing-free manufacturing, flexible manufacturing system, industrial robot, material flow.

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Authors: Maryam Honarmand

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Regarding to the fast growth of computer, internet, and virtual learning in our country (Iran) and need computer-based learning systems and multimedia tools as an essential part of such education, designing and implementing such systems would help teach different field such as science. This paper describes the basic principle of multimedia. At the end, with a description of learning science to the infant students, the method of this system will be explained.

Keywords: Multimedia tools, computer based learning, science, student.

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Authors: K. K. Starkov, A. Y. Pogromsky, I. J. B. F. Adan, J. E. Rooda

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In this paper we present our results on the performance analysis of a multi-product manufacturing line. We study the influence of external perturbations, intermediate buffer content and the number of manufacturing stages on the production tracking error of each machine in the multi-product line operated under a surplusbased production control policy. Starting by the analysis of a single machine with multiple production stages (one for each product type), we provide bounds on the production error of each stage. Then, we extend our analysis to a line of multi-stage machines, where similarly, bounds on each production tracking error for each product type, as well as buffer content are obtained. Details on performance of the closed-loop flow line model are illustrated in numerical simulations.

Keywords: Flexible manufacturing systems, tracking systems, discrete time systems, production control, boundary conditions.

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Authors: K. Petcharat, Y. Areepong, S. Sukparungsri, G. Mititelu

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These paper, we approximate the average run length (ARL) for CUSUM chart when observation are an exponential first order moving average sequence (EMA1). We used Gauss-Legendre numerical scheme for integral equations (IE) method for approximate ARL0 and ARL1, where ARL in control and out of control, respectively. We compared the results from IE method and exact solution such that the two methods perform good agreement.

Keywords: Cumulative Sum Chart, Moving Average Observation, Average Run Length, Numerical Approximations.

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Authors: Mohammad Jafarifar

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Multiphase Induction Machine (IM) is normally controlled using rotor field oriented vector control. Under phase(s) loss, the machine currents can be optimally controlled to satisfy certain optimization criteria. In this paper we discuss the performance of double manifold sliding mode observer (DM-SMO) in Sensorless control of multiphase induction machine under unsymmetrical condition (one phase loss). This observer is developed using the IM model in the stationary reference frame. DM-SMO is constructed by adding extra feedback term to conventional single mode sliding mode observer (SM-SMO) which proposed in many literature. This leads to a fully convergent observer that also yields an accurate estimate of the speed and stator currents. It will be shown by the simulation results that the estimated speed and currents by the method are very well and error between real and estimated quantities is negligible. Also parameter sensitivity analysis shows that this method is rather robust against parameter variation.

Keywords: Multiphase induction machine, field oriented control, sliding mode, unsymmetrical condition, manifold.

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Authors: Abdelwahed Echchatbi, Adil Rizki, Ali Haddi, Nabil Mrani, Noureddine Elalami

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In this note, the robust static output feedback stabilisation of an induction machine is addressed. The machine is described by a non homogenous bilinear model with structural uncertainties, and the feedback gain is computed via an iterative LMI (ILMI) algorithm.

Keywords: Induction machine, Static output feedback, robust stabilisation.

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Authors: I. Abuiziah, A. Oulhaj, K. Sebari, D. Ouazar

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The primary objectives of transient analysis are to determine the values of transient pressures that can result from flow control operations and to establish the design criteria for system equipment and devices (such as control devices and pipe wall thickness) so as to provide an acceptable level of protection against system failure due to pipe collapse or bursting. Because of the complexity of the equations needed to describe transients, numerical computer models are used to analyze transient flow hydraulics. An effective numerical model allows the hydraulic engineer to analyze potential transient events and to identify and evaluate alternative solutions for controlling hydraulic transients, thereby protecting the integrity of the hydraulic system. This paper presents the influence of using the protection devices to control the adverse effects due to excessive and low pressure occurs in the transient.

Keywords: Flow Transient, Water hammer, Pipeline System, Surge Tank, Simulation Model, Protection Devices.

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Authors: Joseph C. Chen

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Machine vision system provides automatic inspection to reduce manufacturing costs considerably. However, only a few principles have been found to optimize machine vision system and help it function more accurately in industrial practice. Mostly, there were complicated and impractical design techniques to improve the accuracy of machine vision system. This paper discusses implementing the Six Sigma Define, Measure, Analyze, Improve, and Control (DMAIC) approach to optimize the setup parameters of machine vision system when it is used as a direct measurement technique. This research follows a case study showing how Six Sigma DMAIC methodology has been put into use.

Keywords: DMAIC, machine vision system, process capability, Taguchi parameter design.

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Authors: Jasna Dragosavac, Žarko Janda, J.V. Milanović, Dušan Arnautović

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This paper discusses coordinated reactive power - voltage (Q-V) control in a multi machine steam power plant. The drawbacks of manual Q-V control are briefly listed, and the design requirements for coordinated Q-V controller are specified. Theoretical background and mathematical model of the new controller are presented next followed by validation of developed Matlab/Simulink model through comparison with recorded responses in real steam power plant and description of practical realisation of the controller. Finally, the performance of commissioned controller is illustrated on several examples of coordinated Q-V control in real steam power plant and compared with manual control.

Keywords: Coordinated Voltage Control, Power Plant Control, Reactive Power Control, Sensitivity Matrix

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Authors: W. R. Li, J. K. Xia, R. Q. Peng, Z. Y. Guo, L. Jiang

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According to 3D magnetic circuit of the transverse flux PM linear machine, distribution law is presented, and analytical expression of axial end flux leakage is derived using numerical method. Maxwell stress tensor is used to solve detent force of mover. A 3D finite element model of the transverse flux PM machine is built to analyze the flux distribution and detent force. Experimental results of the prototype verified the validity of axial end flux leakage and detent force theoretical derivation, the research on axial end flux leakage and detent force provides a valuable reference to other types of linear machine.

Keywords: Transverse flux PM linear machine, flux distribution, axial end flux leakage, detent force.

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Authors: T. Benmiloud, A. Omari

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This paper presents a new technique of compensation of the effect of variation parameters in the direct field oriented control of induction motor. The proposed method uses an adaptive tuning of the value of synchronous speed to obtain the robustness for the field oriented control. We show that this adaptive tuning allows having robustness for direct field oriented control to changes in rotor resistance, load torque and rotational speed. The effectiveness of the proposed control scheme is verified by numerical simulations. The numerical validation results of the proposed scheme have presented good performances compared to the usual direct-field oriented control.

Keywords: Induction motor, direct field-oriented control, compensation of variation parameters, fuzzy logic controller.

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Authors: R. Kamali, A. R. Binesh, S. Hossainpour

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To understand working features of a micro combustor, a computer code has been developed to study combustion of hydrogen–air mixture in a series of chambers with same shape aspect ratio but various dimensions from millimeter to micrometer level. The prepared algorithm and the computer code are capable of modeling mixture effects in different fluid flows including chemical reactions, viscous and mass diffusion effects. The effect of various heat transfer conditions at chamber wall, e.g. adiabatic wall, with heat loss and heat conduction within the wall, on the combustion is analyzed. These thermal conditions have strong effects on the combustion especially when the chamber dimension goes smaller and the ratio of surface area to volume becomes larger. Both factors, such as larger heat loss through the chamber wall and smaller chamber dimension size, may lead to the thermal quenching of micro-scale combustion. Through such systematic numerical analysis, a proper operation space for the micro-combustor is suggested, which may be used as the guideline for microcombustor design. In addition, the results reported in this paper illustrate that the numerical simulation can be one of the most powerful and beneficial tools for the micro-combustor design, optimization and performance analysis.

Keywords: Numerical simulation, Micro-combustion, MEMS, CFD, Chemical reaction.

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Authors: M. M. Pawade, S. S. Banwait

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Electrical Discharge Machine (EDM) is especially used for the manufacturing of 3-D complex geometry and hard material parts that are extremely difficult-to-machine by conventional machining processes. In this paper authors review the research work carried out in the development of die-sinking EDM within the past decades for the improvement of machining characteristics such as Material Removal Rate, Surface Roughness and Tool Wear Ratio. In this review various techniques reported by EDM researchers for improving the machining characteristics have been categorized as process parameters optimization, multi spark technique, powder mixed EDM, servo control system and pulse discriminating. At the end, flexible machine controller is suggested for Die Sinking EDM to enhance the machining characteristics and to achieve high-level automation. Thus, die sinking EDM can be integrated with Computer Integrated Manufacturing environment as a need of agile manufacturing systems.

Keywords: Electrical Discharge Machine, Flexible Machine Controller, Material Removal Rate, Tool Wear Ratio.

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Authors: İres İskender, Ahmet Karaarslan

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In this study, the performance of a high-frequency arc welding machine including a two-switch inverter is analyzed. The control of the system is achieved using two different control techniques i- fuzzy logic control (FLC) ii- state space averaging based sliding control. Fuzzy logic control does not need accurate mathematical model of a plant and can be used in nonlinear applications. The second method needs the mathematical model of the system. In this method the state space equations of the system are derived for two different “on" and “off" states of the switches. The derived state equations are combined with the sliding control rule considering the duty-cycle of the converter. The performance of the system is analyzed by simulating the system using SIMULINK tool box of MATLAB. The simulation results show that fuzzy logic controller is more robust and less sensitive to parameter variations.

Keywords: Fuzzy logic, arc welding, sliding state space control, PWM, current control.

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Authors: Kejun Zhuang, Hailong Zhu

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In this paper, stability and Hopf bifurcation analysis of a novel hyperchaotic system are investigated. Four feedback control strategies, the linear feedback control method, enhancing feedback control method, speed feedback control method and delayed feedback control method, are used to control the hyperchaotic attractor to unstable equilibrium. Moreover numerical simulations are given to verify the theoretical results.

Keywords: Feedback control, Hopf bifurcation, hyperchaotic system, stability.

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Authors: Aikaterini Fountoulaki, Nikos Karacapilidis, Manolis Manatakis

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This paper proposes an innovative methodology for Acceptance Sampling by Variables, which is a particular category of Statistical Quality Control dealing with the assurance of products quality. Our contribution lies in the exploitation of machine learning techniques to address the complexity and remedy the drawbacks of existing approaches. More specifically, the proposed methodology exploits Artificial Neural Networks (ANNs) to aid decision making about the acceptance or rejection of an inspected sample. For any type of inspection, ANNs are trained by data from corresponding tables of a standard-s sampling plan schemes. Once trained, ANNs can give closed-form solutions for any acceptance quality level and sample size, thus leading to an automation of the reading of the sampling plan tables, without any need of compromise with the values of the specific standard chosen each time. The proposed methodology provides enough flexibility to quality control engineers during the inspection of their samples, allowing the consideration of specific needs, while it also reduces the time and the cost required for these inspections. Its applicability and advantages are demonstrated through two numerical examples.

Keywords: Acceptance Sampling, Neural Networks, Statistical Quality Control.

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Authors: J. Fernandez de Canete, S. Gonzalez-Perez, P. del Saz-Orozco

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Neural networks offer an alternative approach both for identification and control of nonlinear processes in process engineering. The lack of software tools for the design of controllers based on neural network models is particularly pronounced in this field. SIMULINK is properly a widely used graphical code development environment which allows system-level developers to perform rapid prototyping and testing. Such graphical based programming environment involves block-based code development and offers a more intuitive approach to modeling and control task in a great variety of engineering disciplines. In this paper a SIMULINK based Neural Tool has been developed for analysis and design of multivariable neural based control systems. This tool has been applied to the control of a high purity distillation column including non linear hydrodynamic effects. The proposed control scheme offers an optimal response for both theoretical and practical challenges posed in process control task, in particular when both, the quality improvement of distillation products and the operation efficiency in economical terms are considered.

Keywords: Distillation, neural networks, software tools, identification, control.

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Authors: J. Fernandez de Canete, P. Del Saz Orozco, S. Gonzalez-Perez

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LabVIEW and SIMULINK are two most widely used graphical programming environments for designing digital signal processing and control systems. Unlike conventional text-based programming languages such as C, Cµ and MATLAB, graphical programming involves block-based code developments, allowing a more efficient mechanism to build and analyze control systems. In this paper a LabVIEW environment has been employed as a graphical user interface for monitoring the operation of a controlled distillation column, by visualizing both the closed loop performance and the user selected control conditions, while the column dynamics has been modeled under the SIMULINK environment. This tool has been applied to the PID based decoupled control of a binary distillation column. By means of such integrated environments the control designer is able to monitor and control the plant behavior and optimize the response when both, the quality improvement of distillation products and the operation efficiency tasks, are considered.

Keywords: Distillation control, software tools, SIMULINKLabVIEWinterface.

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Authors: Salah Alrabeei, Mohammad Yousuf

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The goal of option pricing theory is to help the investors to manage their money, enhance returns and control their financial future by theoretically valuing their options. Modeling option pricing by Black-School models with jumps guarantees to consider the market movement. However, only numerical methods can solve this model. Furthermore, not all the numerical methods are efficient to solve these models because they have nonsmoothing payoffs or discontinuous derivatives at the exercise price. In this paper, the exponential time differencing (ETD) method is applied for solving partial integrodifferential equations arising in pricing European options under Merton’s and Kou’s jump-diffusion models. Fast Fourier Transform (FFT) algorithm is used as a matrix-vector multiplication solver, which reduces the complexity from O(M2) into O(M logM). A partial fraction form of Pad`e schemes is used to overcome the complexity of inverting polynomial of matrices. These two tools guarantee to get efficient and accurate numerical solutions. We construct a parallel and easy to implement a version of the numerical scheme. Numerical experiments are given to show how fast and accurate is our scheme.

Keywords: Integral differential equations, L-stable methods, pricing European options, Jump–diffusion model.

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Authors: B. Engel, Sara Salman Hassan Al-Maeeni

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Human consumption of the Earth's resources increases the need for a sustainable development as an important ecological, social, and economic theme. Re-engineering of machine tools, in terms of design and failure analysis, is defined as steps performed on an obsolete machine to return it to a new machine with the warranty that matches the customer requirement. To understand the future fatigue behavior of the used machine components, it is important to investigate the possible causes of machine parts failure through design, surface, and material inspections. In this study, the failure modes of the shaft of the rotary draw bending machine are inspected. Furthermore, stress and deflection analysis of the shaft subjected to combined torsion and bending loads are carried out by an analytical method and compared with a finite element analysis method. The theoretical fatigue strength, correction factors, and fatigue life sustained by the shaft before damaged are estimated by creating a stress-cycle (S-N) diagram. In conclusion, it is seen that the shaft can work in the second life, but it needs some surface treatments to increase the reliability and fatigue life.

Keywords: Failure analysis, fatigue life, FEM analysis, shaft, stress analysis.

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Authors: Abdelaziz Khernane, Naceur Khelil, Leila Djerou

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The aim of this work is to study the numerical implementation of the Hilbert Uniqueness Method for the exact boundary controllability of Euler-Bernoulli beam equation. This study may be difficult. This will depend on the problem under consideration (geometry, control and dimension) and the numerical method used. Knowledge of the asymptotic behaviour of the control governing the system at time T may be useful for its calculation. This idea will be developed in this study. We have characterized as a first step, the solution by a minimization principle and proposed secondly a method for its resolution to approximate the control steering the considered system to rest at time T.

Keywords: Boundary control, exact controllability, finite difference methods, functional optimization.

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Authors: Gaurav D. Sonawane, Vikas G. Sargade

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The present investigation is a study of the effect of advanced Physical Vapor Deposition (PVD) coatings on cutting temperature residual stresses and surface roughness during Duplex Stainless Steel (DSS) 2205 turning. Austenite stabilizers like nickel, manganese, and molybdenum reduced the cost of DSS. Surface Integrity (SI) plays an important role in determining corrosion resistance and fatigue life. Resistance to various types of corrosion makes DSS suitable for applications with critical environments like Heat exchangers, Desalination plants, Seawater pipes and Marine components. However, lower thermal conductivity, poor chip control and non-uniform tool wear make DSS very difficult to machine. Cemented carbide tools (M grade) were used to turn DSS in a dry environment. AlTiN and AlTiCrN coatings were deposited using advanced PVD High Pulse Impulse Magnetron Sputtering (HiPIMS) technique. Experiments were conducted with cutting speed of 100 m/min, 140 m/min and 180 m/min. A constant feed and depth of cut of 0.18 mm/rev and 0.8 mm were used, respectively. AlTiCrN coated tools followed by AlTiN coated tools outperformed uncoated tools due to properties like lower thermal conductivity, higher adhesion strength and hardness. Residual stresses were found to be compressive for all the tools used for dry turning, increasing the fatigue life of the machined component. Higher cutting temperatures were observed for coated tools due to its lower thermal conductivity, which results in very less tool wear than uncoated tools. Surface roughness with uncoated tools was found to be three times higher than coated tools due to lower coefficient of friction of coating used.

Keywords: Cutting temperatures, DSS2205, dry turning, HiPIMS, surface integrity.

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