Industrial Prototype Research Articles

The behaviour of micro-injection moulding inserts produced with material jetting technology

The increasing interest in additive manufacturing and advancements in precision and production quality have sparked attention to its use in industrial prototyping. High-performance polymer resins enhance flexibility in mass production processes like micro-injection moulding. This flexibility allows for reconfigurable moulds using resin inserts, enabling the transition of devices, such as microfluidics, from labs to large-scale production. Despite progress, limitations exist in additive manufacturing, including the minimum size of microstructures and the brittle behaviour of resin inserts during moulding cycles, impacting overall production capacity. This study focuses on using a micro-injection moulding machine to reproduce PMMA thin plates with single straight microchannels (250 μm) and with different side wall angles (0°, 15°, and 30°), investigating the best compromise between capability and insert resistance to moulding cycles. A careful study of the dynamics leading to the insert failure and the resin limits was carried out. The results showed that it is possible to produce about 15 micro-structured thin plates with good accuracy using a resin insert realised with Material Jetting technology.

Main Stages and Results of the Development of Mobile Space Environment Simulation Facility “Metamorphosis”

Abstract This article presents the main stages and results of the project “Mobile Space Environment Testing Equipment Development of “Metamorphosis” Prototype for Transportation Intermodal Traffic”. For successful implementation of the project, the project has been divided into four stages: 1) Design calculations and design documentation for the design elements of the prototype; 2) Prototype software development; 3) Manufacturing of construction details and prototype assembly; 4) Industrial research and prototype testing. The goal of the project is, based on industrial research, to develop a prototype of the Mobile Space Environment Test Facility (MSTF) “Metamorphosis” transported in an intermodal environment, and to achieve the level of scientific and technical readiness of MSTF from TRL2 to TRL4 (by the scale of the European Space Agency (ESA)) for further development of the project. This project is unique and has no comparable analogues, as all existing test facilities are stationary. The project is implemented by Riga Technical University in cooperation with Cryogenic and Vacuum Systems Ltd.

Explainable Deep Learning Approach for High Impedance Fault Localization in Resonant Distribution Networks Considering Quantization Noise

ABSTRACTIn addressing the quantization noise challenge in high impedance fault (HIF) localization within resonant distribution networks, we propose a cutting‐edge, explainable deep learning approach that significantly advances existing methods. This approach utilizes differential zero‐sequence voltage (DZSV) and zero‐sequence current (ZSC) and introduces a novel “Vague” classification to improve localization accuracy by effectively managing quantization noise‐distorted signals. This approach extends beyond the conventional binary classification of “Fault” and “Sound,” incorporating a multi‐scale feature attention (MFA) mechanism for enriched internal explainability and applying gradient‐weighted class activation mapping (Grad‐CAM) to visualize critical input areas precisely. Our model, validated in an industrial prototype, exhibits unparalleled adaptability across various environmental conditions, including environmental noise, variable sampling rates, and triggering deviations. Comparative analysis reveals that our approach outperforms existing methods in managing diverse fault scenarios.

Digital twin-enabled quality control through deep learning in industry 4.0: a framework for enhancing manufacturing performance

ABSTRACT In the context of Industry 4.0, integrating Digital Twin (DT) technology stands out as a critical challenge for enhancing manufacturing processes and productivity. The combination of DT and Artificial Intelligence (AI) provides a significant benefit for improving processes in real-time. Industries are actively researching these technologies to keep pace with the rapid evolution of technology, utilizing virtual representations for efficient real-time monitoring and control. The present paper proposes a new approach that relies on DT technology for monitoring, optimizing manufacturing processes and enabling quality control through Deep learning (DL). The proposed methodology involves creating a digital replica of the physical system and utilizing DL models for quality control purposes. This approach improves automation and productivity while maintaining high levels of quality assurance in factories. DL is deployed within the DT for gathering data from the physical system and making predictions regarding product quality. The approach is illustrated by considering an experimental industrial prototype. The results obtained are particularly intriguing, demonstrating heightened predictive accuracy in assessing product quality and real-time issue resolution. Overall, the findings underscore the significant and interesting impact of DT technology with DL on manufacturing processes in the context of Industry 4.0.

On-bottom stability of a radial fin integrated surface-laid pipe-section against vertical penetration

This study focuses on the on-bottom stability of surface-laid submarine pipelines during vertical penetration under thermal-induced buckling. Submarine pipelines are susceptible to buckling due to their high slenderness ratio, and the resistance to such displacement relies on pipeline stiffness and soil resistance. To investigate this, laboratory model tests were conducted using a scaled-down pipe section placed on a clay bed. The clay bed was prepared with remoulded Kaolin clay, ensuring uniform moisture content, and the model pipe was scaled down from a typical industry prototype. These tests were conducted in 2D plane strain conditions within a tank, equipped with observation windows to monitor pipe movement and soil behaviour. A significant improvement in the pipe section's penetration resistance and on-bottom stability was observed after incorporating fin in the pipe. The addition of fins altered the earth pressure distribution beneath the vertically loaded pipe, leading to a larger failure mechanism in the adjacent soil. Furthermore, the soil-surface-heaving progressed towards the tank wall with increasing angular distance between the radial fins. Thus, the research demonstrated the effectiveness of radial fins in enhancing the stability and resistance of submarine pipelines against vertical penetration, shedding light on potential improvements in submarine pipeline design and deployment.

Invariant flow rate measurement system for three-component oil-gas-water flow

The paper presents an invariant flow rate measurement system for individual components for a flow that consists of oil, water, and gas. The proposed flow measurement system is a continuation of the work of the authors, which is based on the application of the multichannelling principle of invariance theory. The paper proposes and discusses the structure of the invariant system for measuring the flow rate of oil-water-gas, analytical expressions are obtained for the implementation of algorithms for measuring the flow rate of individual substances that make up the flow. The uncertainty of the flow rate measurement results was assessed separately for oil, water, and gas. In this work, it is shown that by selecting flow meters of the main and additional channels with an uncertainty of less than 0.5 %, for almost any ratio of components in the additional pipeline, it is possible to measure the flow rate of water or oil with an uncertainty of less than 3 %, and the flow rate of the gas fraction in free form can be measured with an uncertainty value of less than 1 %. The paper discusses the practical aspects of the implementation of an industrial prototype of the system and the characteristics that affect its accuracy and efficiency.

Development of NEMESI: A Multiparameter Library Generator Prototype for Industrial VVER and PWR Applications Based on APOLLO3®

A nuclear reactor’s design and safety assessment relies on a calculation platform consisting of a series of calculations performed using different simulation tools, each dedicated to modeling a specific phenomenon. The European Union H2020 CAMIVVER Work Package 4 aims to establish lattice neutronics calculation methodologies for VVER and pressurized water reactor fuel assemblies employing the new-generation deterministic multipurpose neutron transport code APOLLO3®, developed by the CEA (Commissariat à l’Énergie Atomique et aux Énergies Alternatives) with the support of EDF (Electricité de France) and Framatome. The present work aims to present NEMESI, an industrial prototype of a flexible lattice calculation tool developed as part of the CAMIVVER project, showing the applicability of APOLLO3 for industrial research and development and proposing dedicated VVER calculation schemes. Given the intense focus on the industrial issues of the entire CAMIVVER project, the elements constituting the rationale behind the development of such a computational platform are flexible modeling and analysis options, compliance with a series of specified requirements, implementation of innovative algorithms with improved precision, and a modern software and architectural base.

Live application programming in the defense industry with the Molecule component framework

At Thales Defense Mission Systems (DMS), software products first go through an industrial prototyping phase. Prototypes are serious applications that we evaluate with our end-users during demonstrations. End-users have a central role in the design process of our products. They often ask for software modifications during demonstrations to experiment new ideas or to focus the existing design on their needs.In this paper, we present how we combined Smalltalk’s live-programming capabilities with software component models to obtain flexible and modular software designs in our context of live prototyping. We present Molecule, an open-source implementation of the Lightweight CORBA Component Model in Pharo. We use Molecule to build HMI systems prototypes, and we benefit from the dynamic run-time modification capabilities of Pharo during demonstrations with our end-users where we explore software designs in a lively way.Molecule is an industrial contribution to Smalltalk, as it capitalizes 20 years of usage and maturation in our prototyping activity. The Molecule framework and tools are now mature, and we started building end-user software used in production at Thales DMS. We present two such end-user software and analyze their component architecture, that are representative of how we (learnt to) build HMI prototypes. Finally, we analyze our technological decisions with regards to the benefits we sought for our industrial activity.

Life cycle greenhouse gas emissions of retrofit electrification: Assessment for a real case study

Nowadays fleet electrification appears the most concrete opportunity to reduce the environmental burdens of the transportation sector. However, Battery Electric Vehicle penetration has to deal with crucial challenges, such as new BEVs high price, customers’ reluctant and scarcity of materials. In this regard, electric retrofit is emerging as a low-cost and short-term solution to deal with these issues. However, to date only few studies focus on regulatory framework of electric retrofit and fewer quantify the environmental benefits of a converted BEV used in a certain context. This paper analyses a retrofit industrial prototype made by a local start up with all features available for a future homologation and it proposes a comparative Life Cycle Assessment, stressing the significant environmental hotspots to suggests in which geographical context governments should promote retrofit conversion. Two scenarios composed by two time-related parts are evaluated: a vehicle replacement with a new Internal Combustion Engine Vehicle and a retrofit conversion process of a SmartForTwo W450. The production stage of conversion kit is assessed mainly through primary data, while operation consumption is calculated through an analytic model implemented in MATLAB- Simulink. A detailed sensitivity analysis is performed in which different options for electricity grid mix, energy consumption, battery pack maintenance and EoL pathways are combined, for a total of 274 scenario combinations. The results reveal that retrofit conversion allows achieving about 45 % Greenhouse Gases saving compared to new replacement, in particular when urban driving and renewable electricity grid mix are considered.

Sustainable bio-hydrogen production: Assessing economic and environmental implications of a scaled-up industrial bioethanol prototype

This study comprehensively evaluates a bioethanol steam reforming plant in Colombia for green hydrogen (H2) production, sourced from the country's sugar industry. By integrating experimental data and Aspen Plus simulations, the research examines the techno-economic and environmental aspects of utilizing bioethanol as a renewable feedstock for H2 production. Rigorous process modeling, capital investment appraisal, operational cost estimation, economic performance metrics, and environmental assessment are considered. Key findings indicate an H2 yield of 0.155 kg/kg of bioethanol and 34 % energy efficiency, eliminating reliance on fossil fuels. The Levelized Cost of Hydrogen (LCOH) at a Colombian sugar mill is calculated at 10.27 USD/kg under specific assessment conditions. The process exhibits a carbon footprint of 2.16 kgCO2-eq/kgH2 from an environmental perspective. These results emphasize the potential of bioethanol steam reforming as a sustainable and economically viable pathway for green-H2 production, advancing energy transition efforts away from fossil fuels.

The Effect of the Iso‐Thermal Heat Treatment on the Microstructure and Properties of Powder Bed Fusion–Laser Beam AlSi10Mg Alloy

The effect of iso‐thermal heat treatments on powder bed fusion–laser beam (PBF–LB) AlSi10Mg alloy has been studied; however, an extensive process–property relationship evaluation has not yet been undertaken. In addition, the coarsening of eutectic Si from low‐to‐high (200–500 °C) temperature heat treatment has not been investigated systematically. Therefore, AlSi10Mg alloy is heat‐treated at 200, 300, 400, and 500 °C for holding times ranging from 0.5 to 32 h. Uniaxial tensile and hardness tests are conducted, and the microstructure is characterized. A unique approach is adopted for estimating Si solubility where 200 °C heat‐treated microstructure data to estimate solute trapping due to the high cooling rate in the as‐fabricated state. It is observed that increasing the heat‐treatment temperature and time reduces the strength and strain‐hardening rate but increases the tensile elongation up to 400 °C heat treatment. At 500 °C, the yield strength increases, and the elongation reduces compared with the 400 °C heat treatment owing to the refined Fe containing dispersoid formation at 500 °C. The important outcome of this study is heat‐treatment process–property contour maps that are useful for fine‐tuning the mechanical properties of PBF–LB AlSi10Mg alloy for industrial prototyping application.

Autonomous mobile robots for outdoor tasks

This paper presents a low-cost hardware platform for outdoor robots, being suitable for education, industrial prototyping and private use. The choice of components isdiscussed, including platform, sensors and controller as well as GPS and image processing hardware. Furthermore, a software approach is proposed, allowing students and researchers to easily implement own algorithms for localization, navigation and the tasks to fulfill. Several robots can be integrated in a framework which connects various different hardware platforms, called the BOSPORUS network. Together with other components, they form an intelligent network for gathering sensor and image data, sensor data fusion, navigation and control of mobile platforms. The architecture of a reference platform on the campus of the Brandenburg University of Applied Sciences is presented and evaluated.

Computing The Kinematics Study of a 6 DOF Industrial Manipulator Prototype By Matlab

Since the mechanical parts in the robot are designed to do the movement, studying and analyzing the motion considered a primary issue that should be taken into consider when studying and designing the robot.
 In this research 6-DOF sample of the industrial manipulator based on ABB IRB 4400 model had been studied. The mathematical model of manipulator is established by DH (Denavait Hartenberg) method. The forward kinematics was done using DH Parameters in order to get the final transformation matrix. The inverse kinematics was done using geometrical and analytical methods in order to get the end effector final position and direction by calculate Euler angles values.
 Finally, the forward and inverse kinematics equations were computing by MATLAB to get angles, end effector, position, direction and Euler angles values.
 The kinematics study and the arm movement’s equations were compered with the practical measurements to make sure it fulfills the desired purpose.

Advancing high impedance fault localization via adaptive transient process calibration and multiscale correlation analysis in active distribution networks

Fault localization is crucial for ensuring stability, particularly in high impedance faults (HIF) characterized by low current levels and prolonged transient processes (TP). Existing methods predominantly analyze differences in the fixed-length transient waveform, potentially causing delays in triggering or failure in HIF scenarios. To address these challenges, a novel AI application paradigm for HIF localization was introduced, incorporating both adaptive TP calibration and multiscale correlation analysis. Based on 1D-Unet, the TP of the zero-sequence voltage (ZSV) can be adaptively calibrated to maximize the utilization of transient information. Subsequently, the differential zero-sequence voltage (DZSV) and transient zero-sequence current (TZSC) can be acquired to facilitate multiscale correlation analysis. Combined with a sliding window strategy, the micro correlation between DZSV and TZSC is articulated through the local correlation degree (LCD). The comprehensive correlation degree (CCD) between DZSV and TZSC is then formulated to realize fault feeder/ section localization at the macro level. The 1D-Unet model achieved a classification accuracy of 99.2 % for sample points in test datasets and showed robustness with an accuracy exceeding 93.5 % in the presence of 20 dB noise interference. When integrated with the well-trained 1D-Unet, the proposed approach underwent further validation using simulation data and field recordings. These tests confirmed the model's resilience to noise interference up to 20 dB and its efficacy across networks of diverse topologies, such as the IEEE-13 and 34-node distribution networks. Additionally, an industrial prototype applying this framework identified all fault conditions without false positives or omissions, outperforming existing methods under various fault scenarios, including those involving high impedance materials and different resistance levels across multiple feeders.

Industrial prototyping in the German automotive industry: bridging the gap between physical and virtual prototypes

The automotive industry is undergoing a profound transformation characterized by the transition from hardware-centric to software-driven vehicles. This results in a variety of challenges, such as the increasing complexity of components, shortened development cycles, and evolving regulatory requirements that need to be met. In this context, our article explores the impact of UNECE regulations R.155 and R.156 on the technical prototyping phase in the development of mechatronic systems. Furthermore, we use the findings as an objective and examine the implications for the current landscape of prototyping research. Using a comprehensive case study in the German automotive industry with four OEMs, we investigate the current state of prototyping in the German automotive industry. Our analysis shows that although previous research suggests prototyping processes, they reach their limits in complex systems and cannot cope with the challenges of the industry. At the center of the conclusions is the need to develop a prototyping framework that includes a taxonomy of projects and forms the basis for a testing strategy to shorten time-to-market. As part of this, we propose the introduction of the novel term "phygital prototype" to bridge the gap between physical and virtual prototypes. Furthermore, we argue that product compliance should not only be integrated methodically but also propose concrete procedural steps within the prototyping framework.

A comprehensive review of Fused Deposition Modeling (FDM) method using PLA, ABS, and PET-G polymers

A notable increase in prominence has been observed in the application of Fused Deposition Modeling (FDM) 3D printing, resulting in a transformative influence on manufacturing processes in various sectors. The paramount importance of careful material selection for fully harnessing the capabilities of this technology is acknowledged. Within the scope of this comprehensive study article, an examination is conducted regarding the characteristics, benefits, and limitations associated with the three primary materials used in FDM 3D printing, namely Polylactic Acid (PLA), Acrylonitrile Butadiene Styrene (ABS), and Polyethylene Terephthalate Glycol (PET-G). Each of these materials is recognized for possessing unique characteristics that render them suitable for a diverse array of applications, including educational and creative pursuits, as well as industrial prototyping and the creation of functional components. Importantly, the potential to enhance the mechanical, thermal, and electrical characteristics of these substances has been demonstrated through the integration of additives, such as carbon nanotubes, nanoclay, and graphene. Through the cooperative efforts of material scientists, engineers, and 3D printing enthusiasts, it is anticipated that FDM 3D printing will emerge as an essential and invaluable instrument across a wide range of disciplines.

Combustion of waste solids in a fluidized bed to generate sustainable energy

Exploring alternative options to address the impending global energy crisis while taking into account environmental concerns and climate change mitigation and addressing the sky-rocketing energy demand has become urgently essential. This need is further highlighted by the significant reliance of the Republic of Serbia on imported energy sources so that the focus of its energy sector strategy is rational use of energy resources, use of renewable energy sources (RES), and waste management with satisfying environmental regulations. The use of low-calorific and waste materials in conjunction with fluidized bed combustion technology is a method to achieve all the above goals synergistically. This paper presents experimental results of combustion of several solid wastes (coal mining waste from the ?RB Kolubara? complex, Serbia, paper sludge and hazelnut shells), conducted in an industrial prototype and experimental bubbling FB boiler (capacity up to 500 kW). Burning these wastes has a variety of advantages, including recovering substantial energy remaining in the waste and minimizing the overall waste volumes. The work focused on determination of furnace temperature profiles, composition of the flue gas at the furnace outlet as well as fluidization air and fuel flowrates, the minimum fluidization rate, fluidization number, maximum heat output and the transferred heat of the tested fuels. Based on the obtained results, potentials of FBC of waste fuels and the possibility of utilization of their energy potential are evaluated.

Functional system for experimentation and testing of products for professional use - Professional risk management tool for workers performing industrial activities

The products intended for professional use must guarantee the fulfilment of the safety and health requirements from the design phase; they are being tested in the experimentation and “zero series” stage to validate the series production. The work equipment for professional use, the industrial product prototype’s functional, operating and protection properties must be defined to establish the necessary conditions for their experimentation. In this sense, it is necessary to develop specific tools for the management of professional risks in order to take the decision at the managerial level to protect the workers who carry out industrial activities. The study presents research results regarding establishing security and compliance conditions to develop a methodology for experimentation, testing and validation of product prototypes intended to protect workers and prevent occupational risks in electrical installations. As part of the research study, a managerial tool for managing professional risks was developed in order to ensure the protection of people who carry out industrial activities and the prevention of occupational risks in the energy sector, which consisted of an intelligent decision support tool necessary for designing, experimenting the product prototype, the testing of the upgraded product model and its validation, to introduce it into series production.

3D Printing of Continuous-Fibers Cementitious Composites

Significant developments in 3D concrete have been made over the past few decades. Yet, unreinforced printed components generally do not comply with existing construction standards or regulations and are therefore not used as load-bearing components. There is still a gap between research and use, and despite several proposals, standard commercial solutions for the reinforcement of 3D-printed structural members are still awaited. The proposed technology is inspired by the composites industry and called flow-based pultrusion for additive manufacturing. The reinforcement is provided by long and aligned fibers, and produces a transverse isotropic composite mortar. Here we show the first experimental setup, and the material tests performed on the printed material. An increase in tensile strength and ductility is shown. An industrial prototype, in collaboration with the company XtreeE, is being developed. This new equipment has made it possible to print beams of 1m50 whose intrados is reinforced with carbon fibres.

The use of soluble resin for additive manufacturing of automotive industry prototypes

The article describes the method of producing car parts using the Freeform method (FIM). The injection process into a mold obtained by 3D printing was simulated and the surface condition of the finished product made of high-strength PEEK was assessed.