Mechatronic Solutions Research Articles

Design of a material sorting digital twin system based on NX MCD

Current methods of manually checking whether materials meet the required standards are inefficient and harmful to workers' health. To address the complexity and variability of real-world systems, it is imperative to establish highly consistent digital models for subsequent operations. However, there is a challenge in unifying various modules and components into a single system and optimizing them for functionality. A mechatronic solution is proposed for material sorting within the production manufacturing process, leveraging Siemens TIA Portal and NX 2007. The solution involves constructing a physical platform and realizing a digital twin system to enable real-virtual interaction via communication protocols. Initially, a virtual material sorting simulation and debugging platform is established using NX software, while operations are conducted in the TIA Portal. Subsequently, the control program is designed within the TIA Portal, and Virtual PLCs are created using PLCSIM Advanced for virtual debugging and analysis, confirming the solution's feasibility. Following this, the physical material sorting platform is developed, utilizing Siemens S7-1500 PLC to manage inverter and servo motor operations. Ultimately, the OPC UA communication protocol facilitates information exchange between the physical PLC and the virtual platform, establishing effective linkage between the virtual system and the physical model to ensure coordination and consistency. Results demonstrate real-time synchronization and virtual sorting operations during joint real-virtual debugging. This digital twin design solution is poised to significantly enhance manufacturing efficiency, reduce initial hardware costs in factory design, and augment automation and intelligence in production.

Magnetic effects on surface waves in a rotating non-homogeneous half-space with grooved and impedance boundary characteristics

Investigation on the Mathematical modeling of waves in a rotating grooved and impedance boundary of a non-homogeneous fibre-reinforced solid half‐space under the influence of magnetic field and mechanical force is envisaged. We derived analytically, the dynamical equations for the rotating grooved and impedance boundary of the non-homogeneous fibre-reinforced solid under the influence of magnetic fields and mechanical force. Harmonic solution method of wave analysis is utilized. This is such that the component of displacements and stresses are developed and studied after employing dimensionless parameters in the equations of motion. Numerical computations are presented in graphical form by using Mathematica Software for a particular chosen material. We observed that the combined grooved, magnetic fields, impedance boundary etc. physical parameters, have remarkable effects on the material. A decrease in horizontal impedance yielded maximum amplitudes of displacements and stresses of the waves on the fibre-reinforced medium. The mechanical force and rotation of the medium induced increased behaviors to the amplitudes of displacement and stress components of the wave on the solid medium. Thus, this work should be of great importance in studies involving seismology and seismic Mechatronics solution for stress-wave generation in non-homogeneous materials.

Intelligent airborne monitoring of irregularly shaped man-made marine objects using statistical Machine Learning techniques

The marine economy has historically been highly diversified and prolific due to the fact that the Earth's oceans comprise two-thirds of its total surface area. As technology advances, leading enterprises and ecological organisations are building and mobilising new devices supported by cutting-edge marine mechatronics solutions to explore and harness this challenging environment. Automated tracking of these types of industries and the marine life around them can help us figure out what's causing the current changes in species numbers, predict what could happen in the future, and create the right policies to help reduce the environmental impact and make the planet more sustainable. The objective of this study is to create a new platform for the automated detection of irregularly shaped man-made marine objects (ISMMMOs) in large datasets derived from marine aerial survey imagery. In this context, a novel nonparametric methodology, which harbours several hybrid statistical Machine Learning (ML) methods, was developed to automatically segment ISMMMOs on the sea surface in large surveys. This methodology was validated on a wide range of marine domains, providing robust empirical proof of concept. This approach enables the detection of ISMMMOs automatically, without any prior training, with accuracy (ACC), Matthews correlation coefficient (MCC), negative predictive value (NPV), positive predictive value (PPV), specificity (Sp) and sensitivity(Se) over 0.95. The outlined methodology can be utilised for a variety of purposes, but it's especially useful for researchers and policymakers who want to keep an eye on how the maritime industry is deploying and make sure the right policies are in place to meet regulatory and legal requirements to promote maritime tech innovation and shape what the future looks like for the marine ecosystem. For the first time in the literature, a method, the so-called ISMMMOD, has been developed to automate the detection of all types of ISMMMOs by statistical ML techniques that require no prior training, which will pioneer the monitoring of human footprint in the marine ecosystem.

A Smart Wing Rib Structure Suitable for Design for Additive Manufacturing (DfAM) Process

Additive manufacturing has been adopted widely across various industries for producing parts mainly due to their ability to create complex geometries, eliminate material wastage and enable faster production rate, among others. Additive manufacturing has also increased design solution space by enabling exploration of mechatronic solutions for mechanical structures. This includes the integration of smart devices into wing structures to achieve a datadriven predictive maintenance-based system. For this, there is still the need to continuously explore various ways of integrating sensory capability into a mechanical structure during the manufacturing processes to ensure improvement and reliability of aircraft components. The scope of this paper was to analyse different wing rib geometries and the influence of embedding sensory capability via design for additive manufacturing process. In this work, three wing rib geometries with cut-outs and for sensory placement were designed and analysed to estimate their equivalent stress and deformation when such sensory locations are introduced. The results confirm the idea that it is feasible to introduce holding cavities for structural performance monitoring sensors without compromising the structural design requirements. The results also show that deformation and stress are highly dependent on the rib thickness and the insertion of sensory locations

Dielectric Elastomer Actuators, Neuromuscular Interfaces, and Foreign Body Response in Artificial Neuromuscular Prostheses: A Review of the Literature for an In Vivo Application.

The inability to replace human muscle in surgical practice is a significant challenge. An artificial muscle controlled by the nervous system is considered a potential solution for this. Here, this is defined as a neuromuscular prosthesis. Muscle loss and dysfunction related to musculoskeletal oncological impairments, neuromuscular diseases, trauma or spinal cord injuries can be treated through artificial muscle implantation. At present, the use of dielectric elastomer actuators working as capacitors appears a promising option. Acrylic or silicone elastomers with carbon nanotubes functioning as the electrode achieve mechanical performances similar to human muscle in vitro. However, mechanical, electrical, and biological issues have prevented clinical application to date. Here materials and mechatronic solutions are presented which can tackle current clinical problems associated with implanting an artificial muscle controlled by the nervous system. Progress depends on the improvement of the actuation properties of the elastomer, seamless or wireless integration between the nervous system and the artificial muscle, and on reducing the foreign body response. It is believed that by combining the mechanical, electrical, and biological solutions proposed here, an artificial neuromuscular prosthesis may be a reality in surgical practice in the near future.

Design Thinking in Digital Innovation Projects—Exploring the Effects of Intangibility

The locus of innovation has shifted from mechanical advances to digital solutions. By emphasizing the importance of user needs, Design Thinking is apt to develop human-centered innovation, including digital solutions. Using two representative examples from 21 Design Thinking projects spanning the gamut of mechatronic to fully digital solutions, we report on critical incidents as opportunities and challenges of applying Design Thinking in a digital context. In the case of mechatronic solutions, we identified opportunities related to improved collaboration and higher quality prototyping as well as in innovative business models, which in turn created challenges in managing stakeholders. In the fully digital context, we observed opportunities in improved needfinding and the ability to offer individualized products. Conversely, we uncover difficulties in imagining digital features, estimating their feasibility, and correctly setting the fidelity of prototypes. Based on these observations, we discuss the intangibility of digital artifacts as enabler and inhibitor of Design Thinking in a digital context.

Design, modelling and validation of a novel extra slender continuum robot for in-situ inspection and repair in aeroengine

In-situ aeroengine maintenance works are highly beneficial as it can significantly reduce the current maintenance cycle which is extensive and costly due to the disassembly requirement of engines from aircraft. However, navigating in/out via inspection ports and performing multi-axis movements with end-effectors in constrained environments (e.g. combustion chamber) is fairly challenging. A novel extra-slender (diameter-to-length ratio < 0.02) dual-stage continuum robot (16 degree-of-freedom) is proposed to navigate in and out confined environments and perform required configuration shapes for repair operations. Firstly, the robot design presents several innovative mechatronic solutions: (i) dual-stage tendon-driven structure with bevelled disks to perform required shapes and to provide selective stiffness for carrying high payloads; (ii) various rigid-compliant combined joints to enable different flexibility and stiffness in each stage; (iii) three commanding cables for each 2-DoF section to minimise the number of actuators with precise actuation. Secondly, a segment-scaled piecewise-constant-curvature-theory based kinematic model and a Kirchhoff-elastic-rod-theory based static model are established by considering the applied forces/moments (friction, actuation, gravity and external load), where the friction coefficient is modelled as a function of bending angle. Finally, experiments were carried out to validate the proposed static modelling and to evaluate the robot capabilities of performing the predefined shape and stiffness.

Active vibration control development in ultra‐precision machining

This study presents a combined feedback–feedforward adaptive regulator applied to an active vibration control tool holder platform to contain the effect of machining vibrations. The proposed mechatronic solution can be integrated in a milling machine tool as an interface between the beam (Z-axis) and the tool holder. The aim is to counteract vibrations in the broadband frequency range (100 Hz–900 Hz), controlling the tool position in real time. The active vibration control system is based on the harmonic steady-state concept due to the sinusoidal representation of the disturbance signals. The study focuses on the regulator architecture and the main logics applied to satisfy the required performance. A full investigation is executed through simulations and experimental campaigns, proving the disturbance reduction. The active vibration control system is implemented on a 4-axis machine tool and validated using multitonal disturbances. The system is evaluated in compensating a set of undesired effects, such as vibrations generated by unbalanced tools or hard material cutting processes. The obtained results show a maximum reduction of the vibration amplitude by 43.7% at the critical frequency.

A Robotic Device for the Structural Dynamics Inspection of Railway Pantographs through Nonlinearity Tests

The railway industry is progressively embracing mechatronics solutions to improve maintenance operations. In this context, we present a robotic device that introduces structural dynamics analysis in railway pantograph inspection. Specifically, an innovative macro-micro actuation extends the bandwidth performance of actual devices, while a force control strategy proved to support the execution of nonlinearity tests via the estimation of the Frequency Response Function for different levels of the input force. Thereupon we show that the exploitation of nonlinearity can enhance the detection of even a minor localized fault.

Novel actuation approach for active control of slender bars with simulated delayed excitation

This research is motivated by the problem of regenerative chatter vibration, which is a pronounced problem in machining. The problem of chatter vibration is especially critical in the internal turning process, where the material is removed from the inner part of a rotating workpiece using a slender bar. Active mechatronic solutions to the problem of regenerative chatter vibration in internal turning are mostly given by means of piezoelectric actuators embedded into the boring bar. However, due to the volume needed for accommodation of the actuators, it is difficult to apply these solutions to narrow bars. This paper presents a novel actuation approach with a potential application for active control of regenerative chatter vibration in internal turning. This approach involves a bar whose clamping has an ability to move perpendicularly to the bar axis. In addition, it involves two actuators: one of them is placed near the bar clamping, and another one is placed at the bar clamping. The presented actuation approach is compared to the related approaches in the literature. Additionally, this paper presents a method for robustness analysis of the actively controlled cutting process, which is based on the structured singular value methodology. Experiments performed on a specially designed testbed imitating the internal turning process demonstrate the potential applicability of the introduced actuation approach, as well as the utility of presented robustness analysis method.

Rehabilitation Device Supporting Active and Passive Upper Limb Exercises

This article presents a mechatronic solution for rehabilitation devices supporting active and passive exercises in persons with motor dysfunctions of the upper limbs in the area of the elbow and shoulder joints. A planar positioner integrated with original software and a control system, served as the basis for creating the present solution. Bellman’s programming method was applied to optimize the motion trajectory of the planar positioner along with the upper limb undergoing rehabilitation. The design of the planar coordinate positioner and the components of the system for supporting a therapy conducted by a rehabilitation specialist are presented.

Functional design for customizing sit-to-stand assisting devices

Standing up refers to the transition from the seating to the standing postures to perform a movement that involves several body segments and requires both voluntary action and equilibrium control during an important displacement of the body Centre of Gravity (COG). This task can be considered very important for people with reduced mobility to achieve minimal independence in Activity of Daily Living (ADL). In this paper, we propose solutions for the homecare of persons with reduced mobility, describing a functional design to customize assisting devices for the Sit-to-Stand (STS). In particular, the support mechanism that generates the requested motion and sustains the body of a person can be synthesized ad-hoc according to the experimental data of the subject. Experimental tests carried out during the Sit-To-Stand are used to track and record point trajectories and the orientation of the trunk of an individual, and they are used to design a 1-DOF mechanism able to reproduce the assigned rigid-body motion. A four-bar linkage has been synthesized according to the desired features. Simulation results are reported to illustrate the engineering soundness of the proposed mechatronic solution.

Mechatronic Solutions for the Safety of Workers Involved in the Use of Manure Spreader

An internationally acknowledged requirement is to analyze and provide technical solutions for prevention and safety during the use and maintenance of manure spreader wagons. Injuries statistics data and specific studies show that particular constructive criticalities have been identified on these machines, which are the cause of serious and often fatal accidents. These accidents particularly occur during the washing and maintenance phases—especially when such practices are carried out inside the hopper when the rotating parts of the machine are in action. The current technical standards and the various safety requirements under consideration have not always been effective for protecting workers. To this end, the use of SWOT analysis (Strengths, Weaknesses, Opportunities, and Threats) allowed us to highlight critical and positive aspects of the different solutions studied for reducing the risk due to contact with the rotating parts. The selected and tested solution consists of a decoupling system automatically activated when the wheels of the wagon are not moving. Such a solution prevents the contact with the moving rotating parts of the machine when the worker is inside the hopper. This mechatronic solution allowed us to obtain a prototype that has led to the resolution of the issues related to the use of the wagon itself: in fact, the system guarantees the stopping of manure spreading organs in about 12 s from the moment of the wheels stopping.

Design and development of an Inspection Robotic System for indoor applications

Abstract The inspection and monitoring of industrial sites, structures, and infrastructure are important issues for their sustainability and further maintenance. Although these tasks are repetitive and time consuming, and some of these environments may be characterized by dust, humidity, or absence of natural light, classical approach relies on large human activities. Automatic or robotic solutions can be considered useful tools for inspection because they can be effective in exploring dangerous or inaccessible sites, at relatively low-cost and reducing the time required for the relief. The development of a paradigmatic system called Inspection Robotic System (IRS) is the main objective of this paper to demonstrate the feasibility of mechatronic solutions for inspection of industrial sites. The development of such systems will be exploited in the form of a tool kit to be flexible and installed on a mobile system, in order to be used for inspection and monitoring, possibly introducing high efficiency, quality and repetitiveness in the related sector. The interoperability of sensors with wireless communication may form a smart sensors tool kit and a smart sensor network with powerful functions to be effectively used for inspection purposes. Moreover, it may constitute a solution for a broad range of scenarios spacing from industrial sites, brownfields, historical sites or sites dangerous or difficult to access by operators. First experimental tests are reported to show the engineering feasibility of the system and interoperability of the mobile hybrid robot equipped with sensors that allow real-time multiple acquisition and storage.

NVH Optimization of Range Extender Engines by Electric Torque Profile Shaping

Range extender operation in an electric vehicle should be imperceptible to the driver from a noise/vibration standpoint. Rolling torque compensation allows virtually vibration-free range extender engine operation by utilizing a balanced counter-rotating inertia that is geared to the cranktrain. The combustion process results in engine torque fluctuations that could cause gear rattle in such a system due to a combination of torque reversal and lash in the geared connection. This brief paper addresses the problem of gear rattle in a rolling torque compensation system. First, a preloaded split gear is introduced as a potential mechanical solution to eliminate the clearance in the gear contact zone. In addition, an approach for a mechatronic solution involving active shaping of the generator torque is introduced. This methodology includes measurement of the combustion engine torque via cylinder pressure indication data, calculation of allowable torque limits, and the determination of a generator torque profile to address gear rattle. A multicriteria cost function is introduced to determine the optimal torque within the established constraints. Variations of the cost function are investigated with respect to their impact on efficiency and range extender acoustics.

DEVELOPMENT OF HUMAN BALANCE CAPABILITY TESTING PROTOTYPE

The detection of human balance functional disorders may provide some kind of awareness or even warning about potential problems for human health both in organs responsible for ensuring the balance function and in organs related to fulfilment of other important life functions. Modern world offers some sophisticated solutions which enable not only determination of the human balance functional capacity but also offer some kind of training environment to provide corresponding rehabilitation. Unfortunately, such systems are very expensive. And this make limitations of their accessibility and practical usability for a wide range of the target group / population. Software solutions, including mobile applications, on the other hand, are incomparably cheaper. However, they do not allow to make precise balance capability measurements, limiting to simplified balance retention simulators.&#x0D; During implementation of the Latvian National State Research Program VPP INOSOCTEREHI from 2015 to 2017 three human balance capability testing prototypes were developed using a variety of electronic and mechatronic solutions. The last one was successfully approbated during two pilots in Latvian schools in 2016 and demonstrated at the International Invention and Innovation Exhibition MINOX-2016. This paper analyses benefits and disadvantages of approaches used in creating of these prototypes. Besides, authors make initial comparison of developed third prototype version against the BioSway system offered in the market. The paper gives also insight into particular system interface development and new effective graphic portrayal of the balance testing output data, as well as sets the goals for further possible commercialization of the developed balance testing prototype.

Development of a slender continuum robotic system for on-wing inspection/repair of gas turbine engines

The maintenance works (e.g. inspection, repair) of aero-engines while still attached on the airframes requires a desirable approach since this can significantly shorten both the time and cost of such interventions as the aerospace industry commonly operates based on the generic concept power by the hour. However, navigating and performing a multi-axis movement of an end-effector in a very constrained environment such as gas turbine engines is a challenging task. This paper reports on the development of a highly flexible slender (i.e. low diameter-to-length ratios) continuum robot of 25 degrees of freedom capable to uncoil from a drum to provide the feeding motion needed to navigate into crammed environments and then perform, with its last 6 DoF, complex trajectories with a camera equipped machining end-effector for allowing in-situ interventions at a low-pressure compressor of a gas turbine engine. This continuum robot is a compact system and presents a set of innovative mechatronics solutions such as: (i) twin commanding cables to minimise the number of actuators; (ii) twin compliant joints to enable large bending angles (ź90°) arranged on a tapered structure (start from 40mm to 13mm at its end); (iii) feeding motion provided by a rotating drum for coiling/uncoiling the continuum robot; (iv) machining end-effector equipped with vision system. To be able to achieve the in-situ maintenance tasks, a set of innovative control algorithms to enable the navigation and end-effector path generation have been developed and implemented. Finally, the continuum robot has been tested both for navigation and movement of the end-effector against a specified target within a gas turbine engine mock-up proving that: (i) max. deviations in navigation from the desired path (1000mm length with bends between 45° and 90°) are ź10mm; (ii) max. errors in positioning the end-effector against a target situated at the end of navigation path is 1mm. Thus, this paper presents a compact continuum robot that could be considered as a step forward in providing aero-engine manufacturers with a solution to perform complex tasks in an invasive manner. A novel slender continuum robot is introduced for in-situ repair/inspection of jet engines.A new kinematic model is introduced for the new tapered design.Modes of control for the continuum robot were developed, including tip-following, feeding-in/out, Machining commands.Navigation and inspection/machining tests in engine model were introduced.

Mechatronic System for Spectral Monitoring of the Crops Vegetation Status

This paper presents a mechatronic solution for monitoring the crops vegetation status. A data acquisition system containing different types of sensors (multispectral, temperature, plant height, GPS) is placed on a terrestrial mechatronic platform that is carried by a tractor or on an UAV (Unmanned Aerial Vehicle). The multispectral sensor offers information about the reflectance, for discrete wavelengths, necessary to compute the so called vegetation indices. They are correlated with the degree of development and plant health, thermal and water stress, pests, fertilizer need and so on. Knowing these information, a timely intervention is possible, allowing to supply water, pesticide and fertilizer in the proper quantity, at the proper time and in the precise place, leading to major economic impact and significant environmental protection. Geographical information are used for geo-referencing the acquired data, so that the thematic maps to be generated.

Trackhold: A Novel Passive Arm-Support Device

This article introduces the design and the experimental validation of the Trackhold, a novel mechanical motion-tracker for upper limb physical rehabilitation. The Trackhold is based on a passively balanced mechanism that can approximately relieve the weight of the patient’s arm regardless of the position. The system features a novel kinematic architecture with large workspace and custom developed joint sensors providing accurate real-time measure of the upper limb posture. The design approach of the device, which went through kinetostatic and dynamic analyses, is presented and details on the employed mechatronic solutions are provided. A prototype of the Trackhold has been fabricated and functionally validated.

CONTRIBUTION OF INNOVATIVE TECHNOLOGIES TO NEW DEVELOPMENTS IN HORTICULTURE

This paper reviews new developments in high-tech horticulture. It will focus on sensors, energy solutions, covering materials, production technology and robotics. Driving forces for new technologies are identified and Dutch crop production is used as an example. Sensors are introduced in horticulture using the latest techniques from medical and industrial research. A 3D volumetric intersection technique is used to sort tomato seedlings at a speed of 40.000 pieces per hour and measures the full 3D geometric features, which is clearly an impossible challenge when done manually. Other 3D techniques like stereo vision, time of flight and laser triangulation are introduced in horticulture to control robots, measure the geometric quality features as flower diameter and bulb orientation or to separate target features from its agricultural surroundings (e.g., Anthurium, chicory, lily bulbs). But also the interest to measure internal quality features as ripeness, food compounds, internal defects and the ability of photosynthesis capacity can be measured by spectral cameras, fluorescence techniques and X-ray. First applications in research and production are being introduced (e.g., rose, Alstroemeria, tulip, tomato or cucumber). To apply integrated management on pests and diseases in the greenhouse, sensors are needed to determine pests and diseases and its magnitude automatically at an early stage (e.g., long horn beetle, botrytis, sticky plates). More future sensor applications are expected in this field. New developments in energy solutions in greenhouses will lead to more profitable options in crop production. Energy saving in horticulture has been the subject of research for more than 20 years in a special program greenhouse as energy financed by the Dutch ministry of agriculture and growers. The result is that Horticultural industry in The Netherlands consumes now 50% less energy compared to 1990 due to all energy saving measures. Various technologies developed are now common practice in greenhouses like the application of thermal screens and temperature integration. More recent developments in humidity control have been adopted further decreasing energy consumption and thereby even increasing production quality and quantity. Alternative energy sources like geothermal heat are being used by some growers allowing fossil-fuel free vegetable production. More futuristic concepts where electricity and heat are produced in combination with production are still in the experimental phase. When all new developments lead to products with excellent quality in the right amount, price and ready just in time, products need to be harvested with a predictable capacity and reliability. Progress is made on robotic harvesting of fruits, flowers and vegetables. First robots that are tested in practice on a 24/7 base (cutrose, strawberry, kiwi) have shown to be very close to market introduction. Progress is made and big efforts by several consortia are put in actual developments to harvest tomato leaves, cucumbers and sweet peppers. Self-learning algorithms, open source robotic software and generic mechatronic solutions are available and adaptive to new tasks and products and will enable fast future robot solutions after first successful introductions.