Search Results (41)

To further enhance the performance of the fast tool servo (FTS) system in terms of stroke, load capacity, and application area, this paper proposes a novel fast tool servo device driven by a voice coil motor (VCM), based on a three-segment uniform corrugated flexure (CF) guiding mechanism, with a large stroke, high accuracy, and high dynamics. To describe the unified static characteristics of such device, the compliance matrix method is applied to establish its model, where the influence of CF beam structural parameters on the FTS device is investigated in detail. Furthermore, resolution and positioning accuracy tests are conducted to validate the features of the system. The testing results indicate that the maximum stroke of the FTS device is up to 3.5 mm and the positioning resolution values are 3.6 μm and 2.4 μm for positive and negative stroke, respectively, which further verifies the device’s effectiveness and promising application prospect in ultra-precision microstructure machining. Full article

This research investigates the integration of Floating Offshore Wind Turbines (FOWTs) with Oscillating Water Columns (OWCs) to enhance sustainable energy generation, focusing on addressing dynamic complexities and uncertainties inherent in such systems. The novelty of this study lies in its dual approach, which integrates regressive modeling with an aero-hydro-elasto-servo-mooring coupled system with a deep data-driven network and implements a proportional-integral-derivative (PID) control mechanism to improve system stability. By employing Artificial Neural Networks (ANNs), the study circumvents the challenges of real-time closed-loop control on FOWT structures using the OpenFAST simulation tool. Data-driven models, trained on OpenFAST datasets, facilitate real-time predictive behavior analysis and decision-making. Advanced computational learning techniques, particularly ANNs, accurately replicate the dynamics of FOWT-OWC numerical models. An intelligent PID control mechanism is subsequently applied to mitigate structural vibrations, ensuring effective control. A comparative analysis with traditional barge-based FOWT systems underscores the enhanced modeling and control methodologies’ effectiveness. In this sense, the experimental results demonstrate substantial reductions in the mean oscillation amplitude, with reductions from 5% to 35% observed across various scenarios. Specifically, at a wave period from 20 s and a wind speed of 5 m/s, the fore-aft displacement was reduced by 35%, exemplifying the PID control system’s robustness and efficacy under diverse conditions. This study highlights the potential of ANN-driven modeling as an alternative to managing the complex non-linear dynamics of NREL 5 MW FOWT models and underscores the significant improvements in system stability through tailored PID gain scheduling across various operational scenarios. Full article

To address the tracking control problem of the periodic motion fast tool servo system (FTS), we propose a control method that combines adaptive sliding mode control with closed-loop iterative learning control. Adaptive sliding mode control enhances the system’s robustness to external non-repetitive disturbances, and exponential gain iterative learning control compensates for the influence of periodic disturbances such as cutting force. The experimental results show that the proposed iterative learning controller based on adaptive sliding mode control can effectively eliminate the influence of various interference factors, achieve accurate tracking of the FTS system’s motion trajectory within a limited number of iterations, and ensure the stability of the system, which has the advantages of a fast convergence speed, high tracking accuracy, and strong robustness. Full article

This study demonstrates robot technology for harvesting edible bird’s nests within swiftlet houses. A comprehensive manipulator’s movement analysis of harvesting operation with a separating tool is provided for precisely collecting swiftlet nests. A robotic manipulator mounted on a mobile platform with a vision system is also analyzed and evaluated in this study. The actual harvesting or separating the swiftlet nests is performed with visual servo feedback. The manipulator performs the gross motions of separating tools and removing the nests under computer control with velocity and position feedback. The separating principle between the objective nest and wooden frame has been applied to a demonstration removal of nests using a four-degrees-of-freedom manipulator to perform the gross movements of tool. The actual separations using this system are accomplished as fast as the manipulator can be controlled to perform the necessary deceleration and topping at the end of separating. This is typically 2.0 s. This efficiency underscores the system’s capability for swift and precise operation in harvesting an edible bird nest task. Full article

Floating offshore multi-wind turbines (FOMWTs) are an interesting alternative to the up-scaling of wind turbines. Since this is a novel concept, there are few numerical tools for its coupled dynamic assessment at the present time. In this work, a numerical framework is implemented for the simulation of multi-rotor systems under environmental excitations. It is capable of analyzing a platform using leaning towers that handle wind turbines with their own features and control systems. This tool is obtained by coupling the seakeeping hydrodynamics solver SeaFEM with the single wind turbine simulation tool OpenFAST. The coupling of SeaFEM provides a higher fidelity hydrodynamic solution, allowing the simulation of any structural design using the finite element method (FEM). Additionally, a methodology is proposed for the extension of the single wind solver, allowing for the analysis of multi-rotor configurations. To do so, the solutions of the wind turbines are computed independently using several OpenFAST instances, performing its dynamic interaction through the floater. This method is applied to the single turbine Hywind concept and the twin-turbine W2Power floating platform, supporting NREL 5-MW wind turbines. The rigid-body response amplitude operators (RAOs) are computed and compared with other numerical tools. The results showed consistency in the developed framework. An agreement was also obtained in simulations with aerodynamic loads. This resulting tool is a complete time-domain aero–hydro–servo–elastic solver that is able to compute the combined response and power generation performance of multi-rotor systems. Full article

This paper presents a comparison of two methods to represent variable blade inertia in two codes for aero-servo-elastic simulations of wind turbines: the nonlinear aeroelastic multi-body model HAWC2 and the nonlinear geometrically exact beam model BeamDyn for OpenFAST. The main goal is to enable these tools to simulate the dynamic behavior of a wind turbine with variable blade inertia. However, current state-of-the-art load simulation tools for wind turbines cannot simulate variable blade inertia, so the source code of these tools must be modified. The validity of the modified codes is proven based on a simple beam model. The validation shows very good agreement between the modified codes of HAWC2, BeamDyn and an analytical calculation. The add-on of variable blade inertias is applied to reduce the mechanical loads of a 5-megawatt reference wind turbine with an integrated hydraulic-pneumatic flywheel in its rotor blades. Full article

Micro-structured surfaces possess excellent properties of friction, lubrication, drag reduction, antibacterial, and self-cleaning, which have been widely applied in optical, medical, national defense, aerospace fields, etc. Therefore, it is requisite to study the fabrication methods of micro-structures to improve the accuracy and enhance the performance of micro-structures. At present, there are plenty of studies focusing on the preparation of micro-structures; therefore, systematic review of the technologies and developing trend on the fabrication of micro-structures are needed. In present review, the fabrication methods of various micro-structures are compared and summarized. Specially, the characteristics and applications of ultra-precision machining (UPM) technology in the fabrication of micro-structures are mainly discussed. Additionally, the assistive technologies applied into UPM, such as fast tool servo (FTS) technology and slow tool servo (STS) technology to fabricate micro-structures with different characteristics are summarized. Finally, the principal characteristics and applications of fly cutting technology in manufacturing special micro-structures are presented. From the review, it is found that by combining different machining methods to prepare the base layer surface first and then fabricate the sublayer surface, the advantages of different machining technologies can be greatly exerted, which is of great significance for the preparation of multi-layer and multi-scale micro-structures. Furthermore, the combination of ultra-precision fly cutting and FTS/STS possess advantages in realizing complex micro-structures with high aspect ratio and high resolution. However, residual tool marks and material recovery are still the key factors affecting the form accuracy of machined micro-structures. This review provides advances in fabrication methods and assistive technologies of micro-structured surfaces, which serves as the guidance for both fabrication and application of multi-layer and multi-scale micro-structures. Full article

The compliant mechanism (CM)-based fast-tool servo (FTS) is used in ultraprecision machining contexts to produce high value products for technically advanced applications. Far too often, the FTS’ machined products are expected to be geometrically complex with minimal form tolerance and surface roughness. Since the FTS’ enclosing CM is responsible for guiding the cutting motion, its design is of utmost importance in determining the quality of the machined product. The objective of this paper is therefore to review specifically the design and structural related aspects of CM-based FTS that affects its ultraprecision machining performance. After a brief introduction, the fundamentals for designing ultraprecision capable CMs such as flexure hinge modelling, actuator selection and isolation and CM designing are comprehensively explained. In the subsequent section, the various configurations of CM-based FTSs that exist so far and their functionalities are listed. The critical factors which impact the CM-based FTS’ ultraprecision machining performance are identified and mitigating measures are provided wherever possible. Before concluding, the research questions that should be investigated for raising the state of the art of CM-based FTSs are presented as food for thought. With this review article, not only can practitioners have a clearer picture of how better to design their CMs for their FTSs, but they can also improve upon existing FTS designs from leading researchers so that products of higher quality than before can be made for the future. Full article

Piezoelectric actuators are characterized by high positioning accuracy, high stiffness and a fast response and are widely used in ultra-precision machining technologies such as fast tool servo technology and ultrasonic machining. The rapid response characteristics of piezoelectric actuators often determine the overall quality of machining. However, there has been little research on the fast response characteristics of piezoelectric actuators, and this knowledge gap will lead to low precision and poor quality of the final machining. The fast response characteristics of a piezoelectric actuator were studied in this work. Firstly, the piezoelectric actuator was divided into a no-load state and a load state according to the working state. A fast response analysis and output characteristic analysis were carried out, the corresponding dynamic model was established, and then the model was simulated. Finally, an experimental system was established to verify the dynamic model of the piezoelectric actuator’s fast response by conducting an experiment in which the piezoelectric actuator bounces a steel ball. The experimental results verify the correctness of the model and show that the greater the cross-sectional area and height of the piezoelectric actuator, the higher the bouncing height of the ball, and the better the dynamic performance of the piezoelectric actuator. It is believed that this study has guiding significance for the application of the dynamic characteristics of piezoelectric actuators in the machining field. Full article

Vertical-axis wind turbines (VAWTs) have a long history, with a wide variety of turbine archetypes that have been designed and tested since the 1970s. While few utility-scale VAWTs currently exist, the placement of the generator near the turbine base could make VAWTs advantageous over tradition horizontal-axis wind turbines for floating offshore wind applications via reduced platform costs and improved scaling potential. However, there are currently few numerical design and analysis tools available for VAWTs. One existing engineering toolset for aero-hydro-servo-elastic simulation of VAWTs is the Offshore Wind ENergy Simulator (OWENS), but its current modeling capability for floating systems is non-standard and not ideal. This article describes how OWENS has been coupled to several OpenFAST modules to update and improve modeling of floating offshore VAWTs and discusses the verification of these new capabilities and features. The results of the coupled OWENS verification test agree well with a parallel OpenFAST simulation, validating the new modeling and simulation capabilities in OWENS for floating VAWT applications. These developments will enable the design and optimization of floating offshore VAWTs in the future. Full article

This study entailed a load evaluation for the tower design of a large floating offshore wind turbine system in accordance with the wave conditions. The target model includes the IEA 15 MW reference wind turbine and a semi-submersible VolturnUS-S reference floating offshore wind turbine platform from the University of Maine. The OpenFAST, which is an aero-hydro-servo-elastic fully coupled analysis tool, was used for load analysis. The DLC1.2 and 1.6 were used as the design load cases, and the environmental conditions suitable for the design load cases were cited in the VolturnUS-S platform report. Load evaluation was performed according to time series and FFT results. The findings of the study are as follows: first, in the correlation analysis, the tower-top deflection had the highest correlation, and this further affects nacelle acceleration. Second, the tower-base pitch moment increased with the significant wave height. However, the wave peak period increased until it matched the tower-top deflection frequency and decreased thereafter. Third, the comparison between the normal and severe sea state conditions revealed that the tower-base pitch moments for the two conditions are almost similar, despite the conditions wherein the wave spectral energy differs by a factor of 3.5. Fourth, the tower shape is changed while adjusting the diameter of the tower, and the tower-top and tower-base pitch moments are reviewed using a redesigned tower. Even if the mass is the same, adjusting the diameter of the tower reduces only the pitch moment. Full article

The fast tool servo (FTS) technology has unique advantages in the machining of complex surfaces such as special-shaped targets and free-form surfaces. In view of the shortcomings in the performance of the existing FTS device, this paper puts forward a novel FTS which uses two piezoelectric ceramics instead of flexure hinges to provide restoring force. Firstly, the feasibility of the double-drive principle is verified theoretically, and the corresponding mechanism is optimized accordingly. Then, the system control hysteresis model is established and identified, and the appropriate control strategy is designed. Finally, the performances of the proposed FTS device are tested, and a typical microstructure is machined based on the device and ultra-precision lathe. The results indicate that the proposed device effectively improves the performance of the FTS system, which is useful for the processing of microstructures and free-form surfaces. Full article

To comprehensively obtain the effect of the machining process on the three-dimensional surface topography of machined potassium dihydrogen phosphate crystals, a dynamic response model of a machining system was built to calculate the dynamic displacement variables in the different processing directions. This model includes almost all processing factors, such as cutting parameters, environment vibration, radial and axial runout of the spindle, cutting tool parameters, material parameters, guide way error, fast tool servo and lubrication condition errors, etc. Compared with the experimental results, the three-dimensional topographies and two-dimensional profiles of the simulation surfaces were nearly consistent with those of experimental machined surfaces. As the simulation shows, the cutting parameters, axial runout of the spindle, and the output noise of the fast tool servo can respectively impact the main, low, and high frequencies of the machined surface topography. The main frequency of all the simulated and experimental surfaces in this study was 0.0138 μm⁻¹. The low and high frequencies of the simulation surfaces had slight differences, about 0.003 μm⁻¹ from those of the experimental surfaces. The simulation model, based on dynamic response, can accurately predict the entire machining process and three-dimensional topographies of machined potassium dihydrogen phosphate surfaces. Full article

This paper proposes a novel, fast, and automatic modeling method to build a virtual model with minimum degrees of freedom (DOFs) without the need for FE models or human judgment. The proposed program uses the iterative closest point (ICP) algorithm to analyze the mode shape vector of structural dynamic characteristics to define the position and DOFs of the joints between structural components. After the multi-body dynamics model was developed in software, it was converted into an SSM to connect the servo loop model. Then, the mechatronic integration analysis was performed to verify the dynamic characteristics of the tool center point (TCP) and the workbench in the experiment and simulation. The model created by the proposed identification process has a small DOF and can accurately simulate the dynamic characteristics of a machine. This model can be used for dynamic testing and control strategy development in mechatronic integration. Full article

In this study, the performance evaluation of a semi-type floating offshore wind turbine system according to the direction of the incoming waves is investigated. The target model in this this study is a DTU 10 MW reference wind turbine and a LIFES50+ OO-Star Wind Floater Semi 10 MW, which is the semisubmersible platform. Numerical simulation is performed using FAST developed by National Renewable Energy Laboratory (NREL), which is an aero-hydro-servo-elastic fully coupled simulation tool. The analysis condition used in this study is the misalignment condition, which is the wind direction fixed at 0 degree and the wave direction changed at 15 degrees intervals. In this study, two main contents could be confirmed. First, it is confirmed that sway, roll, and yaw motions occur even though the direction of the incoming waves is 0 degree. The cause of the platform’s motion such as sway, roll and yaw is the turbulent wind and gyroscope phenomenon. In addition, the optimal value for the nacelle–yaw angle that maximizes the rotor power and minimizes the tower load is confirmed by solving the multiobjective optimization problem. These results show the conclusion that setting the initial nacelle–yaw angle can reduce the tower load and get a higher generator power. Second, it is confirmed that the platform’s motion and loads may be underestimated depending on the interval angle of incidence of the wind and waves. In particular, through the load diagram results, it is confirmed that most of the results are asymmetric, and the blade and tower loads are especially spiky. Through these results, the importance of examining the interval angle of incidence of the wind and waves is confirmed. Unlike previous studies, this will be a more considerable issue as turbines become larger and platforms become more complex. Full article