Smart Devices and Machines for Advanced Manufacturing

by Wang, Lihui; Xi, Jeff

• ISBN13: 9781848001466
• ISBN10: 1848001460
• Format: Hardcover
• Copyright: 2008-04-01
• Publisher: Springer Verlag

Summary

This book presents a collection of quality chapters on the state-of-the-art of research efforts in the area of smart devices and novel machine design, as well as their practical applications to enable advanced manufacturing. The first section presents a broad-based review of several key areas of research in smart devices and machines. The second section is focused on presenting an in-depth treatment of a particular device or machine. The book will be of interest to a broad readership.

Author Biography

Dr Lihui Wang is a Senior Research Officer at the Integrated Manufacturing Technologies Institute, National Research Council of Canada. His research interests and responsibilities are in Web-Based and Sensor-Driven Real-Time Monitoring and Control, Distributed Machining Process Planning, New Architecture Design and System Development, and Development of Wise-ShopFloor and DPP Systems.Dr Fengfeng (Jeff) Xi, is a Professor at Ryerson University, Canada, and an Adjunct Professor at the East China Jiao-Tong University. His research interests are in the area of manufacturing and automation.

Table of Contents

List of Contributors	p. xvii
Appropriate Design of Parallel Manipulators	p. 1
Introduction	p. 1
Understanding End-user Wishes and Performance Indices	p. 2
Establishing the Required Performances	p. 2
Performance Indices	p. 4
Indices Calculation	p. 6
Structural Synthesis	p. 7
Dimensional Synthesis	p. 8
Choosing Design Parameters	p. 8
Design Methods	p. 8
The Atlas Approach	p. 9
Cost Function Approach	p. 9
Other Design Methodologies Based on Optimisation	p. 10
Exact Design Methodologies	p. 10
The Parameter Space Approach	p. 12
Parameter Space	p. 12
Principle of the Method	p. 12
Finding Allowed Regions	p. 13
Finding Allowed Regions with Interval Analysis	p. 14
Search for Appropriate Robots	p. 19
Design Examples	p. 19
Other Design Approaches	p. 20
Design for Reliability	p. 20
Design for Control	p. 21
Conclusions	p. 21
References	p. 21
Gravity Compensation, Static Balancing and Dynamic Balancing of Parallel Mechanisms	p. 27
Introduction and Definitions	p. 27
Mathematical Conditions for Balancing	p. 28
Static Balancing	p. 30
Static Balancing of a Planar Four-bar Linkage	p. 30
Spatial 6-dof Parallel Mechanism	p. 31
Gravity Compensation	p. 36
Dynamic Balancing	p. 40
Dynamic Balancing of Planar Four-bar Linkages	p. 40
Synthesis of Reactionless Multi-dof Mechanisms	p. 44
Synthesis of Reactionless Parallel 3-dof Mechanisms	p. 44
Synthesis of Reactionless Parallel 6-dof Mechanisms	p. 47
Conclusions	p. 47
References	p. 47
A Unified Methodology for Mobility Analysis Based on Screw Theory	p. 49
Introduction	p. 49
Basic Screw Theory and Mobility Methodology	p. 51
Dependency and Reciprocity of Screws	p. 51
Modified Grubler-Kutzbach Criterion	p. 54
Four Key Techniques	p. 55
Mobility Analysis of Single-loop Mechanisms	p. 57
The Bennett Mechanism	p. 57
The Goldberg Mechanism	p. 60
The Bricard Mechanism with a Symmetric Plane	p. 61
Mobility Analysis of Parallel Mechanisms	p. 63
4-DOF 4-URU Mechanism	p. 63
The CPM Mechanism	p. 65
The 4-DOF 1-CRR+3-CRRR Parallel Mechanism	p. 66
DELTA Robot	p. 68
H4 Manipulator	p. 70
Discussions	p. 73
Conclusions	p. 75
References	p. 76
The Tau PKM Structures	p. 79
Introduction	p. 79
Non-symmetrical PKM Structures	p. 81
The SCARA Tau PKM	p. 84
The Gantry Tau PKM	p. 87
The Reconfigurable Gantry Tau PKM	p. 90
Kinematics and Workspace	p. 92
Calibration	p. 98
Stiffness	p. 101
Mechanical Bandwidth	p. 102
Industrial Potential of PKMs based on Tau Structures	p. 105
Performance Advantages	p. 105
Life-cycle Cost Advantages	p. 106
Relieving People from Bad Working Conditions	p. 107
Conclusions	p. 108
References	p. 109
Layout and Force Optimisation in Cable-driven Parallel Manipulators	p. 111
Introduction	p. 111
Static Force Analysis	p. 112
Optimum Layout for the Redundant Limb	p. 115
Background on Convex Optimisation	p. 117
Optimum Direction of the Redundant Limb	p. 121
Multiple Poses	p. 124
Multiple Redundant Limbs	p. 125
Case Study	p. 126
Minimising Cable Tensions	p. 130
Case Study	p. 132
Conclusions	p. 133
References	p. 134
A Tripod-based Polishing/Deburring Machine	p. 137
Introduction	p. 137
Hybrid Machine Design	p. 139
Description of the Machine	p. 139
ParaWrist Design	p. 141
Motion Planning	p. 142
Tripod Constraints	p. 143
Inverse Kinematics	p. 145
Motion Planning	p. 145
Motion Simulation, Part Localisation and Measurement	p. 146
Forward Kinematics for Motion Simulation and Part Measurement	p. 146
Three-point Method for Part Localisation	p. 148
Tripod Stiffening	p. 150
Compliance Modelling	p. 151
Tripod Stiffening	p. 152
Compliant Toolhead Design	p. 153
Axial Compliance Design	p. 153
Radial Compliance Design	p. 154
Tool Control	p. 157
Parameter Planning Based on Contact Model	p. 157
Control Methods	p. 159
Model-based Control	p. 160
Test Examples	p. 163
Conclusions	p. 164
References	p. 165
Design and Analysis of a Modular Hybrid Parallel-Serial Manipulator for Robotised Deburring Applications	p. 167
Introduction	p. 167
Design Considerations	p. 169
Robot Modules	p. 169
6-DOF Hybrid Parallel-Serial Manipulator	p. 170
Forward Displacement Analysis	p. 172
3RRR Planar Parallel Platform	p. 173
PRR Serial Robot Arm	p. 176
Entire Hybrid Manipulator	p. 178
Inverse Displacement Analysis	p. 179
Orientation Analysis	p. 179
Position Analysis	p. 180
Parallel Platform Analysis	p. 180
Instantaneous Kinematics	p. 181
3RRR Planar Parallel Platform	p. 181
Entire Hybrid Manipulator	p. 182
Computation Examples	p. 183
Application Studies	p. 184
Conclusions	p. 186
References	p. 187
Design of a Reconfigurable Tripod Machine System and Its Application in Web-based Machining	p. 189
Introduction	p. 189
Related Work	p. 190
Design of Reconfigurable Tripod Machine Tools	p. 191
Kinematics, Dynamics and Optimisation	p. 193
Inverse Kinematics	p. 194
Direct Kinematics	p. 195
Stiffness Model	p. 196
Dynamic Model	p. 202
New Criterion in Optimisation	p. 205
Integrated Design Tools	p. 206
Modelling Tool	p. 207
Analysis Tool	p. 209
Simulation Tool	p. 211
Optimisation Tool	p. 211
Monitoring Tool	p. 212
Web-based Machining: a Case Study	p. 213
Testing Environment	p. 213
Tripod 3D Model for Monitoring	p. 214
Web-based Machining	p. 215
Conclusions	p. 217
References	p. 217
Arch-type Reconfigurable Machine Tool	p. 219
Introduction	p. 219
Design and Construction	p. 221
Arch-type RMT Specifications	p. 224
Dynamic Performance	p. 225
Cutting Process Parameters	p. 226
Frequency Response Functions	p. 228
Stability Lobes	p. 231
Conclusions	p. 236
References	p. 236
Walking Drive Enabled Ultra-precision Positioners	p. 239
Introduction	p. 239
One-axis Feed Drive	p. 240
Driving Principle and Control Method	p. 240
One-axis Walking Device	p. 241
Open Loop Control	p. 242
Laser Feedback Control	p. 243
Methods to Overcome Disadvantages	p. 244
Three-axis Feed Drive	p. 245
Three-axis Walking Device	p. 245
Walking Algorithm for Simultaneous 3-axis Drive	p. 247
Three-axis Positioning System with Laser Feedback Control	p. 251
Results of 3-axis Positioning	p. 252
Conclusions	p. 255
References	p. 255
An XY[theta subscript z] Planar Motion Stage System Driven by a Surface Motor for Precision Positioning	p. 257
Introduction	p. 257
The XY[theta subscript z] Surface Motor	p. 259
The Decoupled Controller	p. 264
The XY[theta subscript z] Surface Encoder	p. 271
Precision Positioning by the XY[theta subscript z] Stage System	p. 277
Conclusions	p. 279
References	p. 279
Design and Analysis of Micro/Meso-scale Machine Tools	p. 283
Introduction	p. 283
Overview of Worldwide Research on the mMT Paradigm	p. 285
Overview of mMT Developments in USA	p. 288
Development of a Three-axis mMT	p. 289
Design Considerations for the NU 3-axis mMT	p. 289
Physical Realisation of the NU 3-Axis mMT	p. 290
Performance Evaluations	p. 292
Development of a Five-axis mMT	p. 294
Design Considerations for the UIUC 5-axis mMT	p. 295
Motor and Bearing Placement	p. 298
Summary of 5-axis mMT Design	p. 301
Evaluation of Performance	p. 301
Analysis of 5-axis mMT Motion Parameters	p. 304
Examples of Micro-scale Machining on the UIUC 5-axis mMT	p. 305
A Hybrid Methodology for Kinematic Calibration of mMTs	p. 306
Design of the Measurement System	p. 307
A Hybrid Calibration Methodology	p. 308
Off-machine Measurements	p. 309
On-machine Measurements	p. 309
Kinematic Error Modelling	p. 310
Validation of Calibration Methodology	p. 311
Challenges in mMT Development	p. 312
The Status of mMT Commercialisation Worldwide	p. 313
Conclusions	p. 314
References	p. 315
Micro-CMM	p. 319
Introduction	p. 319
Structure of a Micro-CMM	p. 321
Semi-circular Bridge Structure	p. 321
Co-planar XY Stage	p. 322
Z-axis Design	p. 323
Probes	p. 324
Focus Probe	p. 324
Contact Probe	p. 327
Actuator and Feedback Sensor	p. 329
System Integration and Motion Control	p. 332
System Assembly	p. 332
Motion Control	p. 332
System Errors	p. 332
Conclusions	p. 334
References	p. 334
Laser-assisted Mechanical Micromachining	p. 337
Introduction	p. 337
Development of LAMM-based Micro-grooving Process	p. 339
Basic Approach	p. 339
LAMM Setup for Micro-grooving	p. 339
Process Characteristics	p. 341
Design of Experiment	p. 341
Results and Discussion	p. 342
Process Modelling	p. 347
HAZ Characterisation and Thermal Modelling	p. 347
Force Modelling in Laser Assisted Micro-grooving	p. 354
Summary and Future Directions	p. 362
References	p. 363
Micro Assembly Technology and System	p. 367
Introduction	p. 367
Micro Grippers	p. 368
Pneumatic Grippers	p. 369
Capillary Force Grippers	p. 369
Bio-inspired Grippers	p. 372
Force Feedback	p. 374
Precision Positioning	p. 376
Servomotor	p. 376
Linear Motor	p. 377
Piezoelectric Motor	p. 379
Image Based Feedback	p. 380
A Sample Micro Assembly System	p. 380
Conclusions	p. 382
References	p. 383
Index	p. 385
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