交叉簧片柔性虎克铰在静平衡仪中的应用及性能测试

通过对广义交叉簧片柔性铰链转角公式的分析,揭示了铰链刚度和仪器灵敏度之间的关系。为了避免垂直载荷的变化对铰链转动刚度的影响,设计具有恒定转动刚度的交叉簧片柔性虎克铰,并以柔性虎克铰为转动支撑单元搭建针对万向节装置不平衡力矩测量的两自由度柔性静平衡仪。通过对沿特定方向特定量不平衡力矩的测量,在0～7 000 g有效载荷范围内对仪器分别沿x轴和y轴不平衡力矩测量的同步灵敏度进行测试。结果表明,所搭建的柔性静平衡仪各轴的灵敏度约为1.1 g·mm,灵敏度基本不受仪器有效载荷变化的影响,而且仪器各轴同步测量的灵敏度基本一致。所设计具有恒定转动刚度的交叉簧片柔性虎克铰的转动性能及承载性能优良。     

Torsional thrust balance measurement system development for testing reaction control thrusters

The paper describes the design, development, and testing of a torsional-type thrust stand to evaluate the performance of <40 N class cryogenic propellant reaction control thrusters. New thrust measurement techniques for cryogenic propellant fed reaction control systems at this thrust class are needed as current methods are deficient in providing reliable test data. The torsional thrust stand primarily consists of a balanced moment arm rotating around a set of frictionless pivots. The displacement of the moment arm due to applied thrust was tracked using a laser displacement sensor. A post-processing technique was developed to determine thrust values from displacement data. The measurement capability of the thrust measurement system is exemplified herein through the test firing a LOX/Methane thruster at steady-state and pulsing conditions. Effects of thruster mass and feed system stiffness on thrust-stand measurement characteristics were also assessed. The measurement system provided repeatable thrust data at steady-state and pulsing operating conditions.     

Modeling of cross-spring pivots subjected to generalized planar loads

Cross-spring pivots, formed by crossing two identical flexural beams at their midpoint, have been broadly used in precision engineering and aerospace fields. Many researches have been conducted on modeling and analysis of cross-spring pivots. However the influence of application position and magnitude of the external loads on the load-rotation and parasitic motion characteristics has not yet been discussed. In order to reveal the effect of the external loads, this paper develops the accurate load-rotation and center shift models of cross-spring pivots, with generalized planar loads applied including bending moment, horizontal and vertical forces. Firstly, by using the energy method, the load-displacement models of the pivot are derived with the assumption of small rotational angles. Based on the models, the influence of generalized planar loads on the load-rotation relationship is discussed, which shows that both application position and magnitude of the vertical and horizontal forces influence the load-rotation behaviors. Then the accurate center shift expressions of the pivot with generalized planar loads are developed, which shows that the rotational angle is the dominant term for both components of the center shift while the vertical and horizontal forces are small. Finally, the accuracy of the proposed model is validated by finite element analysis(FEA). Comparing the model data with the results obtained from FEA, the relative error of the load-rotation is less than 6% even if the rotational angle reaches 20°; the relative errors of the two components of center shift are less than 5% and 10% respectively when the rotational angle reaches 10°. The proposed model and analytical conclusions can be used to analyze and preliminarily design the compliant mechanisms containing cross-spring pivots.     

Measurement method and pipe wall misalignment adjustment algorithm of the pipe butting machine

This paper presents a runout measurement method and a novel finite grouping method to predict and optimize the rotational angle and translational displacement of butting pipes to minimize pipe wall misalignment (PWM). This study develops a method to minimize the PWM of the pipes excluding the positions of welding seams. In this method, the measurement data are divided into finite groups and the criteria are created to identify the positions of welding seams and eliminate the effect of the welding seams. Finally, the rotational angle and translational displacement of the butting pipes are optimized to minimize the PWM. A butting machine is designed to implement this method. The machine is benchmarked by a standard smooth pipe to minimize system errors. Three butting experiments have been performed with welded pipes of diameter 406 mm. The comparison shows that the computation results agree with the experimental results very well. The maximum PWMs in three experiments are less than 1.87 mm, which satisfies the butting requirements, that is, a PWM of less than 2.0 mm. Then, the uncertainties of the measurement results are discussed.     

Development and evaluation of a compact 6-axis force/moment sensor with a serial structure for the humanoid robot foot

In order to walk safely, forces and moments exerted on humanoid robot foot should be measured and used for controlling the robot. This paper describes the development and evaluation of a six-axis force/moment sensor used under humanoid robot foot. The developed sensor is capable of measuring 400 N horizontal force, 1000 N vertical force, 20 N·m moment about the horizontal axis and 10 N·m moment about the vertical axis using rectangular cross-sectional beams. The structure of the sensor is newly modeled, and the sensing elements are simulated by using finite element method (FEM). Then the sensor is fabricated by attaching strain gages onto the beams. Finally, a characteristic test of the developed sensor is carried out, and the output from FEM analysis agrees with those from the characteristic test.     

An ultra high-pressure test rig for measurements of small flow rates with different viscosities

Within the framework of a research project regarding investigations on a high-pressure Coriolis mass flow meter (CMF) a portable flow test rig for traceable calibration measurements of the flow rate (mass - and volume flow) in a range of 5 g min⁻¹ to 500 g min⁻¹ and in a pressure range of 0.1 MPa to 85 MPa was developed. The measurement principle of the flow test rig is based on the gravimetrical measuring procedure with flying-start-and-stop operating mode. Particular attention has been paid to the challenges of temperature stability during the measurements since the temperature has a direct influence on the viscosity and flow rate of the test medium. For that reason the pipes on the high-pressure side are double-walled and insulated and the device under test (DUT) has an enclosure with a separate temperature control. From the analysis of the first measurement with tap water at a temperature of 20 °C and a pressure of 82.7 MPa an extensive uncertainty analysis has been carried out. It was found that the diverter (mainly due to its asymmetric behaviour) is the largest influence factor on the total uncertainty budget. After a number of improvements, especially concerning the diverter, the flow test rig has currently an expanded measurement uncertainty of around 1.0% in the lower flow rate range (25 g min⁻¹) and 0.25% in the higher flow rate range (400 g min⁻¹) for the measurement of mass flow. Additional calibration measurements with the new, redesigned flow test rig and highly viscous base oils also indicated a good agreement with the theoretical behaviour of the flow meter according to the manufacturers׳ specifications with water as test medium. Further improvements are envisaged in the future in order to focus also on other areas of interest.     

Experimental evaluation of capacitance transducers for volumetric concentration measurement of particulate solids

This paper presents an example where an off-line experimental technique based upon idealized flow test models is applied as an alternative method of evaluating a commercial solids flow instrument in a well-controlled environment. The systematic characteristics of a 150 mm bore commercial capacitance transducer were quantified as applied to the volumetric concentration measurement of particulate solids. Results obtained from the experimental studies are presented in terms of overall sensitivity, linearity, sensing field homogeneity, material dependence, moisture and temperature effects.     

A novel contact and non-contact hybrid profilometer

A novel hybrid measuring instrument, developed for the characterization of engineering surface, is presented. This instrument is capable of contact and non-contact measurement, and both measurement systems are based on a Linnik interference microscope. So the instrument has a lower cost compared with other counterparts. For the contact measurement, the vertical resolution is less than 1 nm, and for the non-contact measurement, better than 0.5 nm. This paper describes the system and its performance along with results of measuring various samples.     

Feasibility of tracking laparoscopic instruments in a box trainer using a Leap Motion Controller

Motion analysis is employed to assess minimally invasive surgical psychomotor skills in box trainers. Tracking of laparoscopic instruments requires sensor-based systems that can be expensive, limit movements and modify their ergonomic properties. We evaluate the feasibility of using Leap Motion as a cheap, unobtrusive alternative. Four experiments were performed to determine its precision while tracking a laparoscopic instrument inside and outside a box trainer. Static long and short term precision of the Leap Motion was <2.5 mm. Precision between 12 different positions within the box trainer was <0.7 mm for all measured distances between neighbors. Dynamic precision when moving the instrument for 200 mm ranged between 2 and 15 mm. Leap Motion presents acceptable precision values inside a box trainer. Improvements are still required (e.g.: multiple instruments’ tracking). Once solved, a validation study should verify the usefulness of Leap Motion to objectively measure skills of novices and residents during training.     

Study on the evaluation of cylinder’s global sizes

In ISO 14405-1, the global sizes, such as least-squares diameter, minimum circumscribed diameter and maximum inscribed diameter are defined. The diameters above can be measured by using cylindrical coordinate measuring method like the circular section measuring method of cylindricity error. The determination method of the least-squares diameter was firstly given based on the cylindrical measuring system, and the optimization models of the minimum circumscribed diameter and the maximum inscribed diameter were built, respectively. The corresponding objective functions were unified as “minimax” expressions. For the four axis parameters of the cylinder with the minimum circumscribed diameter or the maximum inscribed diameter, the searching ranges of cylinder’s axis parameters for their optimal solutions were defined numerically. Thereafter, the genetic, steepest decent and BFGS-0.618 algorithms were introduced, and the optimization evaluation algorithms of two kinds of diameters mentioned above were given. Based on many cylinders’ profiles obtained by the circular section measuring method on a measuring instrument of cylinder’s global sizes which was developed by Zhongyuan University of Technology, Zhengzhou, China. The accuracy, efficiency and suitability of three optimization algorithms were investigated through the evaluation of a lot of the minimum circumscribed diameters and the maximum inscribed diameters. The measurement uncertainty of the global sizes for the cylindrical specimen was analyzed, and the measurement uncertainties of the sizes in the radial and z directions are ±0.95 μm and ±0.5 μm, respectively. The total measurement uncertainties of the global sizes of the cylindrical specimens with the specifications of ϕ10 × 120 mm and ϕ100 × 300 mm are ±3.8 μm and ±5.7 μm, respectively. The investigation results showed that for the evaluation of the globe sizes, any one of three algorithms above is not absolutely prior to the other two algorithms while considering both evaluation accuracy and efficiency, and the difference of their evaluation results do not exceed 0.5 μm. On the other hand, many points between the maximum value and the least value do not affect the evaluation results in optimization process. For improving the evaluation efficiency, by de-selecting those points while considering the characteristic parameter was also studied based on the statistic method and experiment. Coefficient t should be less than 0.3 to ensure the evaluation accuracy. This research may be useful for developing the next generation measurement instrument for the global sizes and the way forward for the digital manufacturing.     

Synthesis of multiple degrees-of-freedom spatial-motion compliant parallel mechanisms with desired stiffness and dynamics characteristics

This paper presents a new design method to synthesize multiple degrees-of-freedom (DOF) spatial-motion compliant parallel mechanisms (CPMs). Termed as the beam-based structural optimization approach, a novel curved-and-twisted (C-T) beam configuration is used as the basic design module to optimize the design parameters of the CPMs so as to achieve the targeted stiffness and dynamic characteristics. To derive well-defined fitness (objective) functions for the optimization algorithm, a new analytical approach is introduced to normalize the differences in the units, e.g., N/m or N m/rad, etc., for every component within the stiffness matrix. To evaluate the effectiveness of this design method, it was used to synthesize a 3-DOF spatial-motion (θ_x − θ_y − Z) CPM that delivers an optimized stiffness characteristics with a desired natural frequency of 100 Hz. A working prototype was developed and the experimental investigations show that the synthesized 3-DOF CPM can achieved a large workspace of 8°×8°×5.5 mm, high stiffness ratios, i.e., >200 for non-actuating over actuating stiffness, and a measured natural frequency of 84.4 Hz.     

Structural optimization for flexure-based parallel mechanisms – Towards achieving optimal dynamic and stiffness properties

Flexure-based parallel mechanisms (FPMs) are a type of compliant mechanisms that consist of a rigid end-effector that is articulated by several parallel, flexible limbs (a.k.a. sub-chains). Existing design methods can enhance the FPMs’ dynamic and stiffness properties by conducting a size optimization on their sub-chains. A similar optimization process, however, was not performed for their sub-chains’ topology, and this may severely limit the benefits of a size optimization. Thus, this paper proposes to use a structural optimization approach to synthesize and optimize the topology, shape and size of the FPMs’ sub-chains. The benefits of this approach are demonstrated via the design and development of a planar X − Y − θ_z FPM. A prototype of this FPM was evaluated experimentally to have a large workspace of 1.2 mm × 1.2 mm × 6°, a fundamental natural frequency of 102 Hz, and stiffness ratios that are greater than 120. The achieved properties show significant improvement over existing 3-degrees-of-freedom compliant mechanisms that can deflect more than 0.5 mm and 0.5°. These compliant mechanisms typically have stiffness ratios that are less than 60 and a fundamental natural frequency that is less than 45 Hz.     

Uncertainty analysis of slot die coater gap width measurement by using a shear mode micro-probing system

A shear mode micro-probing system was constructed for gap measurement of a precision slot die coater with a nominal gap width of 90 μm and a length of 200 mm. A glass micro-stylus with a nominal tip ball diameter of 52.6 μm was oscillated by a tuning fork quartz crystal resonator with its oscillation direction parallel to the measurement surfaces. An on-line qualification setup was established to compensate for the influences of the uncertainty sources, including the water layers on the measurement surfaces. The measurement uncertainty of the measured gap width was estimated to be less than 100 nm.     

Subpixel edge location method proposed to improve the performance of optical fiber spherical coupling probe during dimensional measurement of micro-cavities with high aspect ratio

A subpixel edge location method based on orthogonal Jacobi–Fourier moments is proposed in this paper to improve the performance of optical fiber spherical coupling probe during dimensional measurement of micro-cavities with high aspect ratio. The effectiveness of the proposed method is proved through the performance test of a micro-hole measuring machine with optical spherical coupling probe. Test results indicate that a blind micro-hole of 400 μm in diameter can be experimentally measured at the depth of 2000 μm with a repeatability of 40 nm and an extremity resolution of 42 nm.     

Examining the trend in loss of flexural stiffness of simply supported RC beams with various crack severity using model updating

The flexural stiffness of simply supported cracked reinforced concrete beams was determined by model updating. The beams were 150 mm wide, 250 mm deep and 2200 mm long. Different FE models were created which include a datum and models with a single crack at three different locations along the length of the beam. The mode shape equation was obtained by using non-linear regression. The equation used in the regression was the generalized solution of transverse vibration of a prismatic beam. Local flexural stiffness, EI, at each coordinate point was derived by substituting the regressed data by using the centered-finite-divided-difference formula. Experimental modal analysis was performed on a control beam and beams with load-induced cracks at predetermined loading. Results from FE analyses showed the trend in the loss of stiffness was similar to the results obtained on the experimental beams. The more severe the damage, the higher the loss of stiffness and the loss patterns are similar for damage at different locations along the beam. The updating technique is able to indicate the trend in the loss of stiffness as a result of cracks of varying severity in the RC beams showing good agreement with experimental results.     

Development of high-precision micro-roundness measuring machine using a high-sensitivity and compact multi-beam angle sensor

With recent development in advanced manufacturing, demand for nanometric accuracy in dimensional metrology has increased dramatically. To satisfy these requirements, we propose a high-accuracy micro-roundness measuring machine (micro-RMM) using a multi-beam angle sensor (MBAS). The micro-RMM includes three main parts: the MBAS, a rotary unit, and a bearing system. The MBAS has been designed and established in order to improve motion accuracy of the micro-RMM. The dimensions of the MBAS are 125(L) mm × 130(W) mm × 90(H) mm. Compared with other methods, an MBAS is less susceptible to spindle error (stage-independence) when detecting angles, can maintain high sensitivity with miniaturized size, and can be used conveniently at the factory level. The optical probe, reported in this paper, is based on the principle of an autocollimator, and the stability is improved when using the MBAS. Unlike multi-probe methods, the micro-RMM is constructed to realize roundness measurement by using only one probe, which is less susceptible to instrumental errors. Experimental results confirming the feasibility of the multi-beam angle sensor for roundness measurement are also presented.     

Videogrammetric technique for three-dimensional structural progressive collapse measurement

In order to solve the shortcomings of the traditional transducers for monitoring the structural progressive collapse, this paper proposes to adopt the high-speed videogrammetric measurement technique to monitor the structural progressive collapse. First, the videogrammetric hardware components are presented. Second, three key issues about the stereo videogrammetric technique are studied in the paper, including camera calibration and placement, movable network control and tracking targets layout and image sequences processing. At last, three different kinds structural progressive collapse of five-story reinforced concrete frame-wall are performed, and the absolute accuracy of 0.43 mm, 0.87 mm and 0.65 mm and the relative accuracy of 0.61 mm, 0.29 mm and 0.62 mm are achieved in the X, Y and Z direction. The results show that the non-contacted videogrammetry is an alternative technique to monitor the structural progressive collapse.     

Simultaneous distributed measurement of the strain and temperature for a four-point bending test using polarization-maintaining fiber Bragg grating interrogated by optical frequency domain reflectometry

We demonstrate a simultaneous distributed strain and temperature measurement technique with the spatial resolution of 1 mm using fiber Bragg gratings inscribed in a polarization-maintaining and absorption-reducing fiber (PANDA-FBGs) and optical frequency domain reflectometry (OFDR). We conduct four-point bending tests in an environmental chamber. Using high birefringent PANDA-FBGs that are manufactured specifically for the simultaneous measurements, the uniform temperature distributions and the typical strain distribution profiles of the four-point bending tests were successfully obtained. The measurement errors of strain were from −31 με to 19 με, and of temperature were from −0.9 °C to 1.3 °C. The spatial standard deviation was 7.5 με and 0.9 °C. We also discussed the effect of the residual strain of the sensor-bonding procedures and the data averaging.     

A long-stroke 3D contact scanning probe for micro/nano coordinate measuring machine

This paper presents a long-stroke contact scanning probe with high precision and low stiffness for micro/nano coordinate measuring machines (micro/nano CMMs). The displacements of the probe tip in 3D are detected by two plane mirrors supported by an elastic mechanism, which is comprised of a tungsten stylus, a floating plate and two orthogonal Z-shaped leaf springs fixed to the outer case. A Michelson interferometer is used to detect the vertical displacement of the mirror mounted on the center of the floating plate. An autocollimator based two dimensional angle sensor is used to detect the tilt of the other plane mirror located at the end of the arm of the floating plate. The stiffness and the dynamic properties are investigated by simulation. The optimal structural parameters of the probe are obtained based on the force-motion model and the constrained conditions of stiffness, measurement range and horizontal size. The results of the performance tests show that the probe has a contact force gradient within 0.5 mN/μm, a measuring range of (±20 μm), (±20 μm), and 20 μm, respectively, in X, Y and Z directions, and a measurement standard deviation of 30 nm. The feasibility of the probe has preliminarily been verified by testing the curved surface of a convex lens.