Current-sensor-based feed cutting force intelligent estimation andtool wear condition monitoring

Tool wear condition monitoring has the potential to play a critical role in ensuring the dimensional accuracy of the workpiece and prevention of damage to cutting equipment. It could also help in automating cutting processes. In this paper, the feed cutting force estimated with the aid of an inexpensive current sensor installed on the AC servomotor of a computerized numerical control tuning center is used to monitor tool wear condition. To achieve this, the feed drive system is modeled, using neuro-fuzzy techniques, to provide the framework for estimating the feed cutting force based on the feed motor current measured. Functional dependence of the feed cutting force on tool wear and cutting parameters are then expressed in the form of a difference equation relating variation in the feed cutting force to tool wear rate. The computerized system automatically compares successive feed cutting force estimates and determines the onset of accelerated tool wear in order to issue a request for tool replacement. Experimental results show that the tool wear condition monitoring is effective and industrially applicable     

Modeling the forces of cutting with scissors

Modeling forces applied to scissors during cutting of biological materials is useful for surgical simulation. Previous approaches to haptic display of scissor cutting are based on recording and replaying measured data. This paper presents an analytical model based on the concepts of contact mechanics and fracture mechanics to calculate forces applied to scissors during cutting of a slab of material. The model considers the process of cutting as a sequence of deformation and fracture phases. During deformation phases, forces applied to the scissors are calculated from a torque-angle response model synthesized from measurement data multiplied by a ratio that depends on the position of the cutting crack edge and the curve of the blades. Using the principle of conservation of energy, the forces of fracture are related to the fracture toughness of the material and the geometry of the blades of the scissors. The forces applied to scissors generally include high-frequency fluctuations. We show that the analytical model accurately predicts the average applied force. The cutting model is computationally efficient, so it can be used for real-time computations such as haptic rendering. Experimental results from cutting samples of paper, plastic, cloth, and chicken skin confirm the model, and the model is rendered in a haptic virtual environment.     

Fusion of hard and soft computing techniques in indirect, online tool wear monitoring

Indirect, online tool wear monitoring is one of the most difficult tasks in the context of process monitoring for metal-cutting machining processes. Based on a continuous acquisition of certain process parameters (signals such as cutting forces or acoustic emission) with multi-sensor systems, it is possible to estimate or to classify certain wear parameters. However, despite of intensive scientific research during the past decades, the development of reliable and flexible tool wear monitoring systems is an ongoing attempt. This article introduces a new, hybrid technique for tool wear monitoring in turning which fuses a physical process model (hard computing) with a neural network model (soft computing). The physical model describes the influence of cutting conditions (such as tool geometry or work material) on measured force signals and it is used to normalize these force signals. The neural model establishes a relationship between the normalized force signals and the wear state of the tool. The advantages of this approach are demonstrated by means of experimental results. Moreover, it is shown that the consideration of process parameters, cutting conditions, and wear in one model (either physical or neural) is extremely difficult and that existing hybrid approaches are not adequate. The ideas presented in this article can be transferred to many other process monitoring tasks.     

Utilization of information maximum for condition monitoring with applications in a Machining Process and a water pump

This work presents a new method for the condition monitoring based on the so-called information maximum (InfoMax). First, the InfoMax concept is employed to build a neural network. The neural network is used for independent component analysis to identify the source (input) that causes malfunctions (output). To demonstrate the new method, two application examples were included. First, tool breakage detection in an end milling process. The monitoring signal is the current of the feed-motor, which is used to detect the change of the cutting force and accordingly, to detect tool breakage. Second, is the monitoring of a water pump. In this example, seven acceleration signals were simultaneously acquired and used to identify the location of the fault (bearing crack). The experiment results indicate that the new method is effective.     

Estimation of elbow-induced wrist force with EMG signals using fast orthogonal search

In many studies and applications that include direct human involvement-such as human-robot interaction, control of prosthetic arms, and human factor studies-hand force is needed for monitoring or control purposes. The use of inexpensive and easily portable active electromyogram (EMG) electrodes and position sensors would be advantageous in these applications compared to the use of force sensors, which are often very expensive and require bulky frames. Multilayer perceptron artificial neural networks (MLPANN) have been used commonly in the literature to model the relationship between surface EMG signals and muscle or limb forces for different anatomies. This paper investigates the use of fast orthogonal search (FOS), a time-domain method for rapid nonlinear system identification, for elbow-induced wrist force estimation. It further compares the forces estimated using FOS with the forces estimated by MLPANN for the same human anatomy under an ensemble of operational conditions. In this paper, the EMG signal readings from upper arm muscles involved in elbow joint movement and sensed elbow angular position and velocity are utilized as inputs. A single degree-of-freedom robotic experimental testbed has been constructed and used for data collection, training and validation.     

An optical fibre sensor for use in a tissue cutting tool

This pre-study investigates a fibre optic alternative to more conventional sensors for measuring force indirectly as bending or deflection in a medical robotic application. The paper discusses problems regarding the integration of fibre optics into a cutting tool for the removal of prostate gland tissue. The aim is to integrate the sensor in a tube rod with an inner diameter of 0.6 mm and use it as a force feedback sensor for the control system of the robot. The paper proposes and evaluates an inexpensive opto-mechatronic device for launching light into and detecting light received from an optical fibre. A simple sensor prototype is constructed to show the feasibility to use a fibre optic sensor for the prostate gland cutting tool.     

Consideration on the measurement of current distribution on bentwire antennas

As part of the measurement of the current distribution on a bent wire antenna with a shielded loop, the electromotive force (EMF) induced on the loop is theoretically formulated, and the relation between the current distribution and the measured values is investigated. The EMF is expressed as a summation of terms involving the current and the derivative of the current with coefficients depending on the measurement point. The calculated EMF agrees well with the measured value. At points away from the antenna ends and bend, the EMF is proportional to the current, but near the ends and bend the difference between EMF and current increases. It is shown that the current distribution is easily estimated from the measured data. The authors also present the measurement of charge distribution using a small dipole. The expression for the open-circuit voltage of the dipole is formulated and compared with measured values     

Recording of real cutting forces along the milling of complex parts

In this paper, a data acquisition system that simultaneously allows the recording of cutting forces and cutting tool position (coordinates X, Y and Z) is presented. Thus, the geometry of the surface being machined and the values of the cutting forces generated during the surface milling can be correlated. In this manner, two usual problems in milling experimentation are solved. First, those derive from the continuous changes in the feed rate value due to the special look ahead functions (being on-line applied by the numerical control in all high-speed milling centres), which affects the correlation between part geometry and forces. Second, those originate by the presence of unexpected stocks coming from previous semi-finishing operations, which changes the value of cutting forces respect to those calculated taking into account the theoretical tool engagement into the part.The objective of this work is the development of a diagnostics tool for allowing the detection of potential milling problems by researchers, making more profitable the performance of machining test on real complex parts. This tool can be used in the optimization of the milling of test-parts, machining real geometries that incorporate problems different from those observed in the linear tests at constant linear feeds (in end-milling conditions).The final goal of the system is the generation of cutting forces maps as a function of the geometry of real workpieces, which is an advance respect the usual forces recording in function of time or tool rotation typical of linear machining tests. In order to do that, the system incorporates a dynamometric plate for the measurement of the three components of the cutting force, as well as an acquisition card connected to the analog output of the position control loops. After machining, the file containing position and force data is post-processed and chromatic and vector maps are generated.The force analysis utility has been applied to three cases, in order to assess its feasibility in machining research projects. The first example shows a reduction of the number of tests and therefore machining time (even by 18 times) in the validation of a mechanistic cutting force model. Second example is focused on the detection of unexpected tool engagement conditions in complex parts. And the last one addresses to the milling of thin walls, for investigation of static and dynamic milling problems.     

Cutting force control of milling machine

In metal cutting processes, an effective control system, which depends on a suitably developed scheme or set of algorithms can maintain machine tools in good condition. In this paper, an approach is developed for cutting force control of CNC machine. Several linear models are identified based on different working conditions. A dominant model plus uncertain terms is derived from these model set, to yield the necessary and key information from the system. Subsequently, it is used as a state estimator, and robust control is carried out by using the observed variables and cutting force. The developed approach is applied to a milling machine center. Examples taken from experimental tests shown that the developed approach is effective for the uncertain CNC machine.     

Tool breakage monitoring using motor current signals for machine tools with linear motors

In recent years, a number of machining centers have been built using linear motors. These machining centers have great potential for precision and high-speed machining. Nevertheless, a number of problems remain unsolved, such as monitoring and control. This paper presents a new tool breakage monitoring method for this type of machining center using the current signal of the linear motor. First, the relationship between the cutting force and the motor current is analyzed. Then, the new tool breakage method is presented. From a mathematical point of view, the new method uses a nonlinear energy operator to capture the abrupt changes of the motor current signal, which is directly related to the tool breakage. The experiment validation is included.     

An optical fiber transducer for single myofibril force measurement

A force transducer has been developed for use in force measurement of skeletal muscle myofibrils. The transducer is suitable for measurement of passive and contractile forces in a range up to 200 μg, with 1 μg resolution. It is based upon the operating principle of the deflection of an optical fiber of known compliance, sensed by the differential illumination of two phototransistors. Attractive features include ease of operation and specimen mounting, high bandwidth, adaptability for different force ranges, and simple and inexpensive construction     

预应力装配式叶片连接单元状态监测

提出了一种基于压电陶瓷激励与传感技术的预应力装配式风电叶片连接单元的状态监测方法。通过逐级施加螺栓预拉力对连接单元进行安装,再对连接段施加轴心拉力直至试件破坏,将压电陶瓷片粘贴在连接单元两侧分别作为驱动端和接收端,对受力全过程进行监测。比较不同激励信号下各阶段测量信号基于小波包分析的健康指标的变化,发现在连接界面脱开时信号出现明显衰减。该文的方法可实现装配式风力发电机叶片连接段状态的有效监测。     

基于超精密切削的柱面微透镜阵列模具制备工艺研究

文章对柱面微透镜阵列纳米压印中用到的精密模具的制作过程开展了仿真分析和实验研究.超精密切削技术是制作精密压印模具的有效手段之一.基于Johnson-Cook本构模型,采用有限元分析方法模拟了超精密切削过程中切削参数与切削力之间的关系,获得了优选的切削参数.实验结果表明,采用优选后的切削参数进行柱面微透镜阵列模具切削能够获得良好的切削效果.切削后模具的面形精度RMS值达到19 nm,表面粗糙度Sq达到4 nm.     

Real time and an in-process measuring system for the grinding process cylindrical workpieces using Kalman filtering

This paper introduces an in-process measurement system that does not pause during the machining processes. The system could result in enhanced productivity and quality control in manufacturing processes that use a surface grinding spindle. For the gauging sensor of the measurement system, we propose an eddy-current sensor because it is a noncontact type, which uses an eddy current induced when a metallic material is placed in a high-frequency electromagnetic field. Also, it is very insensitive to other kinds of interference such as cutting fluids, coolants, contact pressure, and wear at the contact point. For data analysis, the measurement system was modeled as a linearized discrete form, and the states with noises were estimated by an extended Kalman filter. Validation of this system was performed through a simulation and an experiment.     

基于［bmim］NTF2离子液体的MHD驱动

针对离子液体在化学、物理领域较少现象,提出了离子液体可作为一种新型的流体材料应用于微流控芯片。离子液体驱动方法是基于磁流体力学(MHD)原理,采用电磁场相互作用所产生的洛伦兹力,直接作用于流体以驱动流体前进的驱动方式。为了能对离子液体的驱动现象进行直观的观测和验证,设计了电磁驱动下离子液体的流速测量实验。实验结果显示,离子液体在0.4 T稳恒磁场中,8 V直流电压下流量为7.8 μL/s。对比实验与理论结果,可知电磁场驱动下离子液体的运动规律,以此可促进离子液体在微流控技术和光电子器件等领域的应用。     

微悬臂梁谐振技术检测溶液粘度的研究

提出了一种测量溶液粘度的微悬臂梁谐振技术。推导了溶液粘度与微悬臂梁的谐振频率的理论关系式，并利用原子力显微镜的微悬臂梁测量了不同质量分数的甘油溶液和蔗糖溶液的粘度。与落球法测量结果的比较表明，利用微悬臂梁谐振频率技术测量液体粘度的误差小于4％。这种方法不仅可以作为液体粘度的一般性测量方法，也可以通过检测溶液粘度变化来监测溶液中的化学反应。     

A novel weight measurement method based on birefringence in fiber Bragg gratings

Unlike the usual wavelength modulation principle of fiber Bragg grating (FBG) sensors, a novel weight sensor based on birefringence in FBG is proposed in this paper. The creation of the birefringence is based on the different stresses of the two orthogonal directions in the fiber core cross-section. If weight is applied on an FBG in the radial direction, two reflection spectra with different polarization states which can be observed by an optical spectrum analyzer will occur. An experimental prototype is set up and the measurement principle is described in this paper. Preliminary experimental results indicate that the proposed measurement method is very suitable for the application of heavy weight measurement in the range of 20 tons, especially for vehicle load monitoring in highway charge-by-weight systems. The sensitivity of weight measurement is be estimated to be about 5 kg.     

Enabling the Unconstrained Epidermal Pulse Wave Monitoring via Finger-Touching

Unconstrained measurement of physiological signals including electrocardiograph, respiration, and temperature by sensors through incorporation into commonly used objects has sparked a notable revolution in healthcare monitoring. However, unconstrained precision epidermal pulse wave monitoring is rarely reported. Although the current flexible skin-mounted sensors can capture pulse waves, they lack the capability to perceive tiny pulse pressure in an unconstrained manner. Herein, utilizing thin-film materials and multilevel microstructure design, an ultrathin and flexible sensor (UFS) with the features of high flexibility, shape-adaptability, and ultra-broad-range high pressure sensitivity is proposed for unconstrained precision pulse wave sensing. Given these compelling features, the UFS is mounted to the surfaces of commonly used objects and successfully detects the fingertip pulse wave even under an ultra-broad-range finger-touching force. Key cardiovascular parameters are also extracted from the acquired fingertip pulse wave accurately. Furthermore, a proof-of-concept healthcare system, by combining the UFS and flexible devices (for example, flexible phones or E-newspapers) is demonstrated, offering a great advancement in developing an all-in-one system for IoT-based bio-health monitoring at all times and places.     

Integration of high frequency current shunts in power electroniccircuits

The majority of power electronic converters employ some kind of current measurement. Current transformers and current sensors employing Hall elements are convenient to use since they are galvanically isolated, and have therefore very good noise characteristics. Shunts on the other hand are very cost effective since it only involves placing a low value resistance in the circuit and amplifying the voltage drop to an acceptable level. Novel geometries are suggested as extensions of shunt design concepts for integrating inexpensive current measurement shunts directly into loads and various other structures. Typical applications would be as high power dissipation loads with low inductance, for use at low voltages where it is necessary to measure current or as permanently installed current sensors     

A tele-monitoring system for gait rehabilitation with an inertial measurement unit and a shoe-type ground reaction force sensor

In this paper, a tele-monitoring system is proposed, using an inertial measurement unit (IMU) and a shoe-type ground reaction force (GRF) sensor called a Smart Shoe to measure a patient’s walking data, and transmitting the measured data via the Internet. In our previous work, a mobile gait-monitoring system was developed, which provided visual feedback based on GRFs measured by a Smart Shoe (used as a mobile platform). However, the limited information provided by the Smart Shoe alone may not be adequate for a tele-monitoring system using the Internet. In the present tele-monitoring system for gait rehabilitation, a Smart Shoe is combined with an IMU for detailed monitoring of walking motions. By analyzing the signals from the IMU and the Smart Shoe, foot trajectories, walking distance, length of stride, etc., can be estimated. A user-friendly graphic interface displays the measured or estimated data on separate computers at the patient’s location and the physical therapist’s office. Thus, using the proposed system, it is possible to monitor a patient’s walking motion via the Internet, without restrictions on time or place.