Closed-form inverse kinematics of 6R milling robot with singularity avoidance

For a 6R milling robot, it is necessary to convert the postprocessing cutter locations (CL) into the robot’s revolute joint variables. This paper introduces an algorithm for calculating the forward and inverse kinematics of a 6R robot according to the CL data generated by conventional CAD/CAM systems. A redundant mechanism is analyzed to avoid the singular configurations and joint limits. The Denavit–Hartenberg (D–H) convention is referred to for developing the forward kinematics, and a closed-form solution of the inverse kinematics is presented by means of kinematic decoupling. A fundamental approach with modifying factor for avoiding singularity are developed with regard to three-axis and five-axis CL data. A gap bridging strategy is applied to reduce the jerk motion caused by tool retraction and cut paths connection. Finally, the result is conducted to simulation and machining test to verify the algorithms.     

Mechanical roughing of cylinder bores in light metal crankcases

The increasing demand on vehicles with reduced fuel consumption and emission is the reason why aluminum is frequently used as material for crankcases in the automotive industry. Eutectic aluminum alloys, however, have the disadvantage that they cannot be used for the cylinder bore surface due to their tribological qualities. A method to increase the wear resistance is to coat the surface by using a thermal spray process. In this case a coating material e.g. a steel wire is melted. The molten particles solidify at the boring surface so that a wear resistant coating of the cylinder bore is produced. In order to guarantee that the coating adheres to the aluminum, it is necessary to roughen the surface. This paper describes a method of roughing the surface of the cylinder bores of light metal crankcases by using a modified fine boring process.     

Development of a novel piezoresistive thin film sensor system based on hydrogenated carbon

Thin film sensor systems based on hydrogenated carbon have the advantage to combine two very important characteristics in order to be used in measurement engineering: Firstly, the sensory layer demonstrates piezoresistive behavior and secondly its good properties related to hardness and wear resistance lead in a tribologically stable system. Therefore, the thin film sensor systems can be applied into the main distribution of force within machine parts or used for universal interchangeable sensor systems, e.g. sensory washers. In this article the deposition of a self-contained thin film sensor system on a large technical component (spindle shaft) is shown. The spindle shaft with a length of 480 mm and an outer diameter of 90 mm is part of a belt driven machining spindle for planing machines in woodworking industries. In order to establish a measurement system, which allows monitoring the clamping force of the tool holder and the imbalance of the mounted tool, the thin film sensor system was directly applied to the front surface of the spindle shaft. For this application a novel self-contained thin film sensor system was developed, which consists of an alumina layer for electrical isolation, a chromium layer to establish internal sensor electrodes, a piezoresistive hydrogenated carbon layer (1 μm) and a second covering wear resistance and insulation layer (silicon and oxygen modified carbon layer). The piezoresistive sensor layer and the top layer are part of the diamond like carbon layer family (Robertson, Diam Relat Mater 12:79–84, 2003; Bewilogua et al. DLC based coatings for tribological applications, pp. 67–75, 2006; Biehl et al. Thin Solid Films 515(3):1171–1175, 2006, Novel measurement and monitoring system for forming processes based on piezoresistive thin film systems. Springer Verlag, pp. 879–883, 2010).     

Generation of novel landomycins M and O through targeted gene disruption

Two genes from Streptomyces cyanogenous S136 that encode the reductase LanZ4 and the hydroxylase LanZ5, which are involved in landomycin A biosynthesis, were characterized by targeted gene inactivation. Analyses of the corresponding mutants as well as complementation experiments have allowed us to show that LanZ4 and LanZ5 are responsible for the unique C-11-hydroxylation that occurs during landomycin biosynthesis. Compounds accumulated by the lanZ4/Z5 mutants are the previously described landomycin F and the new landomycins M and O.     

Combinatorial preparation and characterization of thin-film multilayer electro-optical devices

In this article we present a setup for the combinatorial vapor deposition of thin-film multilayer devices as well as methods for the fast and efficient analytic screening of the libraries obtained. The preparation setup is based on a commercially available evaporation chamber equipped with various evaporation sources for both organic and metallic materials. The combinatorial approach is realized by the combination of a rotation stage for the substrate, a five-mask sampler, and an additional mask whose position can be deliberately varied along one axis during the evaporation process. The latter is used to evaporate linear as well as step gradients by continuous or stepwise movement of a shutter mask. The mask sampler allows to define the sectors of the library and to evaporate more complex structures, e.g., an electrode layout. Finally, the simultaneous evaporation of two or more materials enables us to produce layers of varying composition ratio in general and doped materials, in particular. For the control of the evaporation process we have developed an automation software, which is particularly helpful for complex library designs and which grants excellent repeatability of experiments. Efficient and fast characterization of the obtained libraries is realized by (i) a purely optical setup and (ii) an electro-optical setup. (i) The UV/vis reader FLASHScan 530 permits to map out the UV/vis absorbance or fluorescence of the whole library. The UV/vis absorbance is primarily used to determine layer thicknesses and to confirm thickness uniformity across larger regions. The fluorescence measurements are used to determine the composition of layers containing fluorescent dyes. (ii) For a detailed short- and long-term electro-optical analysis we have developed an automated measurement system, which allows the characterization of 8x8 optoelectronic devices and to study their degradation behavior. Both solar cells and organic light-emitting diodes can be tested. Finally, we have developed a data analysis software to extract characteristic values from the huge amount of data and with this facilitate the finding of systematic dependencies.