Digital twin-based analysis of volumetric error mapping procedures

The evaluation of the volumetric accuracy of a machine tool is an open challenge in the industry, and a wide variety of technical solutions are available in the market and at research level. All solutions have advantages and disadvantages concerning which errors can be measured, the achievable uncertainty, the ease of implementation, possibility of machine integration and automation, the equipment cost and the machine occupation time, and it is not always straightforward which option to choose for each application. The need to ensure accuracy during the whole lifetime of the machine and the availability of monitoring systems developed following the Industry 4.0 trend are pushing the development of measurement systems that can be integrated in the machine to perform semi-automatic verification procedures that can be performed frequently by the machine user to monitor the condition of the machine. Calibrated artefact based calibration and verification solutions have an advantage in this field over laser based solutions in terms of cost and feasibility of machine integration, but they need to be optimized for each machine and customer requirements to achieve the required calibration uncertainty and minimize machine occupation time.This paper introduces a digital twin-based methodology to simulate all relevant effects in an artefact-based machine tool calibration procedure, from the machine itself with its expected error ranges, to the artefact geometry and uncertainty, artefact positions in the workspace, probe uncertainty, compensation model, etc. By parameterizing all relevant variables in the design of the calibration procedure, this simulation methodology can be used to analyse the effect of each design variable on the error mapping uncertainty, which is of great help in adapting the procedure to each specific machine and user requirements. The simulation methodology and the analysis possibilities are illustrated by applying it on a 3-axis milling machine tool.     

Synthesis of Hollow Three-Dimensional Channels LiNi_(0.5)Mn_(1.5)O_4 Microsphere by PEO Soft Template Assisted with Solvothermal Method

A appropriate size with three-dimension(3 D) channels for lithium diffusion plays an important role in constructing highperforming LiNi_(0.5)Mn_(1.5)O_4(LNMO) cathode materials, as it can not only reduce the transport path of lithium ions and electrons, but also reduce the side effects and withstand the structural strain in the process of repetitive Li~+ intercalation/deintercalation. In this work, an e fficient method for designing the hollow LNMO microsphere with 3 D channels structure by using polyethylene oxide(PEO) as soft template agent assisted solvothermal method is proposed. Experimental results indicate that PEO can make the reagents mingle evenly and nucleate slowly in the solvothermal process, thus obtaining a homogeneous distribution of carbonate precursors. In the final LNMO products, the hollow 3 D channels structure obtained by the decomposition of PEO and carbonate precursor in the calcination can provide abundant electroactive zones and electron/ion transport paths during the charge/discharge process, which benefits to improve the cycling performance and rate capability. The LNMO prepared by adding 1 g PEO possesses the most outstanding electrochemical performance, which presented an excellent discharge capacity of 143.1 mAh g~(-1) at 0.1 C and with a capacity retention of 92.2% after 100 cycles at 1 C. The superior performance attributed to the 3 D channels structure of hollow microspheres, which provide uninterrupted conductive systems and therefore achieve the stable transfer for electron/ion.     

The influence of FeNi nanoparticles on the microstructures and soft magnetic properties of FeSi soft magnetic composites

In this work, a new type of FeSi/FeNi soft magnetic powder core (SMPC) was successfully fabricated by coating FeNi nanoparticles on the surface of FeSi micrometer powder. The effects of different contents of FeNi nanoparticles on the micromorphology, internal structures, and soft magnetic properties of SMPCs were studied. The results show that FeNi nanoparticles adhere to the surface of FeSi powder, which can effectively fill the air gap between FeSi powder and is beneficial to the compaction of the powder cores during the pressing process. Thus, the density of the SMPCs is increased. Compared to FeSi SMPCs, the comprehensive soft magnetic properties of FeSi/FeNi SMPCs have been greatly improved. When adding 15 wt% FeNi nanoparticles, the SMPCs exhibit excellent magnetic properties with high effective permeability (increased by 43.8 %) and low core loss (decreased by 22.1 %). The high performance FeSi/FeNi SMPCs prepared in this work are expected to be widely used in power choke coils, uninterruptible power supplies, and boosts and inverter inductors.     

A PV installation framework concerning electricity variable rates

This paper assesses building integrated photovoltaic (BIPV) installation parameters based on the profit generated by a photovoltaic system. It takes into consideration a home building case study and it investigates its monthly energy demand based on a specific location and a typical occupancy. The capability of a photovoltaic (PV) system to generate more profit occurs when solar intensity is maximum while the electric energy price is at its highest rate. The paper traces a framework that encompasses different aspects such as energy demand, energy price, and solar intensity. This framework identifies profit alternatives according to different installation parameters. A tool that predicts a PV installation hourly electric energy production is developed. The profit generated is simulated for home buildings located in Beirut (Lebanon) and Xihua (China), both at 33.8° latitude north. The paper highlights a new approach for BIPV installations, taking into account weather conditions, energy demand, and electric energy utility rates.     

Soft sensor for real-time cement fineness estimation

This paper describes the design and implementation of soft sensors to estimate cement fineness. Soft sensors are mathematical models that use available data to provide real-time information on process variables when the information, for whatever reason, is not available by direct measurement. In this application, soft sensors are used to provide information on process variable normally provided by off-line laboratory tests performed at large time intervals. Cement fineness is one of the crucial parameters that define the quality of produced cement. Providing real-time information on cement fineness using soft sensors can overcome limitations and problems that originate from a lack of information between two laboratory tests. The model inputs were selected from candidate process variables using an information theoretic approach. Models based on multi-layer perceptrons were developed, and their ability to estimate cement fineness of laboratory samples was analyzed. Models that had the best performance, and capacity to adopt changes in the cement grinding circuit were selected to implement soft sensors. Soft sensors were tested using data from a continuous cement production to demonstrate their use in real-time fineness estimation. Their performance was highly satisfactory, and the sensors proved to be capable of providing valuable information on cement grinding circuit performance. After successful off-line tests, soft sensors were implemented and installed in the control room of a cement factory. Results on the site confirm results obtained by tests conducted during soft sensor development.     

水力旋冲钻井工具破岩影响因素模拟及应用

常规的冲击钻井工具不能满足井眼轨迹控制要求、使用寿命有限、缓解脱压不显著等问题,影响了在定向井钻井中的推广应用。建立ø215.9 mm PDC钻头和岩石的有限元模型,分析钻井参数对破岩效率的影响规律,结果表明:冲击频率为17.5 Hz和35 Hz时,破岩效率最优; 破岩效率随钻压增大而增加,而后变化逐渐平缓; 破岩效率随钻头转速增大而增加; 破岩效率随冲击载荷的增加变化平缓。据此研制了新型水力旋冲钻井工具。现场试验表明,该工具符合定向水平井“一趟钻”工艺要求,使机械钻速提高56%,使用寿命达150 h,MWD信号正常。     

Local toolpath smoothing for five-axis machine tools

When five axis CNC machine tools follow series linear toolpath segments, the drives experience velocity, acceleration and jerk discontinuities at the block transition points. The discontinuities result in fluctuations on machine tool motions which lead to poor surface quality. This paper proposes to insert quintic and septic micro-splines for the tool tip and tool-orientation, respectively, at the adjacent linear toolpath segments. Optimal control points are calculated for position and orientation splines to achieve C³ continuity at the junctions while respecting user-defined tolerance limits. The geometrically smoothed corners are traveled at a smoothly varying feed with cubic acceleration trajectory profile. The proposed method is experimentally demonstrated to show improvements in motion smoothness and tracking accuracy in five-axis machining of free-form surfaces found in dies, molds and aerospace parts.     

Study on the non-uniform contact during ELID groove grinding

This paper introduces the potential feasibility that ELID (electrolytic in-process dressing) grinding replaces superfinishing in bearing manufacturing, but ELID grinding will bring new challenges. Different regions present distinguish surface profile due to the non-uniform contact in ELID groove grinding. However, few reports explaining the non-uniform contact are available. This article explores the mechanisms of the non-uniform contact during ELID groove grinding. Experiments on the non-uniform contact between bearing raceway and grinding wheel have been carried out under different conditions. The results show that non-uniform contact exists in ELID groove grinding process and it exerts influence on the profile of the raceway surface. Non-uniform contact influences the Rsk and Rku value all the time, but it influences the Ra value occasionally. Improvement strategies of eliminating the non-uniform contact are also discussed based on the experimental study.     

Friction compensation controller for load varying machine tool feed drive

The load applied to a machine tool feed drive changes during the machining process as material is removed. This load change alters the Coulomb friction of the feed drive. Because Coulomb friction accounts for a large part of the total friction the friction compensation control accuracy of the feed drives is limited if this nonlinear change in the applied load is not considered. This paper presents a new friction compensation method that estimates the machine tool load in real time and considers its effect on friction characteristics. A friction observer based on a Kalman filter with load estimation is proposed for friction compensation control considering the applied load change. A specially designed feed drive testbed that enables the applied load to be modified easily was constructed for experimental verification. Control performance and friction estimation accuracy are demonstrated experimentally using the testbed.     

某矿快速掘进最优炮孔间距的选择

山西某矿5308底抽巷在掘进过程中速度慢、效率低，直接影响工作面的瓦斯抽采，为了改善上述情形，对炮孔间距进行研究。通过使用ANSYS软件对不同炮孔间距下快速掘进效果的模拟分析，并经现场验证，得出了适应该矿的最佳炮孔间距。结果表明：炮孔间距为500 mm时，爆破产生裂隙发育范围和岩石损伤区域都最大，快速掘进的效果最好。