Table of Content

25 October 2016, Volume 27 Issue 20

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Design of MR Damper Force Sensor Based on Piezoresistive Principles

Dong Xiaomin, Mao Fei, Wei Yan

2016, 27(20):  2699-2704. 

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In order to meet the requirements of health monitoring in the operation of MR dampers and damping force of MR damper controller for cars, a force transducer was proposed based on piezoresistive principles, which might measure dynamic reciprocating damping forces of MR dampers. According to the operating characteristics of the MR dampers for automobiles and the design principles of piezoresistive pressure sensor, the structure of the damper force sensor was designed. Aiming at reaching design range, acquiring high sensitivity and high natural frequency, the size of the sensor chip was determined by the combined method of theory calculation and finite element simulation. The fabrication materials and the measuring circuit were determined through analytic demonstration. The relationship among the coefficients of pressure resistance and crystal orientation, the arrangement direction, the position, the size and the bending number of the resistance were studied before finishing the sensor layout design.

A Prediction Model and Experimental Study of Gear Hobbing Profile Errors Based on Particle Swarm Optimization

Yuan Bin, Han Jiang, Wu Lulu, Tian Xiaoqing, Xia Lian

2016, 27(20):  2705-2711. 

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A series of 3 factors and 2 levels response surface method experiments were carried out to research the influence rules of processing parameters including the spindle speed, the feed rate in Z direction, and the hobbing depth on the gears' tooth profile errors on the precision horizontal gear hobbing machine equipped with home-made CNC system. The mathematical models of the total profile deviation, the total helix deviation and the total cumulative pitch deviation were built respectively and the influence degrees of the three gear profile errors were finished based on the statical experimental data analyses. A more appropriate model for gear profile errors was established based on the weighting factor of each deviation. A method of using particle swarm optimization to improve the gear hobbing parameters was applied based on the final mathematical model. The results show that it is feasible to preselect the hobbing parameters based on the particle swarm optimization of the gear profile errors model established by response surface method.

Research on Trajectory Planning of Industrial Robots with Double Quaternion

Li Hongsheng, Wang Yunhe, Huang Jiacai, Shi Xinxin

2016, 27(20):  2711-2716. 

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For the curve smoothness and real-time requirements of industrial robot trajectories in cartesian space, the paper represented hyperspheres rotation quaternion of robot trajectory spherical linear interpolation, combined with the algorithm of sinusoidal acceleration curve lifting velocity to control the trajectory planning. It provides a new solution of position and pose planning. Finally, simulations were performed in six joints handling robot control system platform, then to prove the validity of the algorithm solution.

Experimental Investigation on Temperature in Camshaft High Speed Grinding

Deng Zhaohui , Liu Tao, Liao Lipeng, Liu Wei, Wan Linlin, Peng Keli

2016, 27(20):  2717-2722. 

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For further study the evolvement rule of grinding temperature in camshaft high speed grinding, a testing device of workpiece surface temperature in camshaft high-speed grinding was designed based on infrared thermal imager.The orthogonal test method and single factor method were applied to design of experiments. Grinding temperature experiments were carried out under different grinding process parameters, and the range method and variance method were used to analyse the influences of grinding process parameters on the grinding temperature. The feasibility of high speed and high efficiency grinding based on workpiece surface temperature and surface roughness were analysed. These experiments provided reliable evidence to solve the problems of camshaft grinding surface thermal damage.

Design and Simulation of a Lower Limbs Rehabilitative Robot

Liu Ruisu, Xing Xinchuang, Liu Yanan, Ye Xietong, Wang Yongmin

2016, 27(20):  2722-2727. 

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A three-dimensional model of a lower limbs rehabilitative robot was built with Pro/E software. A gait mechanism which might change the step length and the pose of the ankle was designed. Kinematics simulation was carried out on the lower limbs rehabilitative robot, and the simulation results show that this mechanism may simulate human natural gait movement, and accords with robot system requirements.

Evaluation of Jig and Fixture Design Scheme Based on Grey Number TOPSIS

Zhang Li, Feng Dingzhong, Liu Pengyu, Zhu Shuwei

2016, 27(20):  2728-2734. 

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The ideal and non-ideal jig and fixture designs affected the quality and accuracy of workpiece. The selection method of location datum was analyzed, and the evaluation indexes of location datum were deeply studied to construct the corresponding factor expressions. The level model for locator scheme was established. Then, the evaluation model of clamping scheme was proposed, including three indexes, such as the constraint degrees of freedom, the processing stiffnesses, and the process costs. The sorting of location scheme was computed by grey TOPSIS, and the results were used to compute clamping scheme. Finally, the optimal jig and fixture design scheme was obtained by the proposed method.

Parameter Optimization of Torque Bar in Folding Wing

Zhen Wenqiang, Ji Yongqiang, Shi Yunguo

2016, 27(20):  2734-2737. 

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The influences of shear stress distribution in different section shapes and length-width rates of the square section on the bar were analyzed herein. The results show that increasing the length-width rate of the section can decrease the critical length of bar efficiently, while the elastic energy that the bar created remaines the same. Based on the dynamics model of the deploying progresses of the folding-wing and constraints from the wing, a optimization model of the torque bar was built, where the target function was the total mass of the bars. Using Isight and MATLAB software, the length, the width, the height and the number of bar groups were optimized in the program. The optimized parameters may increase the structure efficiency and shorten the size of the bar, which may benefit the engineering designs.

Research on Reliability Test Based on Small Sample Motorized Spindle Performance Degradation

Qiu Ronghua, Ju Kongliang, Dong Yougeng, Qu Pingge, Liu Hongzhao

2016, 27(20):  2738-2742,2748. 

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To avoid the disadvantages of reliability analysis on high-speed motorized spindle, a performance degradation reliability test method was proposed herein by two 170MD18Y16 motorized spindles. Firstly, according to the feature quantity and truncated time, a model of small sample motorized spindle was established with shaft end radial run out data to analyze failure life. Secondly, the characteristic life model of 170MD18Y16 motorized spindle was based on the data and Weibull distribution to analyze the distribution parameters by modified maximum likelihood function. Finally, the characteristic life of motorized spindle is consistent with the actual value. The results indicate that the method of performance degradation reliability test is reasonable, and the degradation model may reflect the performance degradation trajectory.

Evaluation Model for Machine Tool Basic Parts Remanufacturability Based on Optimized BP Neural Network

Pan Shangfeng, Lu Chao, Peng Yibo

2016, 27(20):  2743-2748. 

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To utilize sample data to accomplish the remanufacturability evaluation of the machine tool basic parts, and to improve the prediction accuracy of remanufacturability evaluation of the machine tool basic parts, a BP neural network remanufacturability evaluation model optimized by the simulated annealing algorithm and genetic algorithm was proposed. A BP neural network remanufacturability evaluation prediction model of the machine tool basic parts was built according to the evaluation results of typical remanufacturability evaluation model. The BP neural network evaluation model optimized by the simulated annealing algorithm and genetic algorithm has better initial weights and thresholds to increase the convergence rate and avoid the local convergence. Remanufacturability evaluation of a machine tool basic parts was taken as an example to demonstrate that the remanufacturability evaluation model optimized by simulated annealing algorithm and genetic algorithm has higher prediction accuracy.

A Optimization Method for Non-linear Profile Based LM-BP Neural Networks

Xu Jing, He Zhen, Yuan Rong

2016, 27(20):  2749-2753,2758. 

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A method to optimize the non-linear profile was presented based on the DOE theory BP neural network model with Levenberg-Marquard algorithm, which were compared with the traditional statistical regression modeling by a example. The results show that the estimation errors of the model coefficients due to the design and experimental errors may be avoided based on LM-BP neural network modeling.Compared with the BP algorithm this method overcomes the standard BP algorithm performance of unstability, slow convergence and low convergence precision, the presence of local minima and other short-comings.The method proposed herein has a high accuracy, optimization results are satisfactory

Importance Measures Analyses of CNC Machine in Total Life Cycle

Gu Dongwei, Wang Zhiqiong, Zhao Xilu, Fan Shaohua

2016, 27(20):  2754-2758. 

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This paper introduced reliability importance measure to exploratory analyses. The dividing points were determined through piecewise Weibull model for random failure periods and early failure periods, then the subsystem reliability importance measure dynamic model was established. The failure critical importance measure and operational critical importance measure could be obtained with the statistics of failure numbers and failure down time. Finally, the three importance measures were compared and the key subsystem was determined based on the time variation in random failure periods and early failure periods. The sidedness of ascertaining the key subsystem was elucidated with failure critical importance measure (failure number) alone. Besides, the key subsystems were found and this result will be helpful for design, failure analysis and reliability improvement.

Applications of Fiber Grating Sensor in Construction Stage of Cable Net for FAST

Wang Yuting, Wang Qiming, Zhu Ming, He Lin

2016, 27(20):  2759-2764. 

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Active reflector system of FAST consisted of ring beam, reflector unit, main cable and downhaul, actuator and anchor etc. During the construction phases of cable net，there would produce complex stress factors for the ring beam and lattice column which supported cable net structure. In order to achieve precise stress of the ring beam and lattice column structure, during the construction processes of cable network, this paper presented fiber grating sensors for monitoring the ring beam and lattice column structures. The principles of the sensor, measuring point layout, data collection and analysis methods were introduced. A new exceptional data processing method was proposed according to features of construction monitoring and 3σ criteria. This method was used to analyze and eliminate abnormal data.Then the measured data were analyzed, the results show that the cable network construction process stresses of the ring beam measuring points are always less than the value of the security 201.5MPa, the stresses of measuring points of lattice column are in the safe range, and with the progress of construction of the cable network, this paper found changes in the stresses with a certain regularity.This method of monitoring stress with fiber grating sensors is a good application in the FAST cable network construction phase.

A New Prediction Method of Tool Point Frequency Response Function for Milling Cutters

Zhu Jianmin, He Dandan, Tian Fengqing, Zhao Quanlong

2016, 27(20):  2765-2773. 

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To predict tool point frequency response function of milling cutters accurately and rapidly, a new tool point frequency response function prediction method was proposed, which was based on IRCSA to identify joint parameters of holder-tool. Firstly, the joint parameters of holder-tool changing with the frequency were obtained by calculating frequency response function matrixes of holder end and tool point based on the mathematical models, and applying IRCSA. Secondly, the natural frequency of tool point frequency response function was determined, which was sensitive to variations of the complex stiffness matrixes of holder-tool joints by Cuckoo search algorithm and finite element analysis. At last, the joint parameters under the determined frequency were taken as the result of the complex stiffness matrix, which was used to predict the tool point frequency response function. To confirm the presented theory, a carbide cylindrical rod, 2 fluted milling cutter and 4 fluted milling cutter were taken as examples, and the predicted tool point frequency response functions based on the new method and Cuckoo search algorithm of them were compared with measured ones. It is experimentally demonstrated that the new method has high prediction precision and is time-saving, the errors between the natural frequencies of the predicted tool point frequency response functions based on the new method and measured ones are within 5%, and time the new method used is about 1% of the Cuckoo search algorithm used.

Research on Fractal Model of TCS between Spherical Surfaces Considering Friction Factors

Liu Peng, Chen Qi, Fan Hao, Huang Shouwu

2016, 27(20):  2773-2778. 

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In order to precisely calculate TCS between spherical surfaces, this paper presented the establishment of fractal model for TCS calculations between spheres considering friction factors. This model was obtained by introducing the equation of critical contact area of elasto-plastic deformation with friction and employing the basic theory of TCS, and based on the fractal contact model of two spherical surfaces. The numerical results show that: the TCS increases with normal loads; the relationship between TCS and friction coefficient is vary as the fractal dimension changes. It is efficient to improve the TCS by adding material propertied parameters and fractal roughness amplitude. The maximum value appears in TCS when the fractal dimension is 1.5 and the TCS increases significantly when the fractal dimension is about 1.5. Furthermore, TCS of inner contact is bigger than that of outer contact; TCS increases with curvature radius of cylinders. The theory herein helps to analyze the lubrication and dynamic characteristics between high-pair's joint surfaces(like bearings) in the future.

Experimental Study on Cryogenic Cold Air Grinding of Carbon Fibre Reinforced Plastics

Zhang Gaofeng, He Yang, Lu Yanxin, Zhou Houming, Zhu Kejun

2016, 27(20):  2779-2784,2790. 

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Cryogenic cold air and dry room temperature grinding experiments were carried out for unidirectional CFRP using SD80N100B diamond wheel. The influences of cryogenic cold air and grinding parameters on material grinding performance were discussed. The morphologies of ground surface and sub-surface damage were observed by scanning electron microscope and ultra-depth field optical microscopy and factors influenced on surface roughness were analyzed. The results show that, compared with dry grinding conditions, cryogenic cold air grinding results in larger grinding force, lower surface roughness. Under cryogenic cold air and dry room temperature grinding conditions, the maximum grinding force and minimum surface roughness are obtained when ground surface perpendicular to the fibres lengthen direction.

Shearer Roller Torque Detection System Based on Piezoelectric Vibration Energy Harvesting Device

Zhang Qiang, Shi Kangkang, Wang Haijian, Jing Wang

2016, 27(20):  2785-2790. 

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In order to achieve real-time shearer roller torque detection precision, this paper proposed a self-powered detection system based on piezoelectric vibration energy harvesting device. The vibration energy produced by the shearer in the working processes of Y and Z directions would be converted into electrical energy effectively, which ensured the long-term effectiveness working of the pin shaft sensor and wireless strain collection moduler and avoided the problems of power-supply module which needed replacement and repeated disassembly. The results of the experiments show that the self-powered performance of testing system is stable, the load of the shearer roller in theY and Z directions may be detected precisely in real time, the roller torques are calculated, and indicates that the system has higher accuracy and reliability.

Multi-scale Laplace Feature Mapping for Rotor Fault Feature Extraction

Wang Guangbin, Du Xiaoyang, Luo Jun,

2016, 27(20):  2791-2797. 

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Based on theory of multi-scale decomposition and manifold learning thought, a multi-scale Laplasse feature map algorithm for fault feature extraction was proposed. Firstly, the multi-scale wavelet packet decomposition of the rotor fault vibration signals was carried out. The optimal scale wavelet entropy of each independent frequency band signals was extracted, and the characteristic parameter matrix was constructed and the intrinsic dimension was estimated. Then the characteristic parameters of data were embedded into a low dimensional eigenspace by Laplasse feature mapping to get the most sensitive feature of faults. Lastly, the accurate identification of faults was realized by the fusion decision. Experiments show that, compared with the principal component analysis, local linear embedding and Laplacian eigenmap algorithm, rotor fault feature signal extraction of multi-scale Laplasse feature mapping method is more easily identify.

Research on Cladding Coating Properties of Hydraulic Shield Support by Welding with Rotation Impact

Zhang Yong, Tang Jun, Guo Wei, Zhang Kunpeng

2016, 27(20):  2797-2801. 

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Surfacing on abrasion of hydraulic shield support was carried out by using D112 surfacing electrodes. The influences on surfacing layers by welding with impact were discussed. The static strain digital instrument was utilized to study residual stress. Hardness, wear resistance performance, corrosion resistance and microstructure of the surfacing layers were studied. The results show that the welding residual stress is effectively reduced by welding with impact. At the same time, welding with impact may make the grain finer, and may improve the surfacing layer hardness, wear resistance and corrosion resistance.

Mold Finishing for Multi-factor and Multi-objective

Ji Shiming, Wei Wei, Jin Mingsheng, Zhang Li, Huang Xihuan, Pan Ye

2016, 27(20):  2802-2806. 

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Based on gray correlation analysis, technique for order preference by similarity to ideal solution（TOPSIS） analysis and analytic hierarchy process,  a multiple objectives and multiple contributing factors analysis method was put forward, which was proposed for the whole processes of the mold finishing. Gray correlation method was used to analyze the correlation degrees among multiple parameters, and TOPSIS was used to analyze the correlations among the multi-processing quality evaluation standards. Through the hierarchical method,  a reasonable weight matrix was obtained, which combined the objectivity and subjectivity. The influence degree of each processing parameter on each standard and the correlation forecast model might be obtained via ANOVA analysis. Besides, this method was applied to the surface finishing of laser hardened mold, and the results manifests the method is practical and effective.

Numerical Simulation and Experiments of Continuous Sheathing Process with Four Channels for Large Diameter Aluminum Sheathed Cables

Pei Jiuyang, Song Baoyun

2016, 27(20):  2807-2812. 

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Using the finite element(FE) method, based on SSLB500 konform machine with double wheels and four grooves, the continuous extrusion process ofφ178mm×4mm cable aluminum sheath was numerically simulated. The velocity, temperature, stress and strain fields were observed respectively. The optimized die was tested, the aluminum sheath forms well, diameter uniform reaches 99%，concentricity reaches 90%,the transverse mechanical properties of the welding zone consistents with longitudinal, which indicates that the die design and parameter selections are all reasonable. The simulation and experimental results fit well. It proves that the FE model and results are correct, so they may be used as a theoretical guidance for big size cable aluminum sheath continuous sheathing.

Vehicle Dynamics Analysis and Road Rest of a Sports Utility Vehicle Equipped with Hydraulically Interconnected Suspension

Peng Peng, Zhang Bangji, Zhang Jie, Zheng Minyi, Zhang Nong,

2016, 27(20):  2813-2821. 

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A new type of hydro-pneumatic interconnection suspension was proposed herein, which would contribute to improve the ability of rollover resistance without affecting other performances. In order to study the hydraulically interconnected suspension's impaction on the vehicle steering stability, based on CarSim/Simulink/AMESim cosimulation platform, a vehicle multi-body dynamics model coupled fluid system with hydraulically interconnected suspension systems was employed and the relevant handling stability and ride experimental simulation studies were made. The simulation results show that the vehicle fitted with hydraulically interconnected suspension systems may obtain the higher scores in the handling stability evaluation. In order to verify the accuracy of the cosimulation platform and ongoing study the influences of hydraulically interconnected suspension of vehicles, a hydraulically interconnected suspension was designed for a sports utility vehicle, and a series of road tests were carried out. The experimental results are good agreement with the simulation ones. It illustrates that the cosimulation model is correct, and provides a new computer simulation method for follow-up design and optimization in this kind of suspension. Experimental and simulation results show that hydraulically interconnected suspension may offer larger roll stiffness, enhance the safety of vehicle when cornering at high speeds, and improve the handling stability of vehicles without affecting the ride comfort.

Rollover Warning of Commercial Vehicles Based on Multiple Condition Matching

Chen Keji, Guo Xuexun, Pei Xiaofei

2016, 27(20):  2822-2827. 

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A MTTR(matched time-to-rollover) rollover warning method was proposed herein. The key of this method was the way to obtain the roll angles and roll rates of the vehicles instantaneously and accurately.For this purpose, Kalman filter algorithm was used to estimate the yaw angle rates, three estimation methods of roll angles of commercial vehicles were suggested to adapt to different rollover conditions, and the fuzzy logic inference was established to complete the identification and matching of the rollover situations. Based on the scheme above, taking J-turn, fishhook and double land condition(DLC) as the typical rollover conditions, the co-simulation of TruckSim/Simulink was made. The results show that this MTTR warning method is able to reflect the remaining time to rollover more directly and accurately, which has better warning effectiveness.

Multi-objective Robust Design of Electric Vehicle Powertrain Parameters

Yu Limin, Xiong Huiyuan, , Zong Zhijian, Wu Yizhong

2016, 27(20):  2828-2834. 

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In order to reduce the influences of dynamic driving cycle on economy performance, a multi-objective robust design method for electric vehicle powertrain parameters was presented based on multi-factor driving cycle. With cycle energy consumption, cycle driving range and component cost as comprehensive economy function objectives, battery, motor and transmission parameters as design factors, driving cycle as noise factors, a robust design model for powertrain parameters was proposed, and vehicle performance simulation model was built based on Modelica. A response surface model of cycle simulation was built based on radial basis functions. The uncertainty description of driving cycle was based on probability theory, the design of experiments was carried out to solve the problem. Taking EVBus for example, simulation results show that the means and variances of the comprehensive economy function objectives are improved effectively based on Monte Carlo analysis, which proves the effectiveness of the method.

Nonlinear Dynamics Analysis of  Car Semi-active Suspensions

Song Zuojun

2016, 27(20):  2835-2839. 

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Based on the nonlinear equations of spring, damper and tire, modern nonlinear dynamics theory was applied to analyze the stability of a double-mass suspension model. First of all, based on Hurwitz algebraic criterion, the software of MATLAB was used to calculate, and the double Hopf bifurcation of the suspension system was obtained. Second, the system was reduced to two-dimensional in the light of center manifold theory. The stability of the system was determined using Lyapunov theorem of the first movement stability. At last，the time domain responses and the phase diagrams of spring bearing quality and non spring bearing quality were got, which shows that the processes and results are right, the data was provided for design and control of semi-active suspension systems.