bluuebunny/crossref_metadata_2025 huggingface dataset:
High-Performance Simulation of Mold Filling Using Porous Media Method
Authors: Maeda Yasuhiro ,   Department of Maritime Safety Technology, Japan Coast Guard Academy, Otsuka Yukio ,   Department of Intelligent Mechanical Systems Engineering, Kochi University of Technology
Published: April 2016

The need to speed up calculation and improve analytical accuracy of Casting CAE has grown with optimized casting planning and speeded-up product design. A finite difference method using regular grid of Cartesian coordinates is often used in simulating mold filling because it reduces memory requirements, computation time and easier grid generation. Its disadvantage is that shape expression becomes less precise so that casting slopes and curved surfaces are replaced to stair-step shape. The mold filling simulation developed using porous media method in this paper provides uses two control volume parameters -- porosity rate of grid volume and permeability of grid surface -- to maintain shape expression and analytical accuracy. Results used larger grids than conventionally have with almost the same accuracy as analysis with fine grids. It has also advantages saving on memory and computation time.
Melting Automation Using a Medium-Frequency Induction Furnace
Authors: Morita Arimichi ,   Fuji Electric Thermo Systems Co., Ltd., Kano Toshiyuki
Published: April 2016

Automating the melting process is critical to the economical production of metal castings with stable quality. We discuss manufacturing process monitoring, safety devices, automatic melting operation, and labor-saving furnace refractory construction and dismantling.
Automation of Die Casting
Authors: Tsuji Makoto ,   Die Casting Machine Division, Toshiba Machine Co., Ltd., 4-29-1 Hibarigaoka, Zama-shi, Kanagawa 228-0003, Japan
Published: April 2016

Die-casting is a process to manufacture high-accuracy castings at high productivity using nonferrous metals such as zinc, copper, aluminum and magnesium. Die-casting includes many processes such as lubricant spray to the die, injection of molten metal, taking off the casting from the die, and trimming of unnecessary parts. Nowadays all these processes of die casing can be conducted by fully automated die-casting machines. TOSHIBA MACHINE CO., LTD has taken the lead in development of die-casting machines. Here we will be introducing the common process flow and details of some of major components of the die-casting equipment.
High-Speed Finishing of Hard Gear Teeth with cBN-Tipped Hob
Authors: Umezaki Yoji ,   Faculty of Engineering, Kyushu University, Ariura Yasutsune , Suzuki Toshio , Ishimaru Ryohei ,   Department of Mechanical Engineering, Faculty of Engineering,  Fukuoka University,   Dept. of Mechanical Engineering, Kurume National Collage of Technology
Published: April 2016

The hobbing finish of hard gear teeth such as case-hardened gears is anticipated for practical use in high efficiency production. We studied wear and finished surface properties in cutting tests using a cubic boron nitride (cBN) hob cutter in high-speed cutting at 900 m/min of case-hardened steel. The cBN content in tip ingredients is related to wear, and tips high in cBN content are superior in wear resistance. The high thermal conductivity of cBN tips helps transfer cutting temperature heat to chips, melting and adhering them to the relief surface. Flaking may occur on the cutting edge but new chipping does not occur although chipping may exist after grinding. Finished surface roughness is influenced by horning on the cutting edge. Round horning leads to a smooth surface. High-speed finishing with cBN-tipped hobs is analyzed in view of cBN tip grinding and finished surface properties, in addition to wear properties.
Trajectory Planning of Knife Position of Slitter Robot Based on Identification of Friction and Viscous Damping, and Position Control Experiments
Authors: Kojima Hiroyuki ,   Department of Mechanical System Engineering, Graduate School of Engineering, Gunma University, Orihara Daiki , Matsuda Yamato , Inoue Yusuke , Negishi Hiroyuki ,   Mazda Motor Corporation,   Fujiyuatsu Seiki Corporation
Published: April 2016

In this study, the trajectory planning method of the knife position of a slitter robot is proposed, and the experimental and numerical simulation results are demonstrated. The slitter robot consists of upper and lower knife driving mechanisms, and a knife driving mechanism was constructed with a worm gear, a ball screw and an alternating current (AC) motor. In the trajectory planning, first, the identification algorithm of the friction and the viscous damping is derived by using the equation of motion of the knife drive mechanism and the experimental results of the dynamic response with constant AC motor torque. Then, the trajectory planning algorithm of the knife position is presented, and a knife position control system is constructed. Furthermore, the experiments and numerical calculations have been carried out, and the usefulness of the present trajectory planning method is confirmed.
Multi-Modal Assembly-Support System for Cell Production
Authors: Duan Feng ,   Arai Lab, Intelligent Systems Division, Department of Precision Engineering,  School of Engineering, The University of Tokyo, Morioka Masahiro , Tan Jeffrey Too Chuan , Arai Tamio ,   1st Robot Laboratory, FANUC, Japan
Published: April 2016

Cell production systems meet the diversified production and quantity requirements flexibly. However, their efficiency mainly depends on the human operators' working performance. In order to improve the efficiency of the cell production system, effective assembly-support systems should be developed to assist human operators during the assembly process. In this paper, a multi-modal assembly-support system (MASS) is proposed, which aims to support assembly human operators from both information aspect and physical aspect while meets the actual manufacturing requirements. With the information and physical support from this system, the assembly complexity and burden to the assembly operators are reduced. To evaluate the effect of MASS, a group of human operators are required to execute a cable-insert task. From the experimental results, we can conclude that using this system, the human operators' assembly performance is improved and their mental work load is reduced, which improves the efficiency of the cell production system.
Real-Time Five-Axis Control Based on Digital Copy Milling Concept to Achieve Autonomous Milling
Authors: Shirase Keiichi ,   Dept. of Mechanical Engineering, Graduate School of Engineering, Kobe University, Kobe, Japan, Nakamoto Keiichi , Arai Eiji , Moriwaki Toshimichi ,   Dept. of Mechanical Engineering, Graduate School of Engineering, Osaka University, Osaka, Japan,   Dept. of Materials and Manufacturing Science, Graduate School of Engineering, Osaka University, Osaka, Japan,   Dept. of Industrial and Systems Engineering, Faculty of Engineering, Setsunan University, Osaka, Japan
Published: April 2016

The Digital Copy Milling (DCM) was proposed to achieve autonomous milling, in which tool paths are generated in real time during milling without requiring Numerical Control (NC) programs. In the DCM, a tracing probe and a master model in conventional copy milling are represented by virtual 3D models, and cutter locations are calculated dynamically based on virtual tracing probe movement in real time. Therefore, not only feed speed, but also radial and axial depths of cut are adapted for milling process control. In addition, new tool paths are added to automatically avoid and recover from cutting troubles. In this paper, an added five-axis tool movement control of DCM demonstrated the effectiveness of the DCM concept.
Experimental Analysis of Chatter Vibration in End-Milling Using Laser Doppler Vibrometers
Authors: Nakagawa Heisaburo ,   The University of Shiga Prefecture, 2500 Hassaka-cho, Hikone-shi, Shiga 522-8533, Japan, Kurita Yutaka , Ogawa Keiji , Sugiyama Yuji , Hasegawa Hideyasu ,   Murata Manufacturing Co., Ltd., 2288 Oshinohara, Yasu-shi, Shiga 520-2393, Japan,   Kawasaki Shipbuilding Corporation
Published: April 2016

A problem has emerged during the end-milling of hardened steels: a high frequency chattering phenomenon. On the other hand, a laser Doppler vibrometer has recently been developed to observe such high frequency vibration phenomena. Therefore, we propose a new method of monitoring chattering in the end-milling of hardened steels using laser Doppler vibrometers. The chattering behaviors of the end-mill shank were measured by two laser Doppler vibrometers from the feed and radial directions at the same time during the end-milling of the hardened steel. The following conclusions were reached: (1) Two kinds of chatter vibrations were confirmed as vibration modes whose frequencies differed during high and low cutting speed conditions. (2) The chatter vibrations at the high cutting speeds clearly differed from regenerative chatter, which has only been researched so far, by accurate measurement of chatter vibration modes.
Forming Type Rapid Prototyping Development - Error Compensation with Shape Measurement -
Authors: Tanaka Hidetake ,   Faculty of Engineering, Nagaoka University of Technology, Asakawa Naoki , Hirao Masatoshi ,   Graduate School of Natural Science and Technology, Kanazawa University
Published: April 2016

This study deals with the automation of metal hammering using an industrial robot and trial development of rapid prototyping of sheet metal forming. Computer-aided manufacturing (CAM) takes into account feedback considering tool positioning by using a range finder to improve depth and shape error at workpiece corners. Experimental results confirmed that our proposal reduces shape error through tool positioning optimization.
Optimization of Design and Production Processes of Dies and Molds in Which CAD/CAM the Core Technology
Authors: Watanabe Shinobu ,   R&D Dep't, Computer Engineering Inc.
Published: April 2016

We consider the optimization of the entire process by effectively using CAD/CAM data in each process of various processes that exist in mold/die design and production and in product manufacturing using mold/die.
Development of a Vibration Suppression GUI Tool Based on Input Preshaping and its Application to Semiconductor Wafer Transfer Robot
Authors: Duong Minh Duc ,   Department of Production Systems Engineering, Toyohashi University of Technology, Terashima Kazuhiko , Kamigaki Toshio , Kawamura Hirotoshi ,   New Products Development Laboratory, Shinko Electric Co., Ltd. Toyohashi Plant
Published: April 2016

Speed up movement to increase productivity may cause problems such as vibration. The tool we propose to suppress vibration is based on input preshaping, and its visual graphical user interface makes it easy to use. Testing of the tool at high speed suppressing vibration in a semiconductor wafer transfer robot confirmed the feasibility of our proposal.
Simulator for Reuse of Mechanical Parts with Network Agents
Authors: Hiraoka Hiroyuki ,   Faculty of Science and Engineering, Chuo University, Tanaka Atsushi
Published: April 2016

We propose promoting parts reuse using a part agent consisting of a network agent and radio-frequency identification (RFID) tags to manage parts life cycles, which leads to sustainable production. The part agent advises users on parts reuse and promoting reused parts circulation. We developed a simulator to simulate individual parts behavior in their life cycles. In simulation, a part agent makes decisions based on predicted part behavior and user preference in maintenance handling. A part simulation model represents the behavior of individual parts.
Quasi-Minimum Time Trajectory Planning Method of Robot Arm with Electromagnetic Attraction Hand Using Genetic Algorithm and Experiments
Authors: Mutsuura Yusuke ,   Department of Mechanical System Engineering, Graduate School of Engineering, Gunma University, Kojima Hiroyuki , Takeuchi Yuuichi , Saitou Hiroki ,   Tokyo Rhythm Watch Corporation
Published: April 2016

In this study, a quasi-minimum time trajectory planning method for the electromagnetic attraction transfer control of a magnetic object by use of a three-link robot arm with an electromagnetic attraction hand is proposed. The three joints of the robot arm are driven with reduction gears and DC motors. In the trajectory planning using a genetic algorithm, the magnetic object is assumed to be transferred along a linear trajectory, and the trajectory of the robot arm is formulated by use of a chromosome consisting of two genes. Then, the fitness function of the genetic algorithm for a quasi-minimum time trajectory planning is defined using two kinds of the constraint conditions as to the allowable maximum moment applied to the magnetic object and the allowable maximum DC motor torque. Furthermore, the numerical calculations and the experiments have been carried out, and the usefulness of the present quasi-minimum time trajectory planning method is confirmed theoretically and experimentally.
Intelligent Home-Automation Security System
Authors: Chien Ting-Li ,   Department of Electronic Engineering,  Wu-Feng Institute of Technology, Su Kuo-Lan , Guo Jr-Hung ,   Department of Electrical Engineering, National Yunlin University of Science &Technology,,   Graduate school Engineering Science and technology, National Yunlin University of Science & Technology
Published: April 2016

The objective of the home security detection and appliance control system is to protect occupants against events -- many of which are attributable to human error. We have developed a module based security system for home automation. The structure of the security system is divided into many modules. Each module in the home -- automation security system we develop has a wireless RF and a speech interface. They contain fire detection module, intruder detection module, environment detection module, gas detection module, (AC) power detection and diagnosis module, appliance control module and team robots. In the security detection module, we use multisensor fusion algorithms to decide an exact output. In the application control module, we use two-wire communication via wireless RF interface. These modules have event-condition voice alarms, and send the real-time status to the master controller. In the smart team robot system, we have designed many smart robots for the security system. We have designed a general user interface (GUI) for the intelligent security system. The user interface can supervise these modules and team robots via wireless RF interface, and use wireless Internet and mobile phone for remote supervision.
Study of Printed Circuit Board Inspection System
Authors: Noguchi Masanori ,   Graduate School of Advanced Science and Technology, Tokyo Denki University, Satomi Tadaatsu , Saito Yukio , Tsunoda Okitoshi
Published: April 2016

Presently, the inspection of printed wiring boards includes the conductivity, the capacitance, the appearance inspections, and so forth. There are problems of the conduction defects, the effect of the stray capacitance and the mistaken image in these inspections. In order to resolve these problems, in our research a pin probe with a dielectric substance is produced.
Dynamic Scheduling in Inpatient Nursing
Authors: Cheng Mingang ,   Department of Precision Engineering, the University of Tokyo, Ozaku Hiromi Itoh , Kuwahara Noriaki , Kogure Kiyoshi , Ota Jun ,   National Institute of Information and CommunicationsTechnology,   Knowledge Science Laboratories, Advanced Telecommunications Research Institute International (ATR),   Department of Advanced Fibro-Science, Kyoto Institute of Technology
Published: April 2016

To shorten the notoriously long waits for service in hospitals in Japan and to improve efficiency, we propose a scheduling algorithm with a 2-layer local search based on simulated annealing -- permutating (switching) (i) tasks among nurses and (ii) subtasks on each nurse. The scheduling algorithm generates a solution initializing our proposed dynamic scheduling to iteratively generate new, feasible schedules based on the scheduling algorithm to accommodate interruptions while preventing nurses' work hours from increasing. To verify the effectiveness of our proposed scheduling, we executed a set of nursing scheduling problems taken from those actually observed and focused on those that featuring frequent interruptions.
A Pledge from Automation to Intellimation
Authors: Huang Fred Po-Chih ,   Chairman of Taiwan Association of Machinery Industry
Published: April 2016

Since the Stone Age, when human beings began manufacturing stone instruments and produced fire by striking two stones together, people have attempted to improve their quality of life. Centuries after the Bronze, Iron, and subsequent Ages, the Silicon Age has arrived.

Production started from striking objects only in bare-handed, followed by tool and machine assistance, culminating in today's automated manufacturing-line production. Through thousands of years of improvement leading to reduced production cost, people have learned to saved precious time and begun to enjoy lives surrounded by full of family's love and artful culture.

Through this long evolution, automation first began playing a role in the latter half of the 20th Century.

Entering the late 20th Century, the world has moved from simple automation to intelligent automation. Hardware in the form of machinery and equipment and software in the form of synthesized systems appeared to have responsive ability of primary wisdom of human being.

Given the emphasis among industrial engineers regarding the importance of efficiency and mental ability, or intelligence, I propose the term “intellimation” -- intelligence plus automation -- for designating today's intelligent automation.

This is crucial to promote intelligent automation, and change the automation era to the intellimation era. It can help us to enter the most precious stage in development of automation technology.
Factory Tour of Nidec Servo Co. Ltd.
Authors: Kojima Hiroyuki ,   Mechanical System Engineering, Graduate School of Engineering, Gunma University
Published: April 2016

1. History of Nidec Servo Co. Ltd.

Nidec Servo Co. Ltd. is originated from Turumaki Clock Store founded in Tokyo in 1906, whose clock manufacturing division then developed into Eikosha Co. Ltd. in 1926. Photo 1 shows a wall clock manufactured in Eikosha Co. Ltd. Eikosha Co. Ltd. evacuated from Tokyo to Kiryu City, Gunma Prefecture in 1943 and got shut down in 1949. But forty-eight employees of Eikosha Co. Ltd. voluntarily established a joint venture company, Kiryu Eikosha Co. Ltd., to manufacture industrial equipment in the same year of closure. In 1951 Kiryu Eikosha Co. Ltd. made the best use of the technologies relating to clock gear mechanism in successfully manufacturing servo motors and synchronous motors in Japan, which led to firm establishment of the Company's foundation as a motor maker.
Fast Precision Positioning of a Ball Screw Mechanism Based on Practical NCTF Control
Authors: Sato Kaiji ,   Interdisciplinary Graduate School of Science and Engineering, Tokyo Institute of Technology, Maeda Guilherme Jorge
Published: April 2016

We discuss improvements in a practical nominal characteristic trajectory-following (NCTF) controller for fast positioning. The NCTF controller consists of a nominal characteristic trajectory (NCT) as the movement reference and a PI compensator making object movement follow the NCT. It is easily designed without an exact model, known parameters, or much control theory knowledge. The step speed of NCTF control depends on the NCT. We introduce two ways to construct the NCT for high-speed step movement, - fast positioning is introduced and the performances by two NCTs thus constructed are compared to clarify a more suitable way using two ball screw mechanisms. Experiments in positioning with the NCT by the suitable way are evaluated, whose results show that the NCT increases step speed while preserving the robustness of feature step height and movable mass changes.
Development of Pneumatic Servo Bearing Actuator for Nanometer Positioning
Authors: Kadotani Masato ,   Graduate School of Mechanical Engineering, Doshisha University, Kitagawa Takakazu , Katto Satoshi , Hirayama Tomoko , Matsuoka Takashi , Yabe Hiroshi , Sasaki Katsumi ,   Department of Mechanical Engineering, Doshisha University,   Kyoto University, Osaka Electro-Communication University,   Pneumatic Servo Controls Ltd.
Published: April 2016

The ‘pneumatic servo bearing actuator (PSBA)’ that consists of an aerostatic bearing and a servo valve was proposed and developed for ultraprecise positioning. In the actuator, pressurized air controlled by the servo valve moves an actuated spool ultra-precisely. Even under open-loop control, the PSBA provided accurate replication and positioning resolution on a nanometer order. Applying simple positioning feedback and parallel observation that estimates the disturbance into the system increased the actuator stiffness to be almost infinite and promoted a sharp step response without drift and hysteresis, and thus the minimum positioning resolution of prototype PSBA was about 1 nm.
Fast Positioning of Cutting Tool by a Voice Coil Actuator for Micro-Lens Fabrication
Authors: Noh Young Jin ,   Nanometrology and Control Laboratory, Department of Nanomechanics, Tohoku  University, Nagashima Masayuki , Arai Yoshikazu , Gao Wei
Published: April 2016

This paper describes the design, characteristics evaluation and experiment of a fast tool positioning (FTP) unit driven by a voice coil actuator. Three types of springs for coupling the actuator and the cutting tool, are compared for displacement constant, stiffness, and dynamic response based results of theoretical analysis and experiments. Micro-lens fabrication experiments on an aluminum alloy workpiece are conducted using the FTP with a disc spring, which has a displacement constant of approximately 100 μm/A, a bandwidth of approximately 273 Hz, and a Z direction stiffness of 210 mN/μm.
A Study on Tool Position and Posture Measurement Device by Using Parallel Mechanism
Authors: Ihara Yukitoshi ,   Osaka Institute of Technology, Matsushita Shozo ,   Itoki Corporation
Published: April 2016

The main purpose of this study is to develop a measuring test device by parallel kinematics for measuring a motion accuracy of multiaxis machining centers. The initially developed measuring test device could measure only position of the spindle with three displacement sensors. With the 3DOF device the motion accuracy of machine tools with three-axis was measured. Since the mechanism of the joint was smooth and the sensor resolution was small enough, the measured result showed that the measuring device had an enough performance for the machining centers in normal accuracy. Then the 6DOF measuring test device was developed. It had six displacement sensors and it could measure both position and posture angle of the main spindle. Despite the adoption of parallel kinematics, forward kinematics calculation was possible due to the sophisticated arrangement of sensors, thus the hi-speed data acquisition could be possible.
Amplifying Mechanism Vibration Settling by External Impact Damper
Authors: Henmi Nobuhiko ,   Department of Mechanical Systems Engineering, Faculty of Engineering, Shinshu University, Tanaka Michihiko
Published: April 2016

Displacement amplifying mechanism for piezoelectric actuators using an elastic guide, such as parallel translation with flexure hinges, to avoid solid-friction-induced stick-slip movement has poor damping. Residual vibration lengthens settling time in quick driving. An impact damper uses collision energy rather than friction to dissipate vibration and operates without compromising the flexure guide’s non-stick-slip movement. Impact dampers are divided into external and loading impact dampers. An external impact damper is applied here to settle transient amplifying-mechanism vibration and to determine differences in damping by setting damper conditions appropriately. The impact damper effectively eliminates residual vibration in the step response.
Application of Liquid Bridging Force in Manipulation and Assembly of Microparts
Authors: Koshimizu Shigeomi ,   Advanced Institute of Industrial Technology
Published: April 2016

Development of methods for handling such microparts will increasingly be needed. Microparts are commonly handled by gripping, using tweezers for example. However, this method poses difficulties in quick release, due to static electricity. Here we propose a new handling method based on liquid bridging force. The pick & place method and the assembly method using liquid bridging force for microparts are shown in this paper. Measurement results of liquid bridging force are also described. Effects of parameters such as liquid type, picking up speed and curvature of microparts were investigated.
Influence of Matrix Circuit Switching Device Junction Capacitance on Piezoelectric Actuator Drive Performance
Authors: Furutani Katsushi ,   Department of Advanced Science and Technology, Toyota Technological Institute, Makino Taizo
Published: April 2016

Piezoelectric actuators are widely used as fine-motion actuators for positioning devices. Current pulse driving reduces displacement hysteresis, and the drive circuit provides current pulses considered constant charge pulses to the piezoelectric actuator. The circuit for devices with multiple degrees of freedom using multiple piezoelectric actuators should be simple. Matrix circuits are used to drive liquid crystal displays to reduce the number of drive-circuit control signals and components. A group of 2 × 2 piezoelectric actuators was driven alternately using a 4-switch matrix circuit, and two field effect transistors were used as a fast matrix circuit switch. Piezoelectric actuator drive performance was studied in the case of using the current pulse circuit and the matrix circuit. When the matrix circuit drove actuators performing as capacitive loads, switching device junction capacitors adversely affected drive performance.
Special Issue on Measurement and Control in Machine Tools and Machining Process
Authors: Matsubara Atsushi ,   Department of Micro Engineering, Kyoto University
Published: April 2016

Manufacturing fields in high-income countries have tended to pursue high quality and high productivity together. In conventional machining, however, machine tools, cutting tools, machining process, and measurement technologies have progressed individually rather than together -- mainly due to the production industry configuration.

With society’s needs growing and diversifying, however, development approach that combines distinct technologies without integration no long ensures competitiveness. In a world where knowledge and ideas regarded as know-how and used implicitly, knowledge and ideas should be integrated into explicit software with adequate hardware.

The important issues are as follows:
 (1)Process monitoring technology providing sufficient information for systems to make decisions based on economical investment
 (2)Process control technology based on a deeper understanding of processes themselves and of the nature of control
 (3)Motion control technology for precise, high-speed, versatile movement in support process control

This special issue provides the latest topics related to these issues, and we are sure readers will enjoy reading about and sharing ideas toward a new machine tools and manufacturing technology paradigm.

We thank the authors for their contributions to this special issue and the reviewers and editors for their ongoing efforts.
Development of a High-Performance Spindle for Multitasking Machine Tools
Authors: Yamazaki Taku ,   Development and Design Department, Yamazaki Mazak Corporation, Oguchi-cho, Aichi 480-0197, Japan, Muraki Toshiyuki , Matsubara Atsushi , Aoki Mitsuho , Iwawaki Kenji , Kawashima Kazuyuki ,   Department of Micro Engineering, Kyoto University, Yoshida-honmachi, Sakyo-ku, Kyoto 606-0024, Japan,   Precision Bearing Technology Department, NSK Corporation, 1-5-50, Kugenuma Shinmei, Fujisawa-shi, Kanagawa 251-8501, Japan,   Servo Motor Manufacturing Department, Mitsubishi Electric Corporation, 1-14, Yada-minami 5-chome, Higashi-ku, Nagoya-shi, Aichi 461-8670, Japan
Published: April 2016

In recent years, high-performance spindles are required for multi-tasking machine tools to enhance the productivity. Such spindles enable efficient rough cutting and fine finishing of a workpiece on one machine. In order to meet this requirement, a spindle unit must be highly stiff and operate at high rotational. Spindle specifications require a rotational number of 50,000min-1 and dN value of 3,000,000, a smaller motor was downsized and an electric loss restrained by reducing the thickness of laminate sheets composing the rotor core. A direct-injection type of ultra trace quantity lubrication and a preload switching system were used for ball bearings for high rotational speed and high stiffness. We discuss how these technical requirements were met and the results of basic experiments.
Development of a High Precision Machining Center and its Motion Accuracy
Authors: Oshita Isao ,   YASDA PRECISION TOOLS K.K., 1160 Hamanaka, Satosho-cho, Asakuchi, Okayama 719-0303, Japan, Otsubo Hisashi , Sogabe Masatoyo , Iwashita Yasusuke , Kakino Yoshiaki ,   FANUC LTD, 3580 Oshino-mura, Yamanashi 401-0597, Japan,   Kakino Research Laboratory, Iwakura-Hanazono-cho 256-5, Sakyo-ku, Kyoto 606-0024, Japan
Published: April 2016

In the fabrication of parts and components using dies and molds for optical and/or medical use instruments, there are standing requirements that the accuracy of the form of the final products be maintained within a tolerance of 1.0μm or less and that the roughness of the machined surface be held to 0.2μm Ra or less while high production efficiency is maintained. The required accuracy of form, smoothness of the machined surface, and efficiency of production stated above can be achieved by high precision machine tools, but are beyond the performance properties expected of conventional, general-use machining centers, both of which are readily available on the open market. The authors (hereinafter collectively referred to as “the group”) who did this research agreed to refer to the machining centers that can satisfy both of the above-mentioned performance requirements as “Subject Machining Centers,” or “Subject MC,” while the other machining centers are referred to as “Conventional Machining Centers” or “Conventional MC.” This research includes a structural study of a Subject MC, followed by the actual designing and manufacturing processes of such a Subject MC, It was then subjected to an appraisal of its accuracy of motion from the data obtained through actual measurements, and a verification of the precision attained in the manufacturing process of the lens molds it produced. Through the combined use of a frictionless drive train using a hydrostatic guide and linear motor drive, together with the overall enhancement of the rigidity of the structure of the Subject MC, the following results were achieved.

1.Straight line motion accuracy with a deviation of 0.2μm/100 mm or less was attained. Also, the roundness of 0.36μm of the arc interpolation movement was achieved, confirmed with a grid encorder. (“Roundness” in this study is defined as the magnitude of the deviation of either an arc or a circle as measured against their geometrically correct counterparts.)

2.As a position loop gain as high asKp= 140/s was attained with the servo mechanism adopted, it was confirmed that the actual use of the micro step feed at uniform separations of 10 nanometers had become possible.

3.It became possible to mold a lens with a roundness of 0.53μm and a surface roughness of 0.05μm Ra after machining. (“Ra” denotes the arithmetical average of surface roughness after machining.)
Special Issue on on Biomanufacturing
Authors: Mitsuishi Mamoru
Published: April 2016

The creation of innovative medical and welfare machines is indispensable to assuring the health, comfort, safety and security of citizens. In the biomedical area, manufacturing and automation technologies are essential in making these new technologies affordable, and there are many application areas where these technologies can contribute. Such application areas include medical processes, biomedical systems and human-machine interfaces. Papers were collected on these areas to organize this special issue on biomanufacturing. The first paper relates to dental treatment using a laser, the second paper discusses a droplet system using a magnetically-driven microtool and the third paper describes artificial bone manufacturing using 3D inkjet printing. These three papers relate to processes and the subsequent papers are related to systems. These systems-oriented papers include a medical CAD/CAM system for minimally invasive surgery and an irradiation therapy system. In addition, papers related to blood pressure simulation and the technologizing and digitalization of medical skills are included. These are all useful in the design of medical systems. Finally, papers for rehabilitation systems using ER and MR fluids, and a paper on mental stress in manufacturing assembly workers are presented. I would like to express my sincere thanks to all of the authors and reviewers of these papers.
Medical and Nuclear Applications of Micro Electron-Beam Linear Accelerator X-Ray Sources
Authors: Hashimoto Eiko ,   The Department of Nuclear Engineering, School of Engineering, The University of Tokyo, 2-22 Shirakatashirane, Tokai, Naka, Ibaraki 319-1188, Japan, Yamamoto Tomohiko , Natsui Takuya , Koyama Kazuyoshi , Demachi Kazuyuki , Uesaka Mitsuru , Nakamura Naoki , Yamamoto Masashi , Tanabe Eiji ,   Accuthera Inc., 2-7-6 Kurigi, Asaoku, Kawasaki-city, Kanagawa 215-0033, Japan
Published: April 2016

Our group is engaged in creating an innovative system in which an X-band linac X-ray source and 12TW50fs laser technologies are applied to medical and nano-technical uses. As pioneers in medical physics for reliable and safe medical radiology, we have endeavored to develop advanced laser beam technologies for cross-sectional and fused applications in the humanities and natural sciences to yield new synergies. This paper describes the developmental outcomes we have achieved to date.
Clinical Tests for Detecting Synergy Movements and Clinical Understanding of Stroke Patients Using PLEMO System with Sensor Grip Device
Authors: Ozawa Takuya ,   Kano General Hospital, 7-5-15 Tenjinbashi, Kitaku, Osaka 531-0041, Japan, Kikuchi Takehito , Furusho Junji , Fukuda Kazuki Fukushima Takahiro , Tanida Sosuke , Fujikawa Takamitsu , Kano Shigeaki ,   Graduate School of Engineering, Osaka University, 2-1 Yamadaoka, Suita, Osaka 565-0871, Japan,   Shiga School of Medical Technology, 967 Kitasakachou Higashiohmishi, Siga 527-0145, Japan,   Department of Health Sciences, Bukkyo University, 96 Kitahananobouchou, Murasakino, Kitaku, Kyoto 603-8301, Japan
Published: April 2016

We have developed PLEMO to assist hemiplegic stroke patients in upper-limb rehabilitation using a passive haptic device with electrorheological (ER) fluid brakes. The PLEMO has no moving parts, ensuring safe rehabilitation assistance in the clinical setting. The previously reported version of the PLEMO can determine the operating force and the displacement of the grip by using conventional sensor devices; however, it was not enough to provide information evaluating stroke patient motor function. To cover such shortcomings of the conventional systems, we developed a new grip and motor-functional evaluation software that detects synergy, a symptomatic feature in stroke patients. In clinical evaluation of 14 stroke patients - two Brunnstrom Recovery Stage III, three Stage IV, and nine Stage V - we studied the correlation between PLEMO evaluation and rehabilitation evaluation, and found a strong correlation between them, e.g., changes in wrist movement range and table-reaction force provided useful information on stroke severity.
Proposed Isocontraction Training with Muscle Strengthening and Evaluation Using MR Fluid Brakes
Authors: Oda Kunihiko ,   Dept. of Physical Therapy, Osaka Electro-Communication University, 1130-70 Kiyotaki, Shijonawate, Osaka 575-0063, Japan, Kikuchi Takehito , Oyama Yuki , Furusho Junji ,   Graduate School of Engineering, Osaka University, 2-1 Yamadaoka, Suita, Osaka 565-0871, Japan
Published: April 2016

Isokinetic exercises used in rehabilitation to strengthen muscles often require expensive exercise equipment. The safe isokinetic exercise system we developed uses only brakes with electrorheological (ER) or magnetorheological (MR) functional fluid. Rapid fluid response gives this equipment good response and control. In the sections that follow, we give basic isokinetic exercise concepts using an MR fluid brake, focusing on high-speed control of 900 deg/s at the elbow. We also suggest a new training mode we call isocontraction exercise.
Special Issue on Robotic Technology to Extend Workers' Physical Abilities and Skills
Authors: Moromugi Shunji , Noritsugu Toshiro
Published: April 2016

Robot-related technologies originally developed to cut the manufacturing industry workforce in the 1970s and 1980s produced many excellent high-quality products, high production efficiency, and reduced cost.

As consumer requirements changed, however, the guiding principle in industry shifted from mass production of single components to diversified small-lot “job shop” production favoring expert skills over mechanical automation due to higher efficiency and improved production line quality.

Demands for higher technical efficiency and a reduced burden on human physical labor gained recognition, opening up a new scope of robot activities as the focus changed from replacing human workers to expanding personnel capabilities and skills through robot “power assist” support.

Power assist techniques have just begun practical use in manufacturing fields. This special issue focuses on the new robotic technologies implemented to extend human capabilities and skills.

The first paper introduced discusses safety technology for a power assist system and the second a mobile robot manipulator using impedance control. Paper No.3 relates kinesthetic assist for improving window glass installation on a car production assembly line and No.4 proposes control automatically optimizing a power assist system’s viscosity. Paper No.5 deals with power assist control using human weight perception. The sixth paper describes wire-suspension-based transfer with power assist and the seventh power assist for moving flexible objects. Papers 8, 9, and 10 cover the development of wearable support systems targeting assembly line personnel, farmers, and racehorse trainers. Paper No.11 reports the development of a sensor monitoring pneumatic artificial muscle activation. The closer in this series proposes synchronization-based control for motion assist suits. This special issue thus includes many high-quality papers covering a wide variety of power assist topics reflecting the many viewpoints and expertise of their authors.

In closing, we express our sincerest gratitude to the authors, researchers, and staff who took part in compiling studies and presentations. We also thank the publishers and all those who contributed in so many ways to this issue’s publication.
Human-Robot Cooperative Handling Using Variable Virtual Nonholonomic Constraint
Authors: Takubo Tomohito ,   Department of Systems Innovation, Graduate School of Engineering Science, Osaka University, 1-3 Machikaneyama, Toyonaka, Osaka 560-8531, Japan, Arai Hirohiko , Tanie Kazuo , Arai Tatsuo ,   National Institute of Advanced Industrial Science and Technology (AIST), 1-2 Namiki, Tsukuba, Ibawraki 305-8564, Japan,   Faculty of System Design, Metropolitan University, 6-6 Asahigaoka, Hino, Tokyo 191-0065, Japan
Published: April 2016

In proposing variable nonholonomic constraint for cooperative human-robot handling, we deal with nonholonomic wheel movement manipulated intuitively by the use. We propose implementing virtual nonholonomic constraint in robot grasping, enabling users to transfer objects, similar to using a wheelbarrow, without slipping. Transporting objects accurately in a fixed constraint point requires skill, so we propose preparing multiple constraint points to be selected based on the situation. We apply this to a mobile manipulator, confirming feasibility experimentally.
Muscle Suit Development and Factory Application
Authors: Kobayashi Hiroshi ,   Department of Mechanical Engineering Tokyo University of Science, 1-14-6 Kudankita, Chiyoda-ku, Tokyo 102-0073, Japan, Aida Takamitsu , Hashimoto Takuya
Published: April 2016

Technological progress has liberated most industrial personnel in developed nations from heavy lifting tasks. Such work remains largely unchanged, however, in the fields of agriculture, manufacturing, and construction, among others. Such tasks are an important issue due to their potential for triggering work-related musculoskeletal disorders. The use of the McKibben artificial muscle has opened the way to the introduction of “muscle suits” - compact, lightweight, reliable, wearable “assist-bots” enabling factory personnel to lift and carry weights greater than conventionally possible.
Control Variables for Food Slicing Supporting Cooking and Improved Operation
Authors: Osawa Fumiaki ,   Department of Electrical and Electronic Engineering, Daido University, 10-3 Takiharu-cho, Minami-ku, Nagoya 457-8530, Japan
Published: April 2016

This study focuses on robot-supported cooking in which a robot slices food with a knife. Food such as fish, meat, fish paste products, and bread dough have rheological properties - quantitative and qualitative relationships between deformation and stress and their derivatives [1]. Cutting techniques appropriate to individual materials preserve fiber and cell tissues on the cutting surface. We introduce basic and supplementary control variables for robot food slicing, demonstrating the qualitative relationship between supplementary control variables and cutting force and that operations are improved by adjusting control variables based on inner force information at cutting.
Man-Machine Interface for Human-Robot Collaborative Cellular Manufacturing System
Authors: Tan Jeffrey Too Chuan ,   Arai Laboratory, Intelligent Systems Division, Department of Precision  Engineering, School of Engineering, The University of Tokyo, 7-3-1 Hongo, Bunkyo-ku, Tokyo 113-8656, Japan, Duan Feng , Kato Ryu , Arai Tamio
Published: April 2016

In a human-centered cellular manufacturing system, various machines, including robots, are implemented to support the human operator with the goal of improving overall productivity. In order to ensure the effectiveness of such a system, an effective man-machine interface (MMI) plays an important role in ensuring collaboration and safety, and providing assembly information support. Using a task analysis approach, the assembly operation is broken down into a hierarchical task structure and remodeled for collaboration. In the modeling, appropriate operation properties are extracted as assembly information and, together with reference media in various formats, multimedia support information is produced. The assembly information support is presented on a workbench incorporating a horizontal LCD TV display, and the human operator interacts with the operation control system through a GUI on a touch screen monitor. To ensure collaboration safety, the control system monitors input from safety sensors, an operator safety monitoring system, and robot control. A system performance evaluation study has proven the effectiveness of the system in improving collaborative operation.
Precision Component Technologies for Microfactory Systems Developed at KIMM
Authors: Park Jong-Kweon ,   Nano Convergence and Manufacturing Systems Research Division, Korea Institute of Machinery and Materials (KIMM), 171 Jang-dong, Yuseong-gu, Daejeon 305-343, Korea, Ro Seung-Kook , Kim Byung-Sub , Shin Woo-Cheol , Lee Hyeon-Hwa
Published: April 2016

This paper presents some of the recent research activities in the ongoing project for the development of high-tech component technologies for Microfactories at the Korea Institute of Machinery and Materials. Component technologies for Microfactory systems are key technologies for future development in this area, both in the R&D and industrial sectors, since many components are not currently available on the market. In this project, some key component technologies for Microfactory systems were chosen for development: multi-axis miniature air-bearing stages (including a planar motion stage), miniature high-speed spindles using air and magnetic bearings, shape memory alloy-based clamping devices for micro-tools and workpieces, optical multi-axis sensors for monitoring micro-tools and spindle rotation, and a numerical control system for the realization of flexible control algorithms. The design concepts and results for selected component technologies are briefly illustrated in this paper.
Dynamic Controls of Genetic Algorithm Scheduling in Supply Chain
Authors: Chai Jia Yee ,   Graduate School of Engineering, Kobe University, 1-1 Rokkodai, Nada-Ku, Kobe 657-8501, Japan, Sakaguchi Tatsuhiko , Shirase Keiichi ,   Toyohashi University of Technology, 1-1 Hibarigaoka, Tempaku-cho, Toyohashi-shi, Aichi-ken 441-8580, Japan
Published: April 2016

In a supply chain environment, reactive scheduling process has to deal with both operational objective (minimizing total tardiness) and business objective (accommodating a new order into the current schedule). Genetic algorithm (GA) optimization has been applied in such reactive scheduling problem for job shop style manufacturer in our previous researches. An algorithm is introduced to dynamically adjust the objective function of GA optimization to minimize cost of delay penalties and to maximize the number of contracts captured by the manufacturer. The effectiveness of the proposed model is demonstrated by computational experiments.
Development of Neural-Net-Based Decision Support System for Mattress Patterns Using Particle Swarm Optimization
Authors: Kato Mitsue ,   Teisei Gakuen Junior College, 1-26-13 Kohinata, Bunkyo-ku, Tokyo 112-8630, Japan, Yamamoto Toru ,   Hiroshima University, 1-1-1 Kagamiyama, Higashi Hiroshima, Hiroshima 739-8511, Japan
Published: April 2016

The particle swarm optimization (PSO) concept simulating a simplified social milieu, is optimization useful for solving nonconvex continuous optimization problems. We discuss a new learning algorithm for simultaneously adjusting connection weights in neural networks and user-specified parameters included in units. Based on our algorithm, neural network learning, e.g., learning cost or adaptability, can be improved, as demonstrated in mattress decision support system.