bluuebunny/crossref_metadata_2025 huggingface dataset:
Surface Inspection of Micro Glass Lens Mold Based on Total Angle Resolved Scattering Characterization
Authors: Hayashi Terutake ,   Department of Mechanical Engineering, Graduate School of Engineering, Osaka University, 2-1 Yamadaoka, Suita, Osaka 565-0871, Japan, Takaya Yasuhiro , Motoishi Naohiro , Nakatsuka Yuki
Published: April 2016

The condition of the lens mold surface becomes worse due to several defects that are caused in the lens production process as the number of lens shots increases. An on-machine quantitative evaluation method is required for the lens mold surface. In this study, we have developed an automated light scattering measurement system that enables 3-D detection of the scattered light in various directions caused by flaws and roughness in order to characterize the surface texture and manufacture a high quality lens. The surface characteristic of the lens mold is classified using the scattered patterns. This paper describes the quantitative evaluation results of the surface nano texture for characterizing the spherical lens mold with varying shot numbers.
Optimization of Motion Control in High-Speed Servo Press Line
Authors: Taoka Hideki ,   Honda Engineering Co.,Ltd., 6-1 Hagadai, Haga-machi, Haga-gun, Tochigi 321-3395, Japan, Nobuta Hiroyuki , Meguri Hideo , Kageyama Yoshihiro
Published: April 2016

Honda Engineering Co., Ltd. developed an innovative servo press line that achieves the world’s highest level of productivity in producing deep-drawn automotive body panels. The innovative press production system was made so that the press forming conditions and panel transfer motions are adjusted to the dies very accurately for each part to be produced. The servo press line is planned to be expanded to Honda’s production plants on a global scale while allowing further evolution.
Development of High-Acceleration and Ultra-Precision Linear Motor Driven Machining Center and its Characteristics
Authors: Nakamoto Kazuo ,   Sodick Co., Ltd, 1-5-1 Shinyokohama, Kouhoku-ku, Yokohama, Kanagawa 222-0033, Japan, Matsumoto Shinichi , Anzai Masahiro ,   Shibaura Institute of Technology, 3-9-14 shibaura, minato-ku, Tokyo 108-8548, Japan
Published: April 2016

We have developed machining centers, equipped with damping mechanism, for precision molds, which can not only suppress vibrations during high-acceleration driving of the machine but also perform high-precision and high-efficiency machining in micro regions. We have also achieved automatic exchanges of tools by employing ultrafast rotating main shafts with air hydrostatic bearings and automatic shrinkage fitting methods, as well as we have realized automated operations of the machine by integrating work with tool-measuring system.
An Application of the Modified PID Control System for Heat Flow Experiment
Authors: Hagiwara Takaaki ,   Department of Mechanical System Engineering, Gunma University, 1-5-1 Tenjincho, Kiryu, Gunma 376-8515, Japan, Yamada Kou , Murakami Iwanori , Ando Yoshinori , Matsuura Shun , Aoyama Satoshi
Published: April 2016

The Proportional-Integral-Derivative (PID) controller structure is the most widely used in industrial applications thanks to its structural simplicity and applicability in solving practical control problems. It is not, however, almighty. Yamada and Hagiwara proposed design modified PID controllers to make control for any plant stable and make admissible sets of P, I, and D parameters mutually independent. Applying modified PID control to practical plants requires that the influence of disturbance in the plant be considered. In many cases, this disturbance is unknown, making it difficulty to attenuate. Although designs have been proposed for modified PID control to attenuate unknown disturbances, little has been done in examining the attenuation of unknown disturbances. We demonstrate the effectiveness of modified PID control in attenuating unknown disturbances for temperature control in heat flow experiments.
Rescheduling of Train Shunting in Railway Stations
Authors: Sugi Masao ,   Department of Mechanical Systems Engineering, Graduate School of Engineering, Tokyo University of Agriculture and Technology, 2-24-16 Naka-cho, Koganei-shi, Tokyo 184-8588, Japan, Nagai Hidetoshi , Yamamoto Masashi , Shiomi Yusuke , Ota Jun ,   Systems Research & Development Center, Solutions Corporation, 3-1 Minatomirai 3-chome, Nishi-ku, Yokohama-shi, Kanagawa 220-8401, Japan,   Research into Artifacts, Center for Engineering (RACE), The University of Tokyo, 5-1-5 Kashiwanoha, Kashiwa, Chiba 277-8568, Japan
Published: April 2016

This paper is intended to propose rescheduling rules for train shunting in railway stations in the event of delayed arrival of trains or some problems with resources, such as tracks. In particular, we propose an algorithm using the Affected Operation Rescheduling (AOR) approach in combination with appropriatelytimed operational commutation rules to allow for rapid rescheduling operations. In the problem of the magnitude of six resources (i.e. tracks and lines) and four trains, the proposed algorithm has accomplished in about 1 millisecond train-rescheduling operations in the event of a train problemon a certain track, proving the feasibility of the obtained solutions as well as the effectiveness of the proposed algorithm.
Robust Digital Control of DC-DC Power Supply with Remote Sensing
Authors: Kajikawa Tatsuyoshi ,   Department of Electronic Engineering and Intelligent Systems, The University of Electro-Communications, 1-5-1 Chofu-ga-oka, Chofu, Tokyo 182-8585, Japan, Takegami Eiji , Higuchi Kohji , Nakano Kazushi , Tomioka Satoshi ,   TDK-LAMBDA, 2701 Togawa, Settaya, Nagaoka 940-1195, Japan
Published: April 2016

If the lines which connect the output terminal of a DCDC converter and the load are long, the voltage actually crossing to the load will change greatly due to the impedances of the lines, producing drops in voltage. In this paper, a separate terminal apart from the output terminal of DC-DC converter senses the voltage across to the load, and it leads it to the load. As a result, the voltage across to the load is adjusted so that it does not experience large changes. This method is called remote sensing. When the lines become long, the usual method of adjusting the voltage across to the load cannot sufficiently suppress changes in it. In this paper, a robust digital controller to suppress the change in the voltage across the load is proposed. Experimental studies using DSP demonstrate that this type of digital controller successfully suppresses it.
Realization of Real-Time Balancing of a Machine Tool Spindle Using Magnetic Fluid
Authors: Nakamoto Keiichi ,   Department of Mechanical Engineering, Osaka University, 2-1 Yamada-oka, Suita, Osaka 565-0871, Japan, Nakatsuji Hidenori , Mitsuhashi Shinya , Shirase Keiichi ,   Department of Mechanical Engineering, Kobe University, 1-1 Rokko-dai, Nada, Kobe 657-8501, Japan,   Mitsubishi Heavy Industries, Ltd.
Published: April 2016

Tool vibration shortens tool life and lowers the quality of the machined surface. Even a small mass imbalance in the spindle and tooling generates tool vibration. Additionally, in machining operations, different tooling setups including the cutting tools rotate at different speeds for each machining operation, making it difficult to reduce tool vibration. In order to solve the problem, real-time balancing using magnetic fluid was proposed in our previous study. Magnetic fluid is a type of smart fluid comprised of a stable colloidal suspension of magnetic nanoparticles in a liquid carrier, and its viscosity and behavior are precisely controlled by changes in magnetic field intensity. To compensate for the mass imbalance of a spindle and tooling in real-time, the magnetic fluid enclosed inside the spindle is controlled to alter the distribution of circumferential mass by adjustments in the intensity of the magnetic field made from outside the spindle. Thus, tool vibration, which changes frequently depending on tooling during various machining operations, can be reduced successfully. In this paper, a machine tool spindle with the proposed real-time balancing is developed, and several experiments are conducted. It is confirmed that the mass imbalance in the entire rotating system is significantly reduced in real-time, and tool vibration is effectively suppressed as well.
Integral Sliding Mode Control for Fast Tool Servo Diamond Turning of Micro-Structured Surfaces
Authors: Yu De Ping ,   Department of Mechanical Engineering, National University of Singapore, 1 Engineering Drive 2, NUS, Singapore 117576, Singapore, Hong Geok Soon , Wong Yoke San
Published: April 2016

Fast Tool Servo (FTS) diamond turning is a promising machining process for fabricating high precision micro-structured surfaces. However, the dynamics of FTS affects its performance and causes form error in the machined surfaces, thus shortening the useful bandwidth of the FTS for precision machining. In this paper, an Integral Sliding Mode Control (ISMC) algorithm is proposed to control the FTS in order to achieve the desired closed-loop dynamics. The robustness of the ISMC to disturbance and model uncertainties or variations is ensured by the implementation of disturbance estimation and an integral switching control action. The influence of the FTS dynamics can thereby be minimized by modifying the tool path offline with the inverse of the desired dynamics. Experiments on machining of typical micro-structured surfaces show that the proposed method is effective in reducing the FTS dynamics induced form error in the machined surface.
Milling of Micro Grooves on Glass Cylinder Surfaces
Authors: Matsumura Takashi ,   Tokyo Denki University, 2-2 Kanda Nishiki-cho, Chiyoda-ku, Tokyo 101-8457, Japan, Ueki Yoshihito
Published: April 2016

Micro milling is presented to machine micro grooves on a glass cylinder surface in a depth of cut of more than 10 µm. The milling tool is inclined in the cutter feed direction to finish fine surfaces in the operation. The effect of tool inclination on the cutting process during a rotation of the cutter is discussed in an analytical model. A 4-axis machine tool is developed to machine the micro grooves using the rotational and the linear motions. The cutting position on the cylinder surface is controlled to incline the milling tool in the cutting direction. Machining processes with a linear control in the longitudinal direction, with a rotational control of the workpiece, and with a simultaneous control of those motions are verified on the machine developed. Adjustment of workpiece alignment and pre-finishing are required for a high machining accuracy in the cutting operation. A feed rate of less than 0.24 mm/min is required to finish crack-free surfaces in cutting of fused silica.
Calibration of Articulated Arm Coordinate Measuring Machine Considering Measuring Posture
Authors: Hamana Hiroyuki ,   Tokyo Denki University, 2-2 Kandanishiki-cho, Chiyoda-ku, Tokyo 101-8457, Japan, Tominaga Mitsushi , Ozaki Miyu , Furutani Ryoshu
Published: April 2016

Three-dimensional Coordinate Measuring Machines (CMMs) are widely used to measure wide-ranging accuracy. Parameters describing CMM use mechanisms must be calibrated by measuring artifacts for the target CMM. Most CMM calibration studies have covered orthogonal rather than non-orthogonal CMMs. We focused on calibration for a nonorthogonal articulated-Arm CMM (ACMM), which has more measurement freedom than an orthogonal CMM, although ACMM measurement error exceeds that of orthogonal CMMs. The kinematic parameters of ACMM are calibrated using spherical center coordinates as the artifact. Part of the measuring volume is calibrated, but the ACMM is not sufficiently calibrated. To calibrate arm deformation in different measurement posture as well as kinematic parameters, we produced a new artifact for which we propose calibration confirmed in experiments.
Measurement of Long-Term Dimensional Stability of Glass Ceramics Using a High-Precision Line Scale Calibration System
Authors: Takahashi Akira ,   Instruments Company, Nikon Corporation, 471 Nagaodai, Sakae, Yokohama, Kanagawa 244-8533, Japan
Published: April 2016

Length measurement was conducted for two years on glass ceramics, Zerodur®and Clearceram®, which have a low coefficient of thermal expansion, and on synthetic quartz. Commercially available glass ceramics were used for evaluating long-term stability, or secular change. Synthetic quartz ensured longterm length measurement stability. Two line scales of 300 mm length made of each material for a total of six line scales were simultaneously manufactured and measured to evaluate dimensional stability variation of the materials over time. Measurements were conducted with a line scale calibration systemdeveloped by Nikon. The calibration system is a onedimensional laser interferometer, featuring reduced Abbe’s errors, laser interferometer paths in a vacuum and real-time wavelength calibration of laser frequency using a 633 nm iodine-stabilized He-Ne laser. Long-term quartz stability was 4.3 nm and 5.4 nm (2σ). The yearly stability coefficients of the two glassceramic scales were -0.22 and -0.23 parts per million per year (ppm/yr) for Zerodur and -0.16 and -0.16 ppm/yr for Clearceram. No significant difference in stability between the two scales was observed for Zerodur or Clearceram.
Evaluation of Pitch Deviations with Comprehensive Representation Suitable for Engagement Evaluation in Different Types of Gears
Authors: Kurokawa Syuhei ,   Faculty of Engineering, Kyushu University, 744 Motooka, Nishi-ku, Fukuoka 819-0395, Japan, Ariura Yasutsune , Doi Toshiro
Published: April 2016

Gear tooth flank deviations should be characterized to evaluate individual gear accuracy directly linked to gear performance during engagement. The comprehensive pitch deviation representation we propose is calculated using multiple tooth flank surface deviations as 0-order form deviations. In this representation, pitch error is expressed by angle unit, not by length unit, and calculated from measured conventional deviation (profiles and leads) withoutmeasuring pitch deviation. For spur and helical gears, pitch deviation is expressed by a single length unit and also by a single angle unit. On the other hand, for bevel gear flank, pitch deviation expressed by length unit consists of many different values even on a single flank. Using the angle unit expression, form deviation is described exactly by a single parameter. The comprehensive representation we propose overcomes the disadvantages of conventional pitch deviation evaluation, going right to the point of gear engagement evaluation.
Laser Interferometric Measuring Method of Involute Artifact and Stabilization of Measurement
Authors: Komori Masaharu ,   Kyoto University, Yoshidahonmachi, Sakyo, Kyoto 606-8501, Japan, Takeoka Fumi , Kubo Aizoh , Fujio Hiroshige , Ito Takehiro , Osawa Sonko , Sato Osamu , Takatsuji Toshiyuki ,   National Metrology Institute of Japan (NMIJ), National Institute of Advanced Industrial Science and Technology (AIST), Tsukuba, Ibaraki, 305-8563, Japan
Published: April 2016

Vibration and noise are serious problems with involute spur and helical gears used, e.g., in drivetrains of vehicles such as automobiles. The gear tooth flank form of micrometer order markedly affects gear vibration and noise; therefore, the tooth flank form quality must be strictly controlled to maximize gear performance. Tooth profile measuring machines used in calibration for form error inspection of involute gears usually use an involute artifact, which itself must be calibrated highly accurately. However, it is typically difficult for current tooth profile measuring machine using contact stylus to calibrate the involute artifact with a high accuracy while satisfying traceability to a national standard. A highly precise and traceable measuring technology for the involute artifact is therefore required. The direct measurement of the involute artifact we propose uses a laser interferometer, whose measurement stability is confirmed in experiments measuring the detailed form of an involute tooth flank.
Profile Measurement of Polished Surface with Respect to a Lattice Plane of a Silicon Crystal Using a Self-Referenced Lattice Comparator
Authors: Fujimoto Hiroyuki ,   National Metrology Institute of Japan, National Institute of Advanced Industrial Science and Technology (NMIJ/AIST), AIST Tsukuba Central 3, 1-1-1 Umezono, Tsukuba, Ibaraki 305-8563, Japan, Waseda Atsushi , Zhang Xiaowei ,   Photon Factory (PF), High Energy Accelerator Research Organization (KEK), 1-1 Oho, Tsukuba, Ibaraki 305-0801, Japan
Published: April 2016

A method is proposed for performing surface profile measurements with respect to a reference plane defined by the lattice plane of a silicon single crystal. In this method, a surface normal to a polished plane is detected using an optical autocollimator and the direction normal to the lattice plane is sensed by X-ray diffraction. The relationship between these planes can be determined if the polished plane is connected to the single crystal. In the measurement system, the mirror and the silicon single crystal are attached backto-back. A monochromatized synchrotron radiation X-ray beam is incident on the single crystal and two detectors are used to measure diffracted X-rays. An optical autocollimator placed near the mirror is used to monitor the inclination of the mirror. The normal direction of the crystal lattice plane is obtained from two diffractions from equivalent reciprocal lattice points. The normal to the mirror is taken to be the angle measured by the autocollimator when the two diffractions are observed. Test experiments have been performed using the self-referenced lattice comparator established at beamline BL3C of the Photon Factory, KEK. The proposed method is discussed by comparing the surface profile of the mirror measured with this system with that measured using a Fizeau interferometer.
Investigation on Slurry Flow and Temperature in Polishing Process of Quartz Glass Substrate
Authors: Khajornrungruang Panart ,   Department of Mechanical Information Science and Technology, Kyushu Institute of Technology, 680-4 Kawazu, Iizuka-shi, Fukuoka 820-8502, Japan, Wada Nagisa , Kimura Keiichi , Yui Ryuji , Suzuki Keisuke
Published: April 2016

A fluorescent agent was used instead of slurry to visualize the flow of slurry, the polishing liquid solution supplied in Chemical Mechanical Polishing (CMP). Under ultraviolet irradiation, the fluorescent agent emits light, which performs the flow of the slurry under the quartz glass, which is applied as a photomask substrate in Flat-Panel Display (FPD) manufacturing. The emitted light was observed with a digital camera. Compared to a round shape of quartz glass substrate, a large amount of fluorescent agent supplied was taken away by the straight edges of the quadrilateral geometry of the substrate and moved to the outer edge of a polishing pad placed on a platen. The fluorescent agent that was taken away by the quadrilateral geometry also remained as several uneven spiral patterns on the polishing pad when the revolution speeds both of the quadrilateral substrate and the platen, which are practically set at same or almost revolution speed, were not sufficient. Next, when the quadrilateral substrate rotated at high revolution speed (60 min-1), the fluorescent agent flowed most evenly and spread throughout the entire substrate area in the shortest time. Finally, a combination of thermocouples and a wireless signal transmission system is introduced to investigate the temperature in glass substrate CMP process.
New Detection Technique for Timing of Contact and Noncontact of Athlete’s Foot with the Ground in Sports
Authors: Kurita Koichi ,   Department of Electrical Engineering and Information Science, Kochi National College of Technology, 200-1 Monobe-otsu, Nankoku-shi, Kochi 783-8508, Japan
Published: April 2016

The effective noncontact strategy we developed analyzes motion in sports, for example, by measuring the current generated by changes in capacitance between an electrode and the athlet’s body, i.e., detecting subpicoampere-level electrostatic induction current flowing through an electrode 3 m from a subject. This occurrence model generates current based on changes in the body’s electric potential. This model effectively explains the induction current flowing through the electrode. This detects foot contact with the ground, e.g., during a baseball game, enabling us to quantitatively estimate contact timing.
Diamond Tool Wear in the Ultra-Precision Cutting of Large Electroless Nickel Coated Molding Dies
Authors: Shinozaki Akira ,   Chubu University, 1200 Matsumoto-cho, Kasugai-city, Aichi 487-8501, Japan, Namba Yoshiharu
Published: April 2016

In recent years, in a field of space science, large and high precision aspherical molding dies which are used to make aspherical thin foil mirrors for the hard Xray telescope are needed. Therefore to establish the ultra-precision cutting method for these dies is overly expected. In the actual manufacturing, the largemolding die is required to have both high accurate shape accuracy and very small surface roughness as the finished product. To machine the large molding die which has these high accuracies, we should know factors to cause various errors such as shape error and surface roughness and so on. Because it is necessary to machine the large molding die by using NC machining system that automatically corrects shape error finally. Especially, the tool wear of diamond tool is one of the big factors that influences shape error and surface roughness, so it needs to correct the amount of tool wear while ultra-precision cutting of large molding dies. From these points of view, in this research, a tool wear of diamond tool which is used in the ultra-precision cutting of large electroless nickel coated molding dies is considered with an on-machine measurement and observation system.
Patterned Self-Assembly of Fine Particles as a Proposal of Precisely Allocated Cutting-Edge Tool
Authors: Moronuki Nobuyuki ,   Faculty of System Design, Tokyo Metropolitan University, Japan, 6-6 Asahigaoka, Hino, Tokyo 191-0065, Japan, Kaneko Arata , Takada Ken’ichiro
Published: April 2016

This paper discusses fine-particle self-assembly and its potential applications to abrasive tools. Dispensing suspensions containing particles on substrates, packed structures are self-assembled as solvent evaporates. Applying relative motion between the dispenser and substrate produces patterned assembly without the need for a mask. Silica particles 1 µm in size were typically assembled along lines 20 µm-100 µmwide. Diamond particles were also assembled because these also act as the cutting edge of abrasive tools. Assembled particles were transferred to another substrate using ultraviolet curing resin. The particle edge height was aligned at the same level independent of the assemblylayer number - the key to this process.
Influences on Occurrence of Magnetism During Cutting Processes
Authors: Bähre Dirk ,   Institute of Production Engineering, Saarland University, Campus A4.2, 66123 Saarbrücken, Germany, Trapp Kirsten , Tschuncky Ralf ,   Fraunhofer Institute of Non-Destructive Testing (IZFP), Campus E3.1, 66123 Saarbrücken, Germany
Published: April 2016

Workpieces from ferromagnetic materials influenced by machining can build magnetic fields, which can cause problems in production or application. One of the assumed causes of magnetism occurring in cutting processes is the change in the material structure due to the impact of the tool. To study these influences, milling tests are carried out. The magnetic field is measured by means of sensors functioning on the basis of the Hall effect. The coherences between geometry, kinematics, technological parameters, time dependency, and the magnetisation characteristics of the workpiece are considered.
Numerical Analyses of Turning-Induced and Mapped Ti6Al4V Residual Stresses for a Disc Subjected to Centrifugal Loading
Authors: Afazov Shukri ,   Precision Manufacturing Centre, Faculty of Engineering, University of Nottingham, NG7 2RD, UK, Ratchev Svetan , Becker Adib , Liu Shulong , Segal Joel
Published: April 2016

The paper investigates the effects of turning-induced and mapped Residual Stresses (RSs) for a Ti6Al4V disc subjected to centrifugal loading. The turninginduced RSs are predicted in orthogonal cutting using the Finite Element Method (FEM). The FE predicted RSs are validated after performing face turning followed by hole drilling and x-ray diffraction measurements. Numerical analyses are carried out at different Cutting Velocities (CVs) to obtain the RS profiles. The results show that the compressive RSs increase by increasing the CV and the depth of cut. A disc subjected to a centrifugal load is modelled using the FEM where the turning-induced RSs are introduced as an initial condition using mapping techniques. The predicted CV-dependent RS profiles are incorporated into the mapping techniques using the shape function approach. It is observed that the stress amplitudes at the points at which failure occurs are lower when the mapped turning-induced RS profiles are considered in the disc FE model. The lower stress amplitudes are related to prolonging the disc life due to fatigue.
Fabrication of Less than 20-nm-Diameter Nanodot Arrays Using Inorganic Electron Beam Resist and Post Exposure Bake
Authors: Taniguchi Jun ,   Department of Applied Electronics, Tokyo University of Science, 2641 Yamazaki, Noda, Chiba 278-8510, Japan, Manabe Tetsuro , Ishikawa Kiyoshi ,   Tokyo Ohka Kogyo Co., Ltd., 1590 Tabata, Samukawa, Koza, Kanagawa 253-0114, Japan
Published: April 2016

Next-generation NanoImprint Lithography (NIL) includes photolithography and high-voltage-acceleration (>50 kV) Electron-Beam Lithography (EBL) both of which are expensive, which is why Low-Acceleration-Voltage (LAV) EBL has attracted attention. We fabricated nanodot arrays with a diameter of 20 nm or less combining inorganic resist and LAV EBL. Using Post-Exposure Bake (PEB), we reduced dot-array pattern size and conducted Ultra-Violet (UV) NIL using these nanodot molds. The results we obtained using nanodot arrays 10 nm in diameter fabricated by EBL at an acceleration voltage of 4 kV with PEB yielded a checkerboard design 10 nm in diameter spaced at 20 nm intervals using 10 kV EB. This density corresponds to nanodot-arrays of 1 Tb/in2.
Modification of the Tool-Workpiece Contact Conditions to Influence the Tool Wear and Workpiece Loading During Hard Turning
Authors: Denkena Berend ,   Institute of Production Engineering and Machine Tools (IFW), Leibniz Universität Hannover, An der Universität 2, Garbsen 30826, Germany, Köhler Jens , Meyer Roland , Stiffel Jan-Hendrik
Published: April 2016

Tool wear during hard machining leads to unfavourable changes in the workpiece surface and subsurface layers. Due to increasing flank wear, thermal and mechanical loads affect the microstructure and the residual stress state of the workpiece subsurface. These effects cause a reduction in the lifetime of the machined components during operation. This article presents an approach of modified corner radii of cutting tools for hard turning processes to change the tool wear progression and the influence on the machined subsurface layers. Hereby the size and direction of the contact length of the cutting edge is adjusted as well as the specific load during machining. The results show the potential of controlling the tool wear and the workpiece subsurface properties by the contact conditions of the tool-workpiece interface during hard turning.
Motion Trajectory Measurement of NC Machine Tools Using Accelerometers
Authors: Sato Ryuta ,   Organization of Advanced Science and Technology, Kobe University, 1-1 Rokko-dai, Nada, Kobe 657-8501, Japan, Nagaoka Kotaro ,   Advanced Technology R&D Center, Mitsubishi Electric Corporation, 8-1-1 Tsukaguchi-Honmachi, Amagasaki, Hyogo 661-8661, Japan
Published: April 2016

NC controllers use different types of compensation systems to improve motion accuracy of feed drive systems against pitch error, friction, backlash, and elastic deformation. Compensators for static error, such as pitch and squareness errors, are tuned semiautomatically. However, for dynamic error such as quadrant glitches and vibration, parameter tuning takes too much time. In this study, motion trajectory measurement for parameter tuning using accelerometers has been proposed. In the methods, displacements of each axis can be obtained from measured accelerations along each axis. Although the obtained displacements include some errors, such as setting error, sensitivity error, and integral error in numerical integration, the errors can be compensated for based on the feedback positions measured simultaneously. To confirm the feasibility of the proposed methods, measurement tests using a grid encoder are carried out. Results of the measurements confirm that the circular trajectories and vibrations can be measured by the proposed method. Automatic parameter tuning method for the backlash compensator is also proposed.
Process Monitoring and Control of Machining Operations
Authors: Klocke Fritz ,   Laboratory for Machine Tools and Production Engineering Aachen, RWTH Aachen University, Steinbachstrasse 19, 52074 Aachen, Germany, Kratz Stephan , Auerbach Thomas , Gierlings Sascha , Wirtz Guido , Veselovac Dražen
Published: April 2016

In today’s production, the overall technical aim of a monitoring and control system is to introduce robust manufacturing with maximum performance. Generating targeted values means to transfer production know-how to the application of monitoring and control strategies, whereas such systems include a decisive potential for increasing added value in production companies. Especially in complex processes, important operational sequences should be analyzed and optimized online by means of system analysis and control. This paper reviews certain aspects and introduces recent investigations on process monitoring and control strategies for milling, drilling and broaching operations.
Tool Path Generation for Five-Axis Controlled Machining with Consideration of Motion of Two Rotational Axes
Authors: Morishige Koichi ,   Faculty of Informatics and Engineering, Department of Mechanical Engineering and Intelligent Systems, The University of Electro-Communications, 1-5-1 Chofugaoka, Chofu-shi, Tokyo 182-8585, Japan, Kaneko Makoto
Published: April 2016

In this paper, the original configuration space is applied to generate tool path, which indicate locations of two rotational axes of a 5-axis controlled machine tool. Moreover, A-star algorithm that is one of the methods for route searching is applied to decide tool postures considering the motion of two rotational axes. The developed method can generate tool path limiting the number of used rotational axes, and reducing the moving amount of two rotational axes. Furthermore, the method can generate tool path that avoids the reverse rotation of two rotational axes, which might cause the machining error. As a result, an excellent finished surface is actually obtained, and the usefulness of the developed method is confirmed.
Development of Articulated Manipulators with Pneumatic Cylinders
Authors: Kawakami Yukio ,   Department of Machinery and Control Systems, College of Systems Engineering and Science, Shibaura Institute of Technology, 307 Fukasaku, Minuma-ku, Saitama-city, Saitama 337-8570, Japan, Ito Kazuhisa , Ogawa Masashi , Horikawa Akiyoshi , Shioda Koji , Nagai Kiono ,   Development Department, Development Division, KOGANEI Corporation, 3-11-28 Midori-cho, Koganei-shi, Tokyo 184-8533, Japan
Published: April 2016

We have developed new articulated manipulators with compact pneumatic cylinders and with the high levels of structural flexibilities and safety as a result of adoption of new ideas in the structure. In developing the new articulated manipulators, we have first defined the design concepts and then described the overview of the manipulators which we have actually designed and manufactured. We have carried out experiments with the manufactured articulated manipulators for their positional controllability and stiffness characteristics, the results of which are also reported in this paper. Furthermore, this paper refers to possible applications of the developed new articulated manipulators.
Development and Attitude Control of Flexible Robot Arm Using Flexible Pneumatic Cylinder with Simple Structure
Authors: Akagi Tetsuya ,   Department of Intelligent Mechanical Engineering, Okayama University of Science, 1-1 Ridai-cho, Kita-ku, Okayama 700-0005, Japan, Dohta Shujiro , Zhao Feifei , Fujikawa Takahiro
Published: April 2016

A wearable actuator needs to be flexible so as not to injure the human body. The purpose of our study is to develop a flexible and lightweight actuator which can be safe enough to be attached to the human body, and to apply it to a robot arm and rehabilitation device. New types of flexible pneumatic actuator that can be used even if the actuator is deformed by external force have been developed in our previous studies. In this paper, a robot arm using the flexible pneumatic cylinder that can realize a natural flowing movement with multi-motion such as bending, expanding, and contracting is described. The analytical model of the robot arm is proposed for attitude control. In addition, an inexpensive quasi-servo valve using the on/off control valve is utilized in the master-slave control system to improve the control performance. As a result, the usability of the proposed robot arm and the effectiveness of the attitude control method using the analytical model and the quasi-servo valve are confirmed.
Ankle Rehabilitation Device to Prevent Contracture Using a Pneumatic Balloon Actuator
Authors: Saga Norihiko ,   Department of Human System Interaction, Kwansei Gakuin University, 2-1 Gakuen, Sanda, Hyogo 669-1337, Japan, Saito Naoki , Nagase Jun-ya ,   Department of Machine Intelligence and Systems Engineering, Akita Prefectural University, 84-4 Tsuchiya Ebinokuchi, Yurihonjo, Akita 015-0055, Japan
Published: April 2016

Our proposed rehabilitation device to prevent contracture of the ankle is easy to produce, transport, and install at the time of use in places such as medical institutions. This device is intended for use by hemiplegic people. The ankle is moved when it is worn, preventing ankle contracture. It consists of a new tendon-drive system using a pneumatic balloon actuator, power transfer mechanism, and ankle foot orthosis. This new tendon drive system using a pneumatic balloon was developed as an actuator of this device. The system consists of a tendon and a silicone tube. Both ends of the tube are closed. The tube expands with the supplied air, which distends the silicone tube and thereby pulls the tendon. This simple system is both compact and powerful. Furthermore, its materials and structure make it light. This paper describes characteristics of this tendon drive system using a pneumatic balloon, along with its composition and operation as a rehabilitation device for preventing ankle contracture. Results of operation tests using the device are also presented.
Quantitative Performance Analysis of Exoskeleton Augmenting Devices - Muscle Suit - for Manual Worker
Authors: Muramatsu Yoshiki ,   Department of Mechanical Engineering, Tokyo University of Science, 1-14-6 Kudankita, Chiyoda-ku, Tokyo 102-0073, Japan, Kobayashi Hiroyuki , Sato Yutaka , Jiaou He , Hashimoto Takuya , Kobayashi Hiroshi
Published: April 2016

Exoskeleton systems have been largely developed in spite that quantitative performance estimation has not been reported so far. Consequently, we have been developing the wearable muscle suit for direct and physical motion supports with relevant reports on the performance. The McKibben artificial muscle has introduced “muscle suit” compact, lightweight, reliable, and wearable “assist-bots” enabling users to lift and carry heavy objects. Applying integral electromyography (IEMG), we show the results of quantitative suit performance and posture-preserving efficiency. However, for practical use, lifting seems to be one of the most important tasks for users. We improve the forearm so that the muscle suit assists the user in vertical lifting. Load carrying and lifting experiments show the muscle suit’s effectiveness.
Linear Visual Servoing-Based Control of the Position and Attitude of Omnidirectional Mobile Robots
Authors: Ozato Atsushi ,   Daikin Industries Ltd., 2-4-12 Nakazaki Nishi, Kita, Osaka City, Osaka, Japan, Maru Noriaki ,   Faculty of Systems Engineering, Wakayama University, 930 Sakaedani, Wakayama, Wakayama 640-8510, Japan
Published: April 2016

This article proposes a Linear Visual Servoing (LVS)-based method of controlling the position and attitude of omnidirectional mobile robots. This article uses two markers to express their target position and attitude in binocular visual space coordinates, based on which new binocular visual space information which includes position and attitude angle information is defined. Binocular visual space information and the motion space of an omnidirectional mobile robot are linearly approximated, and, using the approximation matrix and the difference in the binocular visual space information between a target marker and a robot marker, the robot’s translational velocity and rotational velocity are generated. Since those are all generated based only on disparity information on an image, which is similar to how this is done in existing LVS, a camera angle is not required. Thus, the method is robust against calibration errors in camera angles, as is existing LVS. The effectiveness of the proposed method is confirmed by simulation.
Development of Flexible Sensors for Measuring Human Motion and Displacement of Novel Flexible Pneumatic Actuator
Authors: Akagi Tetsuya ,   Department of Intelligent Mechanical Engineering, Okayama University of Science, 1-1 Ridai-cho, Kita-ku, Okayama 700-0005, Japan, Dohta Shujiro , Kuno Hiroaki , Fukuhara Akimasa ,   Chikusui Canycom, Inc., 90-1 Fukumasa, Yoshii-machi, Ukiha-shi, Fukuoka 839-1396, Japan
Published: April 2016

The importance of wearable devices in nursing care and rehabilitation has been strongly recognized. The purpose of our study is to develop a flexible displacement and bending sensor which can measure human movement and the movement of a flexible actuator. In this paper, a skin displacement sensing system using a flexible string-like flexible displacement sensor to measure the body movement, i.e., measuring the displacement of the skin, was proposed and tested. A flexible linear encoder that can measure the displacement of the flexible pneumatic cylinder using four photoreflectors was also developed. In addition, the measurement using both sensors was done to measure the human motion and the flexible actuator.
Drop-on-Demand Printer for Micro Ion-Selective Electrode Fabrication
Authors: Saedan Mana ,   Department of Mechanical Engineering, Chiang Mai University, 239 Huaykaew Rd., Suthep, Muang, Chiang Mai 50200, Thailand
Published: April 2016

Drop-On-Demand (DOD) printing technology has been applied across various fields. Flexibility and efficient use of printing material attract applications where object accretion layer-by-layer is essential. This paper presents the application of DOD in manufacturing a planer ion-selective electrode from all liquid materials. The custom development of key hardware lowers the cost of DOD machine. Also it enables direct control to each device. The printing materials are specifically formulated to meet functional demands of ISEs while not compromise dispensing capability.
Motion Planning of Biped Robot Equipped with Stereo Camera Using Grid Map
Authors: Yamashita Atsushi ,   Department of Mechanical Engineering, Shizuoka University, 3-5-1 Johoku, Naka-ku, Hamamatsu-shi, Shizuoka 432-8561, Japan, Kitaoka Masaaki , Kaneko Toru ,   Tecmo Koei Holdings Co., Ltd., 1-18-12 Minowa-cho, Kohoku-ku, Yokohama-shi, Kanagawa 223-8503, Japan
Published: April 2016

Recognizing its surroundings is important for biped robots seeking a destination. In this paper, we propose a motion planning method of a biped robot including path planning and obstacle avoidance. The robot obtains distance information on its surrounding environment from images captured by a stereo camera system, and generates a 3D map, then, builds a 2D grid map that locates flat floor regions, obstacle regions, bump regions, gate regions, and un-measured regions to decide its path by using the 2D grid map. Experimental results confirm the effectiveness of the proposed method.
A Decision Support System for Capturing CNC Operator Knowledge
Authors: Sakarinto Wikan ,   Department of Mechanical Engineering, Graduate School of Engineering, Kobe University, 1-1 Rokko-dai, Kobe, Hyogo 657-8501, Japan, Narazaki Hiroshi , Shirase Keiichi
Published: April 2016

The main job of Computer Numerical Control (CNC) operators is to capture and use knowledge to assess product data. CNC operators assess Computer-Aided Manufacturing (CAM) files before proceeding to CNC machining processes. Decision Support Systems (DSS), for these operators, is provided by Expert Systems (ES) designed to manage and learn intelligently from previous data and information and produce recommended actions and decisions. The purpose of the DSS is (i) to assist inexperienced operators in assessment using stored know-how of experienced operators and to collect additional knowledge in interaction between the DSS and experienced operators during semiautomatic assessment, and (ii) to present collected knowledge to users based on contexts or constraints the user must deal with in product data assessment. After outlining the DSS, the discussion is about its usefulness in dealing information and knowledge discrepancies between CAM and CNC operators - an important problem in practice that has been rather neglected so far - focusing on CNC milling operations.
Development of On-Machine Measurement System Utilizing Line Laser Displacement Sensor
Authors: Abe Go ,   Hyogo Prefectural Institute of Technology (HiTec), 3-1-12 Yukihira-cho, Suma, Kobe, Hyogo 654-0037, Japan, Aritoshi Masatoshi , Tomita Tomoki , Shirase Keiichi ,   Graduate School of Engineering, Kobe University, 1-1 Rokko-dai, Nada, Kobe, Hyogo 657-8501, Japan
Published: April 2016

Demand for precision machining of dies and molds with complex shapes has been increasing. Though high performance CNC machine tools are widely utilized for precision machining, machining error compensation is still necessary to meet accuracy requirements. For precision measurement, a workpiece must usually be unloaded from a CNC machine tool. Then, the workpiece is measured by a precision measurement device, such as 3D CMM. After the machining error is clarified according to the measurements taken, the workpiece must be re-clamped for the necessary error compensation machining. This error compensation machining is costly and time consuming, and it requires a highly skilled machinists. The re-clamping of the workpiece also causes positioning errors. Therefore, demands for on-machinemeasurement have been increasing. In this paper, an on-machine measurement device that consists of a line laser displacement sensor is developed. This measurement device, attached to the spindle head of a machine tool with magnetic clamps, has special features, such as noncontact, multi-point, high-speed measurement capabilities. Additionally, a sequential multi-point method, an extension of the two-point method, is applied for shape measurement accuracy.
Development of an Interactive Assistance System for Machine Tool Structure Design Considering of Sliding Joint Damping
Authors: Yu Zhangyong ,   Department of Mechanical Engineering, Osaka University, 2-1 Yamada-oka, Suita, Osaka 565-0871, Japan, Nakamoto Keiichi , Takeuchi Yoshimi
Published: April 2016

This paper deals with the development of an interactive design assistance system for machine tool structures. This system supports design engineers determining the suitable machine prototype in the conceptual and fundamental stages in a short time. In this study, all of the machine components are approximated by a set of beam elements to reduce the Degrees Of Freedom (DOF). Thus, it is easy to model and analyze the static stiffness and dynamic behaviors of the machine prototypes, especially in terms of sliding joint damping. By comparing their static stiffness and dynamic behaviors, design engineers can select the proper machine prototype in a short time. A case study shows the process, including the proposal, modeling, analysis, and selection, to determine the suitable machine prototype. This helps the design engineers to make the machine tool structural design efficiently.
Tool Posture Planning Method for Continuous 5-Axis Control Machining on Machine Tool Coordinate System to Optimize Motion of Translational Axes
Authors: Kaneko Jun’ichi ,   Department of Mechanical Engineering, Graduate School of Engineering, Saitama University, 255 Shimo-Okubo, Sakura-ku, Saitama City, Saitama 338-8570, Japan, Horio Kenichiro
Published: April 2016

To realize highly productivity and machine fine surfaces, today’s multi-axis-controlled machine tools require a method of planning to maintain dynamic synchronous accuracy among the tool axes and reduce swinging of the translational axes. To these ends, this paper proposes a new planning method for tool posture based on an integrated main / post processing system. The proposed method is designed to plan tool posture change for continuous 5-axis-controlled machining for a finishing process using a ball end mill. In the planned tool posture, the cutting tool can avoid collision with the workpiece surface and keep travel to a minimum on the translational axes. In the proposed method, first, a large number of candidate tool posture changes are assumed. Then, collision between the cutting tool and workpiece, overtravel and total travel distance of the translational axes are estimated for each candidate. In order to drastically reduce computation time for these estimation processes, we introduce the M-Map method and develop a partial CAVE method. In the M-Map method, machinable range of the rotational axes on the machine tool without collision and estimated position of the translational axes in the post process are illustrated as color images for each cutter location. Then, by referring to these images, in the partial CAVEmethod, a vast number of candidates tool posture changes are compared to detect the optimal changes with the minimum total travel. These estimation processes are realized on graphics hardware known as a GPU. By applying its ultra parallel processing ability, the system we have developed can detect the optimal tool posture changes in a short time.
Numerical Investigation of Static and Dynamic Characteristics of Water Hydrostatic Porous Thrust Bearings
Authors: Nishitani Yuki ,   Department of Mechanical Engineering, Tokyo University of Science, 1-14-6 Kudan-kita, Chiyoda-ku, Tokyo 102-0073, Japan, Yoshimoto Shigeka , Somaya Kei
Published: April 2016

A moving table supported by aerostatic bearings can achieve excellent accuracy of motion because of its noncontact support and, hence, it is used in various precision machine tools and measuring equipment. However, because of low viscosity of air, the damping coefficient of aerostatic bearings is not very high, causing vibration with nanometer-order amplitudes. The accuracy of machine tools and measuring equipment could deteriorate because of this vibration. It is expected that water hydrostatic bearings would have a higher damping coefficient than aerostatic bearings due to the higher viscosity of water. In addition, water, like air, does not pollute the environment. In this paper, the static and dynamic characteristics of water hydrostatic thrust bearings using porous material were numerically investigated and comparedwith conventional pocket hydrostatic bearings with a capillary restrictor. Hydrostatic porous bearings can be easily constructed because the porous material becomes a viscous restrictor itself. It was consequently found that water hydrostatic porous thrust bearings have higher maximum load capacity and slightly lower stiffness than water bearings with a capillary restrictor.