Three-dimensional Tool Radius Compensation for Multi-axis Peripheral Milling

Few function about 3D tool radius compensation is applied to generating executable motion control commands in the existing computer numerical control (CNC) systems. Once the tool radius is changed, especially in the case of tool size changing with tool wear in machining, a new NC program has to be recreated. A generic 3D tool radius compensation method for multi-axis peripheral milling in CNC systems is presented. The offset path is calculated by offsetting the tool path along the direction of the offset vector with a given distance. The offset vector is perpendicular to both the tangent vector of the tool path and the orientation vector of the tool axis relative to the workpiece. The orientation vector equations of the tool axis relative to the workpiece are obtained through homogeneous coordinate transformation matrix and forward kinematics of generalized kinematics model of multi-axis machine tools. To avoid cutting into the corner formed by the two adjacent tool paths, the coordinates of offset path at the intersection point have been calculated according to the transition type that is determined by the angle between the two tool path tangent vectors at the corner. Through the verification by the solid cutting simulation software VERICUTwith different tool radiuses on a table-tilting type five-axis machine tool, and by the real machining experiment of machining a soup spoon on a five-axis machine tool with the developed CNC system, the effectiveness of the proposed 3D tool radius compensation method is confirmed. The proposed compensation method can be suitable for all kinds of threeto five-axis machine tools as a general form.

Anisotropic Force Ellipsoid Based Multi-axis Motion Optimization of Machine Tools

The existing research of the motion optimization of multi-axis machine tools is mainly based on geometric and kinematic constraints, which aim at obtaining minimum-time trajectories and finding obstacle-free paths. In motion optimization, the stiffness characteristics of the whole machining system, including machine tool and cutter, are not considered. The paper presents a new method to establish a general stiffness model of multi-axis machining system. An analytical stiffness model is established by Jacobi and point transformation matrix method. Based on the stiffness model, feed-direction stiffness index is calculated by the intersection of force ellipsoid and the cutting feed direction at the cutter tip. The stiffness index can help analyze the stiffness performance of the whole machining system in the available workspace. Based on the analysis of the stiffness performance, multi-axis motion optimization along tool paths is accomplished by mixed programming using Matlab and Visual C＋＋. The effectiveness of the motion optimization method is verified by the experimental research about the machining performance of a 7-axis 5-linkage machine tool. The proposed research showed that machining stability and production efficiency can be improved by multi-axis motion optimization based on the anisotropic force ellipsoid of the whole machining system.

Laser Interferometer Based Measurement for Positioning Error Compensation in Cartesian Multi-Axis Systems

Accuracy is one of the most important key indices to evaluate multi-axis systems’ (MAS’s) characteristics and performances. The accuracy of MAS’s such as machine tools, measuring machines and robots is adversely affected by various error sources, including geometric imperfections, thermal deformations, load effects, and dynamic disturbances. The increasing demand for higher dimensional accuracy in various industrial applications has created the need to develop cost-effective methods for enhancing the overall performance of these mechanisms. Improving the accuracy of a MAS by upgrading the physical structure would lead to an exponential increase in manufacturing costs without totally eliminating geometrical deviations and thermal deformations of MAS components. Hence, the idea of reducing MAS’s error by a software-based alternative approach to provide real-time prediction and correction of geometric and thermally induced errors is considered a strategic step toward achieving the full potential of the MAS. This paper presents a structured approach designed to improve the accuracy of Cartesian MAS’s through software error compensation. Four steps are required to develop and implement this approach: (i) measurement of error components using a multidimensional laser interferometer system, (ii) tridimensional volumetric error mapping using rigid body kinematics, (iii) volumetric error prediction via an artificial neural network model, and finally (iv) implementation of the on-line error compensation. An illustrative example using a bridge type coordinate measuring machine is presented.

DEVELOPMENT OF NEW GENERATION THERMOMECHANICAL SIMULATOR-MULTI-AXIS RESTRAINT COMPRESSION(MARC-STRAIN^(TM))SYSTEM

Ultrafine grain size is often achieved by severe plastic deformation. A few techniques have been devel- oped to achieve severe plastic deformation,such as equal channel angular (ECA ) processing, torsion, and accumulative roll bonding (ARB) techmpues. This paper will introduce a moftiaxis deformation technique which can achieve essentially unlimited strain with constant deformation volume. The mul- tiaxis deformation can be fully restrained or unrestrained.The bulk volume of a multiaxis restraint compression specimen can be easily machined into mechanical testing specimens for mechanical property measurement and other studies.

Observation of tropospheric NO_2 by airborne multi-axis differential optical absorption spectroscopy in the Pearl River Delta region,south China

An airborne multi-axis differential optical absorption spectroscopic （AMAX-DOAS） instrument was developed and applied to measure tropospheric NO2 in the Pearl River Delta region in the south of China. By combining the measurements in nadir and zenith directions and analyzing the UV and visible spectral region using the DOAS method, information about tropospheric NO2 vertical columns was obtained. Strong tropospheric NO2 signals were detected when flying over heavilly polluted regions and point sources like plants. The AMAX-DOAS results were compared with ground-based MAX-DOAS observations in the southwest of Zhuhai city using the same parameters for radiative transport calculations. The difference in vertical column data between the two instruments is about 8%. Our data were also compared with those from OMI and fair agreement was obtained with a correlation coefficient R of 0.61. The difference between the two instruments can be attributed to the different spatial resolution and the temporal mismatch during the measurements.

Computational Fluid Dynamics Analysis of Multi-Bladed Horizontal Axis Wind Turbine Rotor

The principal objective of this work was to investigate the 3D flow field around a multi-bladed horizontal axis wind turbine (HAWT) rotor and to investigate its performance characteristics. The aerodynamic performance of this novel rotor design was evaluated by means of a Computational Fluid Dynamics commercial package. The Reynolds Averaged Navier-Stokes (RANS) equations were selected to model the physics of the incompressible Newtonian fluid around the blades. The Shear Stress Transport (SST) k-ω turbulence model was chosen for the assessment of the 3D flow behavior as it had widely used in other HAWT studies. The pressure-based simulation was done on a model representing one-ninth of the rotor using a 40-degree periodicity in a single moving reference frame system. Analyzing the wake flow behavior over a wide range of wind speeds provided a clear vision of this novel rotor configuration. From the analysis, it was determined that the flow becomes accelerated in outer wake region downstream of the rotor and by placing a multi-bladed rotor with a larger diameter behind the forward rotor resulted in an acceleration of this wake flow which resulted in an increase the overall power output of the wind machine.

The Liner Formulas between the Supporting Force and Axis Warp of Large-scale Rotary Kiln with Multi-support

Kilns are the key equipment in the metallurgy,architectural and chemistry industry. It is the statically indeterminate system with over load, large torque and multi-support. The kiln move axis warp resulting in that the load distribution is asymmetry, cause many mechanical failure and safe accidents and the interruption of the produce, which bring a great losses. Treating the distribution of the kiln load and the complexity of the stiffness change, the all-purpose model and matrix, used to solve the variable-stiffness beam upon complex load, are established in this paper. The resultant force of kiln in vertical and horizontal direction is calculated. Accordingly, the liner formulas for calculating the supporting force of the support wheels are obtained, and the wheel supporting force also can be easily obtained based on each shell warp. This will provide theory conference for safety management and rational maintenance.

Research on Contour Error Based on CNC Multi-axis Motion Control System

The contour error was analyzed based on CNC multi-axis motion control, the contour error model was obtained focused on beeline and different radius of curvature and common contour of curve, for a CNC biaxial motion control system and the mechanism of producing contour error and the relationship between tracking error and contour error were presented. The theoretical and practical significance of modeling error and controlling error in motion control systems was carried out.

Research on the random seismic response analysis for multi- and large-span structures to multi-support excitations

The pseudo excitation method(PEM) has been improved into a more practical form,on which the analytic formulae of seismic response power spectral density(PSD) of simplified large-span structural models have been derived.The analytic formulae and numerical computing results of seismic response PSD have been derived to study the mechanism of multi-support excitation effects,such as the wave-passage effect and incoherence effect,for the seismic response of multiand large-span structures.By using a multi-span truss as an example,the influence of multi-support excitation effects on the seismic response of such structures is studied.

HARMONIC, SUBHARMONIC, SUPERHARMONIC, SIMULTANEOUS SUB/SUPER HARMONIC AND COMBINATION RESONANCES OF SELF-EXCITED TWO COUPLED SECOND ORDER SYSTEMS TO MULTI-FREQUENCY EXCITATION

Harmonic, subharmonic, superharmonic, simultaneous sub/super harmonic, and combination resonances of the additive type of self-excited two coupled-second order systems to multi-frequency excitation are investigated. The theoretical results are obtained by the multiple-scales method. The steady state amplitudes for each resonance are plotted, showing the influence of the different parameters. Analysis for each figure is given. Approximate solution corresponding to each type of resonance is determined. Stability analyses are carried out for each case.

Peak earthquake response of structures under multi-component excitations

Accurate estimation of the peak seismic responses of structures is important in earthquake resistant design. The internal force distributions and the seismic responses of structures are quite complex, since ground motions are multidirectional. One key issue is the uncertainty of the incident angle between the directions of ground motion and the reference axes of the structure. Different assumed seismic incidences can result in different peak values within the scope of design spectrum analysis for a given structure and earthquake ground motion record combination. Using time history analysis to determine the maximum structural responses excited by a given earthquake record requires repetitive calculations to determine the critical incident angle. This paper presents a transformation approach for relatively accurate and rapid determination of the maximum peak responses of a linear structure subjected to three-dimensional excitations within all possible seismic incident angles. The responses can be deformations, internal forces, strains and so on. An irregular building structure model is established using SAP2000 program. Several typical earthquake records and an artificial white noise are applied to the structure model to illustrate the variation of the maximum structural responses for different incident angles. Numerical results show that for many structural parameters, the variation can be greater than 100%. This method can be directly applied to time history analysis of structures using existing computer software to determine the peak responses without carrying out the analyses for all possible incident angles. It can also be used to verify and/or modify aseismic designs by using response spectrum analysis.

Software Simulation in GSM Environment and Hardware Implementation of Improved Multi-band Excitation Vocoder

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MODELING AND COMPENSATION TECHNIQUE FOR THE GEOMETRIC ERRORS OF FIVE-AXIS CNC MACHINE TOOLS

One of the important trends in precision machining is the development ofreal-time error compensation technique. The error compensation for multi-axis CNC machine tools isvery difficult and attractive. The modeling for the geometric error of five-axis CNC machine toolsbased on multi-body systems is proposed. And the key technique of the compensation―identifyinggeometric error parameters―is developed. The simulation of cutting workpiece to verify the modelingbased on the multi-body systems is also considered.

Multi-port cavity model and low-level RF systems design for VHF gun

Very high frequency(VHF) photocathode guns have excellent performance and are being increasingly selected as electron sources for high-repetition-rate X-ray free-electron lasers. As a highly loaded quality factor cavity, the VHF gun requires high stability in the amplitude and phase of the cavity field. However, the gun is microwave powered by two solid-state power sources through two separate power couplers. The input difference between the two power couplers will influence the stability of the cavity field. To systematically study this influence and obtain measurement formulae, a multi-port VHF gun LCR circuit model is built and analyzed. During the warm-up condition, the cavity structure will be deformed due to the large-scale change in the cavity temperature. Then, the deformation will result in cavity resonant frequency changes. To prevent the mechanic tuner from suffering damages due to the frequent and long-distance movement for correcting the cavity resonant frequency, a self-excited loop(SEL) control system is considered for changing the loop phase and make the loop frequency follow the resonant frequency. In this study, a steady-state model of the VHF gun cavity is built for obtaining the optimal input coupler coefficient and the stability requirement of the forward voltage. Then, the generator-driven resonator and SEL control system, which combine with the VHF multiport modeling, are modeled and simulated. The simulated results show that the SEL system can perfectly operate in the process of condition and warm-up.

Vertical profile of aerosol extinction based on the measurement of O4 of multi-elevation angles with MAX-DOAS

A method for aerosol extinction profile retrieval using ground-based multi-axis differential optical absorption spectroscopy(MAX-DOAS)is studied,which is based on a look-up table algorithm.The algorithm uses parametric method to represent aerosol extinction profiles and simulate different atmospheric aerosol states through atmospheric radiation transfer model.Based on the method,aerosol extinction profile was obtained during six cloud-free days.The O4 differential air mass factor(dAMF)measured by MAX-DOAS is compared with the corresponding model results under different atmospheric conditions(R^2=0.78).The aerosol optical thickness,aerosol weight factor in boundary layer,and the height of the boundary layer are obtained after the process of minimization and look-up table method.The retrieved aerosol extinction in boundary layer is compared with PM2.5 data measured by ground point instrument.The diurnal variation trends of the two methods are in good agreement.The correlation coefficients of the two methods are 0.71 when the aerosol optical thickness is smaller than 0.5.The results show that the look-up table method can obtain the aerosol state of the troposphere and provide validation for other instrument data.

A new spatial coherence model and analytical coeffi cients for multi-support response spectrum combination

In this paper, a new spatial coherence model of seismic ground motions is proposed by a fitting procedure. The analytical expressions of modal combination （correlation） coefficients of structural response are developed for multi-support seismic excitations. The coefficients from both the numerical integration and analytical solutions are compared to verify the accuracy of the solutions. It is shown that the analytical expressions of numerical modal combination coefficients are of high accuracy. The results of random responses of an example bridge show that the analytical modal combination coefficients developed in this paper are accurate enough to meet the requirements needed in practice. In addition, the computational efficiency of the analytical solutions of the modal combination coefficients is demonstrated by the response computation of the example bridge. It is found that the time required for the structural response analysis by using the analytical modal combination coefficients is less than 1/20 of that using numerical integral methods.

CHAOS IN THE SOFTENING DUFFING SYSTEM UNDER MULTI-FREQUENCY PERIODIC FORCES

The chaotic dynamics of the softening-spring Duffing system with multi-frequency external periodic forces is studied. It is found that the mechanism for chaos is the transverse heteroclinic tori. The Poincaré map, the stable and the unstable manifolds of the system under two incommensurate periodic forces were set up on a two-dimensional torus. Utilizing a global perturbation technique of Melnikov the criterion for the transverse interaction of the stable and the unstable manifolds was given. The system under more but finite incommensurate periodic forces was also studied. The (Melnikov's) global perturbation technique was therefore generalized to higher dimensional systems. The region in parameter space where chaotic dynamics may occur was given. It was also demonstrated that increasing the number of forcing frequencies will increase the area in parameter space where chaotic behavior can occur.

A dual-axis, high-sensitivity atomic magnetometer

Atomic magnetometer （AM） operated in a spin-exchange relaxation-free （SERF） regime features superior sensitivity and non-cryogenic operation, and thus is competitive with the best superconducting quantum interference devices. Previously, SERF AM with fT/Hz1/2 level sensitivity commonly acted as a single-axis sensor. Here we demonstrate a dual-axis SERF AM capable of simultaneously and independently detecting x-and y-field components with a sensitivity of 20 fT/Hz1/2. As there is no necessity to worry about the cross-talk effects arising from field modulations, the dual-axis scheme proposed here is of particular interest to AM array and hence the biomagnetic applications.

Performance analysis of 20 Pole 1.5 KW Three Phase Permanent Magnet Synchronous Generator for low Speed Vertical Axis Wind Turbine

This paper gives performance analysis of a three phase Permanent Magnet Synchronous Generator (PMSG) connected to a Vertical Axis Wind Turbine (VAWT). Low speed wind condition (less than 5 m/s) is taken in consideration and the entire simulation is carried in Matlab/Simulink environment. The rated power for the generator is fixed at 1.5 KW and number of pole at 20. It is observed under low wind speed of6 m/s, a turbine having approximately1 mof radius and2.6 mof height develops 150 Nm mechanical torque that can generate power up to 1.5 KW. The generator is designed using modeling tool and is fabricated. The fabricated generator is tested in the laboratory with the simulation result for the error analysis. The range of error is about 5%-27% for the same output power value. The limitations and possible causes for error are presented and discussed.

A METHOD OF ON-LINE MEASUREMENT FOR THE FREQUENCY RESPONSE AND IMPULSE RESPONSE FUNCTIONS OF MULTIVARIATE SYSTEM

In this paper,a method of multipoint pseudorandom combined excita-tion with the orthogonal reciprocal repeated sequences(ORRS)is presented on thebackground of the on-line identification of multivariate system.The capacity of therestraint to the identification error caused by the non-random D.C.drift of the mul-ti-input excitation with the ORRS in the multivariate system is also discussed.Thevalidity of the method described in this paper is proved by the modelling tests of themulti-plate rotor system.