Table of Content

25 December 2014, Volume 2 Issue 4

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Novel AR-based interface for human-robot interaction and visualization

H. C. Fang, S. K. Ong, A. Y. C. Nee

2014, 2(4):  275-288.  doi:10.1007/s40436-014-0087-9

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Intuitive and efficient interfaces for humanrobot interaction (HRI) has been a challenging issue in robotics as it is essential for the prevalence of robots supporting humans in key areas of activities. This paper presents a novel augmented reality (AR) based interface to facilitate human-virtual robot interaction. A number of human-virtual robot interaction methods have been formulated and implemented with respect to the various types of operations needed in different robotic applications. A Euclidean distance-based method is developed to assist the users in the interaction with the virtual robot and the spatial entities in an AR environment. A monitor-based visualization mode is adopted as it enables the users to perceive the virtual contents associated with different interaction methods, and the virtual content augmented in the real environment is informative and useful to the users during their interaction with the virtual robot. Case researches are presented to demonstrate the successful implementation of the AR-based HRI interface in planning robot pick-and-place operations and path following operations.

Virtual engineering in design and manufacturing

Hirpa G. Lemu

2014, 2(4):  289-294.  doi:10.1007/s40436-014-0085-y

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Manufacturing systems of the future highly demand that the product data are built into the product model, and smooth data transfer to other computer-aided technologies are enabled. Depending on the type of the manufacturing system, it is envisaged that virtual engineering (VE) technologies play a significant role in integrating the computer-based technologies involved in the product’s life cycle. Simulations in a virtual world and exchange of real time product or design data are among the benefits for today’s global oriented manufacturing business. To highlight the significance of design as carrier of product data and the key role played by VE technologies to inter-link design, manufacturing and associated components, this paper presents an overview and analysis of the state-of-the-art VE technologies to indicate potential applications and future research directions.

Kinematic analysis and simulation of a new-type robot with special structure

Shuai Guo, Hua-Wei Li,Jian-Cheng Ji,Zhi-Fa Ming

2014, 2(4):  295-302.  doi:10.1007/s40436-014-0094-x

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Common methods, such as Denavit-Hartenberg (D-H) method, cannot be simply used in kinematic analysis of special robots with hybrid hinge as it is difficult to obtain the main parameters of this method. Hence, a homogeneous transformation theory is presented to solve this problem. Firstly, the kinematics characteristic of this special structure is analyzed on the basis of the closed-chain theory. In such a theory, closed chains can be transformed to open chains, which makes it easier to analyze this structure. Thus, it will become much easier to establish kinematics equations and get the solutions. Then, the robot model can be built in the Simmechanics (a tool box of MATLAB) with these equation solutions. It is necessary to design a graphical user interface (GUI) for robot simulation. After that, the model robot and real robot will respectively move to some spatial points under the same circumstances. At last, all data of kinematic analysis will be verified based on comparison between data got from simulation and real robot.

Effects of roller burnishing process parameters on surface roughness of A356/5%SiC composite using response surface methodology

Shashi Prakash Dwivedi, Satpal Sharma, Raghvendra Kumar Mishra

2014, 2(4):  303-317.  doi:10.1007/s40436-014-0083-0

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In this study, a simple roller burnishing tool was made to operate burnishing processes on A356/5%SiC metal matrix composite fabricated by electromagnetic stir casting under different parameters. The effects of burnishing speed, burnishing force and number of burnishing passes on the surface roughness and tribological properties were measured. Scanning electron microscopy (SEM) graphs of themachined surface with PCD (insert-10) tool and roller burnished surface with tungsten carbide (WC) roller were taken into consideration to observe the surface finish of metal matrix composites. The mechanical properties (tensile strength, hardness, ductility) of A356/5%SiC metal matrix composites were studied for both unburnished samples and burnished samples. The results revealed that the roller burnished samples of A356/ 5%SiC led to the improvement in tensile strength, hardness and ductility. In order to find out the effects of roller burnishing process parameters on the surface roughness of A356/ 5%SiC metal matrix composite, response surface methodology (RSM) (Box–Behnken design) was used and a prediction model was developed relevant to average surface roughness using experimental data. In the range of process parameters, the result shows that roller burnishing speed increases, and surface roughness decreases, but on the other hand roller burnishing force and number of passes increase, and surface roughness increases. Optimum values of burnishing speed (1.5 m/s), burnishing force (50 N) and number of passes (2)during roller burnishing of A356/5%SiC metal matrix composite to minimize the surface roughness (predicted 1.232 lm) have been found out. There was only 5.03% error in the experimental andmodeled results of surface roughness.

Integrated color defect detection method for polysilicon wafers using machine vision

Zai-Fang Zhang,Yuan Liu,Xiao-Song Wu,Shu-Lin Kan

2014, 2(4):  318-326.  doi:10.1007/s40436-014-0095-9

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For the typical color defects of polysilicon wafers, i.e., edge discoloration, color inaccuracy and color non-uniformity, a new integrated machine vision detection method is proposed based on an HSV color model. By transforming RGB image into three-channel HSV images, the HSV model can efficiently reduce the disturbances of complex wafer textures. A fuzzy color clustering method is used to detect edge discoloration by defining membership function for each channel image. The mean-value classifying method and region growing method are used to identify the other two defects, respectively. A vision detection system is developed and applied in the production of polysilicon wafers.

Fabrication method of ultra-small gradient-index fiber probe

Chi Wang, Fang Zhang,Shu-Bo Bi,Xue-Qin Xia,Ting-Ting Xu

2014, 2(4):  327-332.  doi:10.1007/s40436-014-0089-7

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Fabrication method and device of ultra-small gradient-index (GRIN) fiber probe were investigated in order to explore the development of ultra-small probes for optical coherence tomography (OCT) imaging. The beamexpanding effect of no-core fiber (NCF) and the focusing properties of the GRIN fiber lens were analyzed based on the model of GRIN fiber probe consisting of single-mode fiber (SMF), NCF and GRIN fiber lens. A stereo microscope based system was developed to fabricate the GRIN fiber probe. A fiber fusion splicer and an ultrasonic cleaver were used to weld and cut the fiber respectively. A confocal microscopy was used to measure the dimensions of probe components. The results show that the sizes of probe components developed are at the level of millimeter. Therefore, the proposed experimental system meets the fabrication requirements of an ultra-small self-focusing GRIN fiber probe. This shows that this fabrication device and method can be employed in the fabrication of ultrasmall self-focusing GRIN fiber probe and applied in the study of miniaturized optical probes and OCT systems.

A synchronized strategy to minimize vehicle dispatching time: a real example of steel industry

K. R. Zuting, P. Mohapatra,Y. Daultani, M. K. Tiwari

2014, 2(4):  333-343.  doi:10.1007/s40436-014-0082-1

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Time compression in supply chains is a crucial aspect involved in the integration of warehousing and transport operations in the manufacturing industries. Supply chain flows could be interrupted due to many sources of delays that lead to additional time in dispatching process and reduction in customer service level. The problem considered in this paper consists of long waiting times of loading vehicles inside the plant. This work presents a simulation-based study to minimize vehicle dispatching time in a steel wire plant. Value stream map is developed to present a system perspective of processes involved in the overall supply chain. Process activity mapping is completed to provide a step by step analysis of activities involved in the vehicle dispatch process. A simulation model is developed for the system and a new model is proposed to improve the delivery performance by minimizing vehicles’ waiting time.

Modeling and simulation of percussive impact for robotic riveting system

Shuai Guo,Song-Liang Nie, Feng-Feng Xi,Tao Song

2014, 2(4):  344-352.  doi:10.1007/s40436-014-0091-0

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Riveting is one of the major joining methods used in assembly, and the robotic riveting has been gradually introduced into aircraft industry. In this paper, a method is presented for modeling and simulation of percussive robotic riveting. In percussive riveting, vibration always exists. When an impact force is employed, a forced vibration will be induced. If it resonates with a robot natural frequency, the vibration will cause damage to the robot. The main content of this paper is divided into three parts. Firstly, a robot dynamic model is established to compute the driving torque for each joint. Secondly, vibration responses under impact are analyzed for the percussive riveting process. Thirdly, the effect of riveting on robot vibration is studied over the robot workspace. The purpose of this paper is to discuss the suitable regions for riveting where the robot vibration is very minimal. It is shown that based on the presented method an appropriate trajectory can be planned for robotic riveting.

Crystal structure and formation mechanism of the secondary phase in Heusler Ni-Mn-Sn-Co materials

Jin-Ke Yu, Hong-Wei Li, Qi-Jie Zhai, Jian-Xun Fu, Zhi-Ping Luo, Hong-Xing Zheng

2014, 2(4):  353-357.  doi:10.1007/s40436-014-0093-y

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In the present work, crystal structure and formation mechanism of the secondary phase in Heusler Ni-Mn-Sn-Co materials were investigated using X-ray diffraction, scanning/transmission electron microscopy and selected-area electron diffraction techniques. Experimental results showed that the secondary phase presented in both Ni44.1Mn35.1Sn10.8Co10 as-cast bulk alloy and melt-spun ribbon, possessing a face-centered cubic (fcc) Ni17Sn3-type structure. The secondary phase in the as-cast bulk alloy was resulted from a eutectic reaction after the formation of a primary dendritic b phase during cooling. However in the melt-spun rapidly solidified ribbon, the secondary phase was largely suppressed as nano-precipitates distributed along the grain boundaries, which was attributed to a divorced eutectic reaction. The secondary phase exhibited partial amorphous state due to high local cooling rate.

Review of the first principles calculations and the design of cathode materials for Li-ion batteries

Liu-Ming Yan1, Jun-Ming Su1, Chao Sun2, Bao-Hua Yue1

2014, 2(4):  358-368.  doi:10.1007/s40436-014-0086-x

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Cathode materials are the most critical challenge for the large scale application of Li-ion batteries in electric vehicles and for the storages of electricity. The first principles calculations play an important role in development and optimization of novel cathode materials. In this paper, we overview the first principles calculations of energy, volume change, band-gap, phase diagram, and Liion transport mechanism of cathode materials with an emphasis on the design of such materials. We also overview the recent progress of data mining techniques and the high-throughput first principles calculations for the design and development of cathode materials. Finally, we preview the challenges and opportunities of this rapidly developing field.