Rolling bearing fatigue life is an essential criterion in industrial equipment design and manufacturing and requires precise maintenance and replacement predictions. ISO/TS 281:2007 and 16281:2008 are commonly used for angular contact ball bearing (ACBB) fatigue life calculations, but they do not account for the characteristics of individual bearing elements under combined loading conditions. This study proposes an enhanced formula for calculating fatigue life modification factors that considers individual element-specific contact loads and resulting film thickness variations. The proposed fatigue life formula provides longer life predictions than the conventional method of determining modification factors based solely on maximum contact loads. This difference is particularly noticeable in low-speed and/or heavy-loading applications. Analysis conducted using the proposed fatigue life formula on various factors affecting fatigue life revealed that fluid kinetic viscosity coefficients, temperature-associated density changes, and changes in radial loads and rotational speeds could significantly impact the fatigue life of ACBBs. The proposed fatigue life formula is expected to increase the accuracy of ACBB fatigue life predictions.
In this study, a wire electrical discharge milling electrode was developed, and electric discharge machining characteristics were studied by using the electrode. The wire electrical discharge milling electrode is a form, in which the wire is conveyed by using a cylindrical rod with a hemispherical end as a guide, and it also rotates in one direction around the guide axis. If the wire electrical discharge milling electrode is used in electrical discharge machining (EDM), there is no need to consider electrode wear compensation. The EDM characteristics according to capacitance of the RC circuit and the rotational speed of the wire electrical discharge milling electrode were examined. The machining conditions were selected, and a hemispherical shape with good shape accuracy and fine surface finish was fabricated in two stages of roughing and finishing. By applying the wire electrical discharge milling electrode to the electric discharge milling process, straight and curved shapes were successfully machined.
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In ultra-precision processes, such as aerospace parts and precision mold machining, the accuracy of a feed drive system should be secured to achieve sufficient form accuracy. Dual-Servo stages, which compensate for multi-DOF motion errors, are being developed depending on the applied processes. This paper deals with the fine stage of a dual-servo stage to compensate for 6-DOF motion errors of a linear stage. The proposed fine stage measured 6-DOF errors of the linear stage motion with capacitive sensors, a reference mirror, and an optical encoder. It compensated for the errors using the flexure hinge mechanism with piezo actuators. The error equations and the inverse kinematics were derived to calculate the 6- DOF errors and displacements of piezo actuators for 6-DOF motions, respectively. Performance evaluation was implemented to verify feasibility of the developed fine stage of the fabricated dual-servo stage. Through the step response test of the fine stage, compensation resolutions for the translational and the rotational motion were confirmed to be less than 10 nm and 1/3 arcsec, respectively. The 6-DOF motion errors in the verification test were reduced by 73% on average.
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Three-axis magnetometers are widely used in various fields requiring azimuth information. However, accuracy of azimuth estimation based on magnetometer signals may be degraded because of errors such as offset, scale factor, nonorthogonality, hard-iron distortion, and soft-iron distortion. Recently, several ellipsoid-fitting calibration techniques have been proposed and have received much attention. However, comparative analysis of calibration accuracies between these techniques has not been conducted. This study compared and analyzed performance of four ellipsoid-fitting magnetometer calibration techniques such as the linear least square method, the two-step algorithm, and two different nonlinear least square methods. Our analysis and experimental results reveal superiority of the linear least square method compared to other methods in terms of calibration accuracy as well as ease of use in practice.
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This paper introduces a new outdoor localization method for practical application to guide robots. This method uses only encoder data from the robot’s wheels and non-inertial sensors, such as GPS and a digital compass, to guarantee ease of use and economy in real world usage without cumulative error. Position and orientation information from DGPS (Differential Global Positioning System) and a digital compass are combined with encoder data from the robot’s wheels to more accurately estimate robot position using an extended Kalman filter. Conventional robot guidance methods use different types of fusion that rely on DGPS. We use a very simple and consistent method that ensures localization stability by using the validation gate to evaluate DGPS reliability and digital compass data that can be easily degraded by various noise sources. Experimental results of the localization are presented that show the feasibility and effectiveness of the methods using a real robot in real world conditions.
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Light detection and ranging (LiDAR) is one of the most efficient technologies to obtain the topographic and bathymetric map of coastal zones, superior to other technologies, such as sound navigation and ranging (SONAR) and synthetic aperture radar (SAR). However, the measurement results using LiDAR are vulnerable to environmental factors. To achieve a correspondence between the acquired LiDAR data and reality, error sources must be considered, such as the water surface slope, water turbidity, and seafloor slope. Based on the knowledge of those factors’ effects, error corrections can be applied. We concentrated on the effect of the seafloor slope on LiDAR waveforms while restricting other error sources. A simulation regarding in-water beam scattering was conducted, followed by an investigation of the correlation between the seafloor slope and peak timing of return waveforms. As a result, an equation was derived to correct the depth error caused by the seafloor slope.
This paper presents the design and the control performance of a novel dynamic compliant-arm support with parallel elastic actuators that was developed to assist with the daily living activities of those whose arms are compromised by muscular disease or the aging process. The parallel elastic-arm support consists of a compliant mechanism with combined passive and active components for human interaction and to reach the user’s desired positions. The achievement of these tasks requires impedance control, which can change the virtual stiffness, damping coefficients, and equilibrium points of the system; however, the desired-position tracking by the impedance control is limited when the end-effector weight varies according to the equipping of diverse objects. A prompt algorithm regarding weight calibration and friction compensation is adopted to overcome this problem. A result comparison shows that, by accurately assessing the desired workspace, the proposed algorithm is more effective for the accomplishment of the desired activities.
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Calibration Algorithm of a Spring Static Balancer Chang-Hyun Cho, Mun-Taek Choi International Journal of Precision Engineering and Manufacturing.2018; 19(10): 1477. CrossRef
A fine stage is developed for the 3-DOF error compensation of a linear axis in order to improve the positioning accuracy. This stage is designed as a planar parallel mechanism, and the joints are based on a flexure hinge to achieve ultra-precise positioning. Also, the effect of Abbe’s offsets between the measuring and driving coordinate systems is minimized to ensure an exact error compensation. The mode shapes of the designed stage are analyzed to verify the desired 3-DOF motions, and the workspace and displacement of a piezoelectric actuator (PZT) for compensation are analyzed using forward and inverse kinematics. The 3-DOF error of a linear axis is measured and compensated by using the developed fine stage. A marked improvement is observed compared to the results obtained without error compensation. The peak-to-valley (PV) values of the positional and rotational errors are reduced by 92.6% and 91.3%, respectively.
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