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This paper aims to focus on the high-speed rotary lip seal in aircraft engines, combining its service parameters, its own structure and application conditions, to study the influence of different eccentric forms, eccentricity, rotational speed and other factors on the performance of the rotary lip seal.

A numerical simulation model for high-speed eccentric rotary lip seals has been developed based on the theory of elastic hydrodynamic lubrication. This model comprehensively considers the coupling of multiple physical fields, including interface hydrodynamics, macroscopic solid mechanics and surface microscopic contact mechanics, under the operating conditions of rotary lip seals. The model takes into account eccentricity and uses the hazardous cross-sectional method to quantitatively predict sealing performance parameters, such as leakage rate and friction force.

Eccentricity has a large impact on lip seal performance; lips are more susceptible to wear failure under static eccentricity and to leakage failure under dynamic eccentricity.

This study provides a new idea for the design of rotary lip seal considering eccentricity, which is of guiding significance for the engineering application of rotary lip seal.

In the context of fixed-wing aircraft wing assembly, there is a need for a rapid and precise measurement technique to determine the center distance between two double-hole components. This paper aims to propose an optical-based spatial point distance measurement technique using the spatial triangulation method. The purpose of this paper is to design a specialized measurement system, specifically a spherically mounted retroreflector nest (SMR nest), equipped with two laser displacement sensors and a rotary encoder as the core to achieve accurate distance measurements between the double holes.

To develop an efficient and accurate measurement system, the paper uses a combination of laser displacement sensors and a rotary encoder within the SMR nest. The system is designed, implemented and tested to meet the requirements of precise distance measurement. Software and hardware components have been developed and integrated for validation.

The optical-based distance measurement system achieves high precision at 0.04 mm and repeatability at 0.02 mm within a range of 412.084 mm to 1,590.591 mm. These results validate its suitability for efficient assembly processes, eliminating repetitive errors in aircraft wing assembly.

This paper proposes an optical-based spatial point distance measurement technique, as well as a unique design of a SMR nest and the introduction of two novel calibration techniques, all of which are validated by the developed software and hardware platform.

The purpose of this study is to describe the proposed alpha solar rotary mechanism (ASRM) and how it is used to accurately modify the solar array of the China Space Station (CSS) in orbit to maintain continuous tracking of the sun to provide power. It also highlights the need to evaluate the performance of the ASRM and predict potential failure modes in various extreme scenarios.

To evaluate the performance of the ASRM, a dynamic model was created and tested under normal and faulty conditions. In addition, a multidirectional stiffness test was conducted on the prototype to verify the accuracy of the ASRM's dynamic model. The high-precision ASRM model was then used to predict potential failure modes and damaged parts in various extreme scenarios.

The simulation results were in good agreement with the test results, with a maximum error of less than 8.85%. The high-precision ASRM's model was able to accurately predict potential failure modes and damaged parts in extreme scenarios, demonstrating the effectiveness of the proposed model and simulation evaluation test.

The proposed high-precision ASRM model and simulation evaluation test provide an effective way to evaluate the structural safety and optimize the design of the spacecraft. This information can be used to improve the performance and reliability of the CSS's solar array and ensure continuous power supply to the station.

The purpose of this study is to calculate the normal force of a two degree of freedom direct drive induction motor considering coupling effects based on an analytical model. Compared with the traditional single degree of freedom motor, normal force characteristics of two-degree-of-freedom direct drive induction motor (2DOFDDIM) is affected by coupling effect when the machine is in a helical motion. To theoretically explain the influence mechanism of coupling effect, this paper conducts a quantitative analysis of the influence of coupling effect on normal force based on the established analytical model of normal force considering coupling effect.

Firstly, the normal forces generated by 2DOFDDIM in linear motion, rotary motion and helical motion are investigated and compared to prove the effect of the coupling effect on the normal force. During this study, several coupling factors are established to modify the calculation equations of the normal force. Then, based on the multilayer theoretical method and Maxwell stress method, a novel normal force calculation model of 2DOFDDIM is established taking the coupling effect into account, which can easily calculate the normal force of 2DOFDDIM under different motions conditions. Finally, the calculation results are verified by the results of 3D finite element model, which proves the correctness of the established calculating model.

The coupling effect produced by the helical motion of 2DOFDDIM affects the normal force.

In this paper, the analytical model of the normal force of 2DOFDDIM considering the coupling effect is established, which provides a fast calculation for the design of the motor.

Despite the many advantages this type of equipment offers, there are still some major drawbacks. Linear cutting machine (LCM) cannot accurately simulate the true rock-cutting process as 1. it does not account for the circular path along which tunnel boring machine (TBM) disk cutters cut the tunnel face, 2. it does not accurately model the position of a disk cutter on the cutterhead, 3. it cannot perfectly replicate the rotational speed of a TBM. To enhance the knowledge of these issues and in order to mimic the real rock-cutting process, a new lab testing equipment was developed by Hyundai Engineering and Construction.

A new testing machine called rotary cutting machine (RCM) is designed to simulate the excavation process of hard-rock TBMs and includes features such as TBM cutterhead, RPM simulation, constant normal force mode and constant penetration rate mode. Two sets of tests were conducted on Hwandeung granite using different disk cutter sizes to analyze the cutting forces in various excavation modes. The results are analyzed using statistical analysis and dimensional analysis. A new model is generated using dimensional analysis, and its results are compared against the results of actual cases.

The effectiveness of the new RCM test was demonstrated in its ability to apply various modes of excavation. Initial analysis of chip size revealed that the thickness of the chips is largely dependent on the cutter spacing. Tests with varying RPM showed that an increase in RPM results in an increase in the normal force and rolling force. The cutting coefficient (CC) demonstrated a linear correlation with penetration. The optimal specific energy is achieved at an S/p ratio of around 15. However, a slightly lower S/p ratio can also be used in the design if the cutter specifications permit. A dimensional analysis was utilized to develop a new RCM model based on the results from approximately 1200 tests. The model's applicability was demonstrated through a comparison of TBM penetration data from 26 tunnel projects globally. Results indicated that the predicted penetration rates by the RCM test model were in good agreement with actual rates for the majority of cases. However, further investigation is necessary for softer rock types, which will be conducted in the future using concrete blocks.

The originality of the research lies in the development of Hyundai Engineering and Construction’s advanced full-scale laboratory rotary cutting machine (RCM), which accurately replicates the excavation process of hard-rock tunnel boring machines (TBMs). The study provides valuable insights into cutting forces, chip size, specific energy, RPM and excavation modes, enhancing understanding and decision-making in hard-rock excavation processes. The research also presents a new RCM model validated against TBM penetration data, demonstrating its practical applicability and predictive accuracy.

This paper aims to provide an overview of the recent developments and new topologies of single-phase moving magnet linear oscillating actuators (MMLOAs). The key advantage of the MMLOA when compared with conventional LOA is the absence of screws, gears and crankshaft mechanism, which results in fewer mechanical parts, simple structure, easy fabrication, lower noise levels and negligible frictional losses.

The review included papers up to August 2021. The structural designs of alternative topologies are deliberated in detail, and their relative merits and demerits are evaluated. Specific design issues, including pole and tooth number combinations, stroke length, magnet pole ratio and split ratio, are investigated. The imperative phenomena of the resonance, as well as the adjustable stroke, are also discussed in detail.

The electromagnetic performance in terms of thrust force of selected MMLOA topologies is compared. It is observed that the MMLOA with flux bridge topology has the highest thrust force of 365 N because of the large volume of the permanent magnets (PMs) used, which consequently increased the mass of the mover but based on overall performance analysis, single-phase end ferromagnetic Halbach surface-mounted PM LOA has the highest efficiency around 92%.

This review provides a comparative analysis for different tubular MMLOA topologies based on design construction and their electromagnetic performances.

The purpose of this paper is to apply the novel instantaneous power flow balance (IPFB)-based identification strategy to a specific practical situation like nonlinear lap joints having single and double bolts. The paper also investigates the identification performance of the proposed power flow method over conventional acceleration-matching (AM) methods and other methods in the literature for nonlinear identification.

A parametric model of the joint assembly formulated using generic beam element is used for numerically simulating the experimental response under sinusoidal excitations. The proposed method uses the concept of substructure IPFB criteria, whereby the algebraic sum of power flow components within a substructure is equal to zero, for the formulation of an objective function. The joint parameter identification problem was treated as an inverse formulation by minimizing the objective function using the Particle Swarm Optimization (PSO) algorithm, with the unknown parameters as the optimization variables.

The errors associated with identified numerical results through the instantaneous power flow approach have been compared with the conventional AM method using the same model and are found to be more accurate. The outcome of the proposed method is also compared with other nonlinear time-domain structural identification (SI) methods from the literature to show the acceptability of the results.

In this paper, the concept of IPFB-based identification method was extended to a more specific practical application of nonlinear joints which is not reported in the literature. Identification studies were carried out for both single-bolted and double-bolted lap joints with noise-free and noise-contamination cases. In the current study, only the zone of interest (substructure) needs to be modelled, thus reducing computational complexity, and only interface sensors are required in this method. If the force application point is outside the substructure, there is no need to measure the forcing response also.

This paper aims to study the deformation mechanism of polytetrafluoroethylene (PTFE) oil seal under a wide temperature range cycle.

This study categorizes the oil seal operation into three states: assembly, heating-up and cooling. The deformation equation for the oil seal is developed for each state, considering the continuity between them. The investigation of the oil seal’s deformation trends and mechanisms is performed using the ANSYS Workbench.

The assembling process results in a radial shrinkage of the skeleton, causing the centroid to move toward the axis. During heating-up, the outer diameter of the skeleton slightly expands, whereas the inner diameter sharply contracts toward the axis, leading to a further reduction in the centroid’s distance from the axis. Upon cooling, both the inner and outer diameters continue to contract toward the axis, causing the centroid to persist in its movement toward the axis. Consequently, after undergoing a heating-up and cooling cycle ranging from 20°C to 180°C, the outer diameter of the PTFE oil seal reduces by 0.92 mm from its original deformation, ensuring minimal contact between the skeleton and housing. As a result of the reduced static friction torque at the skeleton, the oil seal rotates along the shaft.

The deformation mechanism of PTFE oil seals under a wide temperature range cycle was investigated, aiming to address the concerns related to the rotation along the shaft and leakage.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-05-2023-0142/

Industrial robots are extensively used in the robotic assembly of rigid objects, whereas the assembly of flexible objects using the same robot becomes cumbersome and challenging due to transient disturbance. The transient disturbance causes vibration in the flexible object during robotic manipulation and assembly. This is an important problem as the quick suppression of undesired vibrations reduces the cycle time and increases the efficiency of the assembly process. Thus, this study aims to propose a contactless robot vision-based real-time active vibration suppression approach to handle such a scenario.

A robot-assisted camera calibration method is developed to determine the extrinsic camera parameters with respect to the robot position. Thereafter, an innovative robot vision method is proposed to identify a flexible beam grasped by the robot gripper using a virtual marker and obtain the dimension, tip deflection as well as velocity of the same. To model the dynamic behaviour of the flexible beam, finite element method (FEM) is used. The measured dimensions, tip deflection and velocity of a flexible beam are fed to the FEM model to predict the maximum deflection. The difference between the maximum deflection and static deflection of the beam is used to compute the maximum error. Subsequently, the maximum error is used in the proposed predictive maximum error-based second-stage controller to send the control signal for vibration suppression. The control signal in form of trajectory is communicated to the industrial robot controller that accommodates various types of delays present in the system.

The effectiveness and robustness of the proposed controller have been validated using simulation and experimental implementation on an Asea Brown Boveri make IRB 1410 industrial robot with a standard low frame rate camera sensor. In this experiment, two metallic flexible beams of different dimensions with the same material properties have been considered. The robot vision method measures the dimension within an acceptable error limit i.e. ±3%. The controller can suppress vibration amplitude up to approximately 97% in an average time of 4.2 s and reduces the stability time up to approximately 93% while comparing with control and without control suppression time. The vibration suppression performance is also compared with the results of classical control method and some recent results available in literature.

The important contributions of the current work are the following: an innovative robot-assisted camera calibration method is proposed to determine the extrinsic camera parameters that eliminate the need for any reference such as a checkerboard, robotic assembly, vibration suppression, second-stage controller, camera calibration, flexible beam and robot vision; an approach for robot vision method is developed to identify the object using a virtual marker and measure its dimension grasped by the robot gripper accommodating perspective view; the developed robot vision-based controller works along with FEM model of the flexible beam to predict the tip position and helps in handling different dimensions and material types; an approach has been proposed to handle different types of delays that are part of implementation for effective suppression of vibration; proposed method uses a low frame rate and low-cost camera for the second-stage controller and the controller does not interfere with the internal controller of the industrial robot.

The electromechanical brake system is leading the latest development trend in railway braking technology. The tolerance stack-up generated during the assembly and production process catalyzes the slight geometric dimensioning and tolerancing between the motor stator and rotor inside the electromechanical cylinder. The tolerance leads to imprecise brake control, so it is necessary to diagnose the fault of the motor in the fully assembled electromechanical brake system. This paper aims to present improved variational mode decomposition (VMD) algorithm, which endeavors to elucidate and push the boundaries of mechanical synchronicity problems within the realm of the electromechanical brake system.

The VMD algorithm plays a pivotal role in the preliminary phase, employing mode decomposition techniques to decompose the motor speed signals. Afterward, the error energy algorithm precision is utilized to extract abnormal features, leveraging the practical intrinsic mode functions, eliminating extraneous noise and enhancing the signal’s fidelity. This refined signal then becomes the basis for fault analysis. In the analytical step, the cepstrum is employed to calculate the formant and envelope of the reconstructed signal. By scrutinizing the formant and envelope, the fault point within the electromechanical brake system is precisely identified, contributing to a sophisticated and accurate fault diagnosis.

This paper innovatively uses the VMD algorithm for the modal decomposition of electromechanical brake (EMB) motor speed signals and combines it with the error energy algorithm to achieve abnormal feature extraction. The signal is reconstructed according to the effective intrinsic mode functions (IMFS) component of removing noise, and the formant and envelope are calculated by cepstrum to locate the fault point. Experiments show that the empirical mode decomposition (EMD) algorithm can effectively decompose the original speed signal. After feature extraction, signal enhancement and fault identification, the motor mechanical fault point can be accurately located. This fault diagnosis method is an effective fault diagnosis algorithm suitable for EMB systems.

By using this improved VMD algorithm, the electromechanical brake system can precisely identify the rotational anomaly of the motor. This method can offer an online diagnosis analysis function during operation and contribute to an automated factory inspection strategy while parts are assembled. Compared with the conventional motor diagnosis method, this improved VMD algorithm can eliminate the need for additional acceleration sensors and save hardware costs. Moreover, the accumulation of online detection functions helps improve the reliability of train electromechanical braking systems.