Proportional Solenoid Valves (PSV) have been successfully used in the hydraulic industry for many years due to the benefits associated with higher accuracy compared to on/off solenoid valves, and the robustness and cost compared to servo valves. Because the PSV plays an important role in the performance of a hydraulic system, a technique commonly referred to as Condition Monitoring Scheme (CMS) has been used extensively to monitor the progress of faults in the PSV. But before any CMS can be implemented on a system, it needs to be thoroughly tested for its reliability of fault detection since, a failure of the CMS to detect any potential fault can be economically disastrous, and dangerous in terms of the safety of personnel. The motivation of this research was to develop a fault simulator which could reliably and repeatedly induce user defined faults in the PSV and thereby aid in testing the efficacy of the CMS for monitoring such simulated faults.<p>Industry research has revealed that the most common mode of failure in spool valves is an increase in the friction between the spool and valve, due to wear, contamination and dirt, which renders the valve inoperable. In this research, a non-destructive fault simulator was developed which induced artificial friction faults in the PSV. The PSV consisted of two solenoids on the opposite sides of the valve spool by virtue of which, bi-directional position control could be achieved. The PSV with the spool and one of the solenoids was used as the system in which the faults were simulated, and the second solenoid was used an a fault simulator for inducing the desired friction characteristics in the system. <p>The friction characteristics induced in the valve were similar to those in the classical friction curve, i.e., stiction at low velocities and Coulomb and viscous friction at higher velocities. By employing a closed loop position control scheme, one of the solenoids was used to generate a linearly increasing velocity profile by virtue of which the desired friction characteristics could be induced in different velocity regimes. The other solenoid was used to generate the desired friction force. A closed loop force control strategy, which used the feedback from a force transducer, allowed for the accurate control of the friction characteristics. stiction was induced at low velocities by passing the required current in both the solenoids that resulted in no net force on the valve spool. Due to the absence of any driving force the spool was stalled at the desired location, thus achieving the same effect of stiction at low velocities. The coulomb and viscous friction were induced at higher velocities by employing an algorithm which was a function of the spool velocity. Different magnitudes of static, coulomb and viscous friction were induced to achieve the friction characteristics represented by the classical friction curve. Since the change in force characteristics of the valve results in a corresponding change in the current drawn by the position control solenoid, a rudimentary CMS for monitoring the current characteristics is presented. Based on the experimental results and validation using the CMS it was concluded that the fault simulator was able to accurately produce the desired frictional loading on the valve spool and was able to do so with a high degree of repeatability. Proportional Solenoid Valves (PSV) have been successfully used in the hydraulic industry for many years due to the benefits associated with higher accuracy compared to on/off solenoid valves, and the robustness and cost compared to servo valves. Because the PSV plays an important role in the performance of a hydraulic system, a technique commonly referred to as Condition Monitoring Scheme (CMS) has been used extensively to monitor the progress of faults in the PSV. But before any CMS can be implemented on a system, it needs to be thoroughly tested for its reliability of fault detection since, a failure of the CMS to detect any potential fault can be economically disastrous, and dangerous in terms of the safety of personnel. The motivation of this research was to develop a fault simulator which could reliably and repeatedly induce user defined faults in the PSV and thereby aid in testing the efficacy of the CMS for monitoring such simulated faults. Industry research has revealed that the most common mode of failure in spool valves is an increase in the friction between the spool and valve, due to wear, contamination and dirt, which renders the valve inoperable. In this research, a non-destructive fault simulator was developed which induced artificial friction faults in the PSV. The PSV consisted of two solenoids on the opposite sides of the valve spool by virtue of which, bi-directional position control could be achieved.The PSV with the spool and one of the solenoids was used as the system in which the faults were simulated, and the second solenoid was used an a fault simulator for inducing the desired friction characteristics in the system. The friction characteristics induced in the valve were similar to those in the classical friction curve, i.e., stiction at low velocities and Coulomb and viscous friction at higher velocities. By employing a closed loop position control scheme, one of the solenoids was used to generate a linearly increasing velocity profile by virtue of which the desired friction characteristics could be induced in different velocity regimes. The other solenoid was used to generate the desired friction force. A closed loop force control strategy, which used the feedback from a force transducer, allowed for the accurate control of the friction characteristics. stiction was induced at low velocities by passing the required current in both the solenoids that resulted in no net force on the valve spool. Due to the absence of any driving force the spool was stalled at the desired location, thus achieving the same effect of stiction at low velocities. The coulomb and viscous friction were induced at higher velocities by employing an algorithm which was a function of the spool velocity. Different magnitudes of static, coulomb and viscous friction were induced to achieve the friction characteristics represented by the classical friction curve. Since the change in force characteristics of the valve results in a corresponding change in the current drawn by the position control solenoid, a rudimentary CMS for monitoring the current characteristics is presented. Based on the experimental results and validation using the CMS it was concluded that the fault simulator was able to accurately produce the desired frictional loading on the valve spool and was able to do so with a high degree of repeatability.

This thesis presents the design, analysis, and numerical and experimental evaluation of nonlinear controllers for co-operation among several hydraulic robots operating in the presence of significant system uncertainties, non-linearities and friction. The designed controllers allow hydraulically driven manipulators to (i) co-operatively handle a rigid object (payload) following a given trajectory, (ii) share the payload and (iii) maintain an acceptable internal force on the object. A general description of the kinematic and dynamic relations for a hydraulically actuated multi-manipulator system is presented first. The entire mathematical model incorporates object dynamics, robot dynamics, hydraulic actuator functions and friction dynamics. For the purpose of simulations, a detailed numerical simulation program of such a system is also developed, in which two three-link planar robot manipulators resembling the Magnum hydraulic manipulators manufactured by ISE, interact with each other through manipulating a common object. The regulating control problem is studied next, in which the desired position of the object and the corresponding desired link displacement change step-wise. Initially, a controller is designed based on a backstepping technique, assuming that full knowledge of the dynamics and kinematics of the system is available. The assumption is then relaxed and the control system is analyzed. Based on the analysis, the controller is then modified to account for the uncertainty of the payload, robot dynamic parameters and hydraulic functions. Next, the regulating controller is extended to a tracking controller, which allows the object to follow a given trajectory and is robust against parameter uncertainties. Additionally, an observer is added to the controller to avoid the need of acceleration feedback. To investigate the effect of friction force, the above controllers are examined by introducing the most recent and complete LuGre friction model into the system dynamics. The tracking controller is then redesigned to compensate the effect of friction. Observers are designed to observe the immeasurable friction states. Based on the observed friction states and estimated friction parameters, an appropriate friction compensation scheme is designed which does not directly use velocity in order to avoid the need of acceleration feedback by the controller. Finally, the problem of “explosion of terms” coming from the backstepping method is solved by using the concept of dynamic surface control in which a low pass filter is integrated to avoid model differentiation. Simulations are carried out for analysis of the control system and verification of the developed controllers. Experimental examinations are performed on an available hydraulic system consisting of two single-axis hydraulic actuators. / February 2008

No description available.

This thesis is concerned with the development of a new measurement device for the realistic assessment of braking capability of landing airplanes for winter runways. Landing represents one of the most safety-critical phases of aircraft operation. Aircraft runway excursion incidents occur due to the unpredictability of the runway pavement condition. This is especially true during winter time when the runway is often covered by deformable contaminants. Several accidents are discussed that list the deteriorated condition of the runway pavement and the inability to accurately report this condition as the main causes for the excursions. The accuracy of the approaches currently adopted by the airport authorities around the world to monitor the condition of the runway pavement are evaluated. The conventional and current practice of runway condition monitoring is focused on identifying the maximum tire-pavement frictional drag mu value and often neglects the characteristics of actual aircraft brake control system as well as the comprehensive effects coming from various factors such as deformable contaminants on the winter runway. The braking availability tester discussed here is designed to take a different approach for the realistic assessment of braking availability of landing aircrafts. The main idea of this device is to mimic the braking operation of actual aircrafts as closely as possible by incorporating the same brake mechanism and the brake control system used in existing aircrafts. The architecture of the device from the ground-up including the suite of sensors, the structure of the wheel, important actuators, and the real-time brake control system are discussed in detail. More importantly, the operational principles of the braking availability tester (BAT) are outlined which help one understand how the system works together. A new method to quantify the braking availability on the runway using the BAT is explained. The testing and data collection strategy for implementing this technique is also outlined. Additionally, the results from preliminary tests are presented to verify the functionality of the BAT. The results are used to verify that the BAT operates with the brake control system of an aircraft. Finally, experimental data sets from dry and contaminated pavement testing are presented to show the effect of different weather conditions on the operation of the BAT.

The widespread use of low friction PVD coatings on machine elements is limited by the high costs associated with fulfilling the demands on the surface quality of both the supporting substrate and the counter surface. In this work, an attempt is made at lowering these demands, by adding a sacrificial carbon overcoat to a TaC/aC low friction coating. Both coatings were deposited by planar magnetron DC sputtering, as separate steps in a single PVD-process. Coatings were deposited on substrates of two different surface roughnesses, in order to test the ability of this coating system to function on rougher substrates. Reciprocating ball on disc tests was performed, using balls with two different surface roughnesses. The worn surfaces were investigated using 3-D profilometry and SEM. The ability of the different overcoats to initially reduce the roughness of both the coated surface and the counter surface and to produce stable, low-friction conditions was examined for the different initial roughnesses. The implications for design of efficient run-in coatings for various systems are discussed.

This dissertation primarily documents the quantification of the interfacial behavior of carbon based nanomaterials, which includes two categories, one is the nanofriction properties evaluation of aligned carbon nanotube carpets, few-layer graphene as well as three types of functionalized graphene nanoribbons, the second is the mechanical characterization of individual functionalized carbon nanofibers and the interfacial fracture toughness quantification in carbon nanotube/polymer derived ceramics nanocomposite. The aligned carbon nanotube carpets have a highly anisotropic friction behavior, which means the friction force are lower for transversely aligned CNTs side than for vertically aligned CNTs surface. We can also tune the friction properties of graphene ribbons by grafting different functional groups. In addition, two narrow angular regions with high friction, separated by a wide angular interval with low friction, were identified between graphene and highly oriented pyrolytic graphite. The distance between the two friction peaks is 61◦, which corresponds well with the 60◦ symmetry of individual atomic layers in the graphite lattice. The technique that involves the usage of mcirodevices and nanoidenter was used to conduct tensile tests on pristine, fluorinated and amino-functionalized carbon nanofibers, which were found to exhibit varied load-bearing abilities and unique fracture modes. The technique was also used to perform single fiber pullout experiments to study carbon nanotube/polymer derived ceramic interface.

Friction Stir Welding (FSW) is a new technology which joins materials by using frictional heat. Inthe first part of this thesis, a profound literature study is performed. The basic principles, therobotic implementation and possibilities to use FSW for high strength titanium alloys areexamined. In the next phase, a FSW-tool is modelled and implemented on an industrial robot in arobot simulation program. Reachability tests are carried out on car body parts and jet engineparts. By using a simulation program with embedded collision detection, all possible weldinglocations are determined on the provided parts. Adaptations like a longer FSW-tool and amodified design are suggested in order to get a better reachability. In different case studies, thenumber of required robots and the reduction of weight and time are investigated and comparedto the current spot welding process.

The purpose with this thesis was to examine the cold rolling mill located at Högskolan Dalarna and to stabilize the rolling process, to achieve steady state. Experiments with cold rolling of an aluminium strip have given results for rolling force, friction, reduction, strip tension and strain hardening. Results show that steady state has been found for the experiments with roll force and strain hardening, and not been found for the experiments with friction and reduction. Results show that increased strip tension gives lower roll forces. The roll force equation of Stone shows comparable results with reality for dry contact with reductions up to 30 %, but starts being incomparable with higher reductions. The roll force equation of Stone shows a bit higher roll forces than reality gave, but was comparable within reductions from 13 to 50 %. Experiments have shown that the aluminium strip has gone through strain hardening. Experiments show how the set roll gap did not yield the desired thickness reduction, there for the elastic spring constant for the rolling mill was examined and determined to be 417 N / mm for the specific alloy band. The influence of tension strip for roll force was examined and Results confirm the theory about how the roll force is decreased by increasing tension strip. The work rolls started to slip against the alumina strip as high tension strip; 70 N/mm2, gave low roll force; < 15kN.

A volumetric contact dynamics model has been proposed by Gonthier et al. [1, 2, 3] for the purpose of rapidly generating reliable simulations of space-based manipulator contact dynamics. By assuming materials behave as a Winkler elastic foundation model, forces and moments between two bodies in contact can be expressed in terms of the volume of interference between the undeformed geometries of the bodies. Friction between bodies is modelled by a dwell-time dependent bristle model for both tangential friction, and spinning friction torque. This volumetric model has a number of advantages. Unlike point-contact models, it allows for the modelling of contact between complex geometries and scenarios where the contact surface is relatively large, while being less computationally expensive than finite element methods. Rolling resistance is included in the model through damping effects across the volume of interference. The friction model accounts for dwell-time dependent slip-stick effects, spinning friction torque, and the Contensou effect. In this thesis, an experimental validation of the volumetric contact model is presented for the first time. Models for simple geometries in contact (e.g. cylinder-on-plane, sphere-on-plane) have been developed for stationary contact and for contact with motion normal and tangential to the contact surface. Tangential motion is modelled with pure translation, pure rotation about the normal axis, and combined motion, in order to separately consider friction forces, spinning friction torque, and the Contensou effect, respectively. An apparatus has been developed to experimentally validate these models for metal-on-metal contact. The apparatus has two configurations, one for validating the normal contact models and the other for the friction models. Experimental measurements of forces and displacements are used to identify model parameters (e.g. volumetric stiffness, friction coefficients, etc.). For normal force experiments, modelling the contact forces as proportional to volume of interference was found to be a reasonable approximation. A Hertzian model was compared with the volumetric model for spherical payloads loaded quasi-statically. Using stiffnesses estimated from spherical experiments, small misalignments of the cylindrical payloads were estimated that corresponded well with measured results. Dynamic experiments suggest an inverse relationship between impact velocity and the hysteretic damping coefficient. The high normal forces applied in the friction experiments were found to create significant wear on the contact surfaces. Coefficients of friction between titanium and aluminum were found to be consistent translationally and rotationally. Friction forces from combined translation and rotation demonstrate that the Contensou effect is accurately described by the volumetric contact model.

Effects of biomimetic micro-patterning of polymeric materials on their interfacial properties were studied experimentally. Micropillars of PDMS and SU-8 epoxy were fabricated through soft lithography and UV lithography techniques, respectively. PDMS pillars were topped by thin terminal films of the same material through dipping method with different thicknesses and viscosities. Adhesion and frictional properties of biomimetic microstructures were examined in two modes of contact, i.e. laid and conformal contact. In the first mode of contact, i.e. laid contact, the contact between adhesive and adherent is laid on top of the micro-protrusions or is in contact with side wall of micropillars. Adhesion properties of the smooth and patterned PDMS were characterized through micro-indentation test. Moreover, the friction properties of the smooth PDMS sample and PDMS micropillars with different aspect ratios were examined in unidirectional friction testing. JKR theory of continuum contact mechanics was utilized to interpret the obtained data. To study the effect of second mode of contact, peeling behaviour of a conformal contact between solidified liquid PDMS and SU-8 micropillars was monitored. Kendall’s model of elastic peeling was used to interpret the peeling data. It was found that patterning of the materials would decrease the real area of contact and accordingly adhesion and friction to the mating surface. Termination of the micropillars with a thin layer of the same material result in increment of adhesion as reduction of the real contact area could be compensated and the compliance of the near surface increases. Elastic energy dissipation as a result of enhanced compliance and crack trapping and crack propagation instabilities are the main reasons behind increment of adhesion of thin film terminated structures. Viscoelasticity of the terminal thin film remarkably increased the adhesion as a result of coupling mentioned mechanisms and viscoelastic loss on the surface. Decline of the overall friction could be tailored through use of different aspect ratios. Higher aspect ratios pillars show higher friction comparing to lower aspect ratio pillars. 550 folds enhancement of adhesion was observed for peeling of the PDMS tape from rigid micropillars with aspect ratio ranging from 0 to 6. It is concluded that for the lower aspect ratio micropillars, the elastic energy dissipation is playing the key role in adhesion enhancement. This role shifts toward side-wall friction during separation by increase in aspect ratio. These all give in hand a versatile tool to control and fine tune the interfacial properties of materials, whether they are concerned with adhesion or friction.