The machining of brittle materials such as glasses and ceramics is an area of rising interest in the 'Precision Engineering' field due to the advantageous characteristics of ceramics and demands for glass machining from optical component manufacturers. In general the 'ductile mode' machining of brittle materials requires cut-geometry to be sub-micrometre. In order to improve machining accuracy of single-point diamond turning for brittle materials in the ductile mode, a controlled micro-tilt stage system was proposed for improvement of the motion accuracy and dynamic stiffness of an aerostatic spindle. Mechanical arrangements for the proposed controlled micro-tilt stage system including slip rings for transferring voltage signals to a rotating body were developed together with a strategy for spindle metrology using three optical fibre sensors. Algorithms for averaging and spacial filtering were applied to remove random noise caused by the variation of surface texture. The micro-tilt stage was designed to satisfy specifications in respect of travel range, resolution, stiffness, and resonant frequency. Efforts were also made to minimize static and dynamic cross-coupling-interference between the required three degrees of freedom. The micro-tilt stage showed satisfactory performance, and the effectiveness of non-crosscoupling design was seen. After considering various control strategies, hardware and software were arranged with PID and repetitive controllers. The diagonal dominance of the micro-tilt stage control system permitted 'SISO' system design. The performance of the controlled micro-tilt stage was investigated both stationary and during rotation. The stationary controlled micro-tilt stage worked satisfactorily; the controlled rotating micro-tilt stage demonstrated its error-correcting capability with some speed limitations, primarily due to the spacial filtering and time averaging required to reduce the surface texture noise.

No description available.

A multi-axis compact positioner is designed and implemented in this thesis. The single-moving-part positioner is designed to move in the magnetic field generated by a superimposed concentrated-field permanent magnet matrix. The compact positioner is primarily for the stepping and scanning applications that require 3-DOF planar motions. In which, the travel ranges in two orthogonal directions are on the order of 100 mm. The moving platen, which has the size of 185.4 mm x 157.9 mm and weighs 0.64 kg, mainly comprises of a plastic frame and six copper coils. It is actuated in the horizontal plane by flowing six independent electric currents into the coils. The platen is supported against gravity by three air bearings. Force calculation is based on the Lorentz force law. With a current-carrying rectangular coil placed in the magnetic field of the supper-imposed Hallbach magnet matrix, the force acting on the coil is calculated by volume integration. The distances between the longer sides and between the shorter sides of the rectangular coil are designed to fit a half pitch and one pitch of the Hallbach magnet array, respectively. Therefore, the volume integration is simplified considerably. The force-current relation for the entire platen with six coils is derived. Three Hall-effect sensors are attached to the moving platen to measure the magnetic flux densities at the center points of the sensors. The position of the moving platen is determined by the field solution of the magnet matrix and the magnetic flux densities sensed by the Hall-effect sensors. A new discrete PID-like controller is proposed and tested. For the step responses with the step sizes within 1000 micrometers, the overshoots and the steady state errors are negligible. The achieved velocity in x is 10.50 cm/s and in y is 16.25 cm/s, respectively. The achieved acceleration in x is 43.75 cm/s^2 and in y is 95.59 cm/s^2, respectively. The achieved travel ranges are 15.24 cm in x, 20.32 cm in y, and 0.21 rad in the rotational motions about the vertical axis. The positioning resolution in x and y is 8 micrometers with the rms positioning error of 6 micrometers. The positioning resolution in rotation about the vertical axis is 130 microrad.

This PhD thesis describes the design and development of a new resonator based tactile sensitive probe. This new sensor was proposed because of the increasing need for high-sensitivity, high-speed touch-sensitive probes in coordinate metrology due to the ever-growing demand for precision and reliability at sub-micron level accuracy. Extensive background research on the current development of touch trigger probes has shown that designs based on the resonator principle have potential for minimising lobing effects and the false triggering associated with most commercially available probes. Resonant based sensors have been investigated over many decades and used very successfully in a wide range of applications. However their commercial exploitation in the field of precision engineering has not been particularly successful. One reason for such slow progress is the complexity of the interaction between oscillatory probes and typical engineering surfaces in less than ideal environments. The main aim of this research was to design a high precision resonator based tactile sensitive probe and to investigate the causes of parametric changes on resonant touch sensors both before and during contact with a variety of engineering surfaces in order to achieve a better understanding of contact mechanisms. The four main objectives were: preliminary design and characterisation of a resonator based touch sensor; development of the mathematical model which predicts parametric changes on a resonant probe considering both near surface effects and mechanical contact; experimental verification of mathematical predictions; and an investigation into possible commercial exploitation of the new probe in precision applications. A novel resonator based tactile sensor that utilises the piezoelectric effect was designed and characterised. The design exploits the fact that when a stiff element (probe) oscillating near or at its resonance frequency comes into contact with the surface of another body (workpiece), the frequency of vibrational resonance of the probe changes depending on the properties of the workpiece. The phase-locked loop frequency detection technique was employed to track changes in frequency as well as in the phase of the resonant system. The initial characterisation of the touch sensor has shown a sensitivity to contact of less then 4 mN, a high triggering rate and good repeatability. The potential for application in measuring material properties was also demonstrated. As a result of the characterisation a comprehensive mathematical model was developed. This novel model was based on Hertzian contact mechanics, Rayleigh's approximate energy method and work carried out by Smith and Chetwynd on the analysis of elastic contact of a sphere on a flat. The model predicts that phase and frequency shift of a resonator based sensor can either increase or decrease depending on the dominant phenomena (added mass, stiffness and damping) in the contact region. Observation of dynamic characteristics at either side of the resonant frequency can be used to identify the predominant effect. In order to confirm the model experimentally, another prototype probe was developed. The new sensor was engaged in observations of contact mechanisms with engineering surfaces. The experimental results have showed favourable agreement with the developed mathematical model. This enabled a better understanding of contact phenomena uncovering possibilities for the application of resonant sensors in many other areas. The research has shown that the new probe has potential in contact measurements where it can be used for the quantitative assessment of the physical properties of different materials (modulus of elasticity, density and energy dissipation) and also in non-destructive hardness testing. It was shown that the device can be successfully used in coordinate metrology as a touch trigger probe and as a 3D vector probe. Finally, applications can also be found in surface topography as a surface characterisation instrument. It is intended that the research described in this thesis will make an important contribution in the area of resonator based probes, providing a better understanding of the causes of parametric changes on the oscillatory sensor during contact with the object being measured. Consequently, this will enable a more effective exploitation of resonant probes for a broad range of precision applications.

No description available.

In the European Union the legislation governing fleet CO2 emissions is already in place with a fleet average limit of 130g/km currently being imposed on all vehicle manufacturers. With the target for this legislation falling to 95g/km by 2020 and hefty fines for noncompliance automotive engineers are working a pace to develop new technologies that lower the CO2 emissions and hence fuel consumption of new to market vehicles. As average new vehicle CO2 emissions continue to decline the task of measuring these emissions with high precision becomes increasingly challenging. With the introduction of real world emissions legislation planned for 2017 there is a development driven need to precisely assess the vehicle CO2 emissions on chassis dynamometers over a wide operating range. Furthermore since all type approval and certification testing is completed on chassis dynamometers, any new technology must be proven against these test techniques. Typical technology improvements nowadays require repeatability limits which were unprecedented 5-10 years ago and the challenge now is how to deliver this level of precision. Detailed studies are conducted into the four key areas that cause significant noise to the CO2 emissions results from chassis dynamometer tests. These are the vehicle electrical system, driver behaviour, procedural factors and the chassis dynamometer itself. In each of these areas, the existing contribution of imprecision is quantified, methods are proposed then demonstrated for improving the precision and the improved case is quantified. It was found that the electrical system can be controlled by charging the vehicle battery, not using auxiliary devices and installing current measurement devices on the vehicle. Simply charging the vehicle battery prior to each test was found to cause a change to the CO2 emissions of 2.2% at 95% confidence. Whilst auxiliary devices were found to cause changes to the CO2 emissions of up to 43% for even a relatively basic vehicle. The driver behaviour can be controlled by firstly removing the tolerances from the driver’s aid which it was found improved the precision of the CO2 emissions by 43.5% and secondly by recording the throttle pedal movements to enable the validation of test results. Procedural factors, such as tyre pressures can be easily controlled by resisting the temptation to over check and by installing pressure sensing equipment. Using a modern chassis dynamometer with low parasitic losses will make the job of controlling the dynamometer easier, but all dynamometers can be controlled by following the industry standard quality assurance procedures and implementing statistical process control tools to check the key results. The implementation of statistical process control alone improved the precision of unloaded dynamometer coastdown checks by reducing the coefficient of variation from 6.6 to 4.0%. Using the dynamometer to accelerate the vehicle before coastdown checks was found to approximately halve the variability in coastdown times. It was also demonstrated that verification of the dynamometer inertia simulation and response time are both critically important, as the industry standard coastdown test is insufficient, in isolation, to validate the loading on a vehicle. Six sigma and statistical process control techniques have shown that for complex multiple input single output systems, such as chassis dynamometer fuel economy tests, it is insufficient to improve only one input to the system to achieve a change to the output. As a result, suggested improvements in each noise factor often have to be validated against an input metric rather than the output CO2 emissions. Despite this, the overall level of precision of the CO2 emissions and fuel consumption seen at the start of the research, measured by the coefficient of variation of approximately 2.6%, has been improved by over six times through the simultaneous implementation of the findings from this research with the demonstration of coefficient of variation as low as 0.4%. Through this research three major contributions have been made to the state of the art. Firstly, from the work on driver behaviour an extension is proposed to the Society of Automotive Engineers J2951 drive quality metric standard to include the a newly developed Cumulative Absolute Speed Error metric and to suggest that metrics are reviewed across the duration of a test to identify differences in driving behaviours during a test that do not cause a change to the end of test result. Secondly, the need to instrument the vehicle and test cell to record variability in the key noise factors has been demonstrated. Thirdly, a universal method has been developed and published from this research, to use response modelling techniques for the validation of test repeatability and the correction of CO2 emissions. The impact of these contributions is that the precision of chassis dynamometer emissions tests can be improved by a factor of 6.5 and this is of critical importance as the new real world driving and world light-duty harmonised emissions legislation comes into force over the next two to five years. This legislation will require an unprecedented level of precision for the effective testing of full vehicle system interactions over a larger operating range but within a controlled laboratory environment. If this level of precision is not met then opportunities to reduce vehicle fuel consumption through technology that only has a small improvement on fuel consumption, which is likely given the large advances that have be achieved over the last few decades, will be missed.

In this thesis, the measurement uncertainty of Coordinate Measuring Machine (CMM) is analysed and software is designed to simulate this. Analysis begins with the inspection of the measurement process and structure of the CMMs. After that, error sources are defined with respect to their effects on the measurement and then an error model is constructed to compensate these effects. In other words, systematic part of geometric, kinematic and thermal errors are compensated with error modelling. Kinematic and geometric error model is specific for the structure of CMM under inspection. Also, a common orthogonal kinematic model is formed and with using the laser error data of the CMM and error maps of the machine volume is obtained. Afterwards, the models are compared with each other by taking the difference and ratio. The definition and compensation of the systematic errors leave the uncertainty of measurements for analysing. Measurement uncertainty consists of the uncompensated systematic errors and random errors. The other aim of the thesis is to quantify these uncertainties with using the different methods and to inspect the success of these methods. Uncertainty budgeting, comparison, statistical evaluation by designing an experiments and simulation methods are examined and applied to the CMM under inspection. In addition, Virtual CMM software is designed to simulate the task specific measurement uncertainty of circle, sphere and plane without using the repeated measurements. Finally, the performance of the software, highly depending on the mathematical modelling of machine volume, is tested by using actual measurements.

<p>Wireless communications and interconnected devices have become ubiquitous in our everyday life. As the rollout of the 5th generation (5G), wireless communication technology is well underway, the number of interconnected devices is increasing exponentially. Estimations for 2021 predicted that 1.5 billion smart devices would sell globally, representing a $53.45 billion market size by 2022. With the increase of communication channels and transmitted data within these networks, the challenge of coexistence without interference will become prominent. Simultaneously, 5G networks are introducing more frequency bands while densifying the network of communication towers. Forecasts predict a 100X increase of the network at the edge by introducing small cell towers, with projections estimating 45 million installed by 2031. As a result, rapid exponential growth in hardware costs is expected. Also, these dense networks will require a higher degree of self-configuration to prevent adjacent band interference.</p> <p>Tunable filters and large-scale manufacturing technologies are two solutions to address these challenges. Reconfigurable high-quality evanescent-mode (EVA) filters have been extensively presented in the literature. Different mechanisms have been employed for tuning, such as piezoelectric actuators and motors, and magnetostatic and electrostatic actuators. Furthermore, these implementations have been realized with printed circuit board (PCB) technology, computer numerical control (CNC) machining, 3D printing, and silicon (Si) micro-machining. Specifically, PCB manufacturing of three-dimensional front-end tunable filters has been promising and can deliver excellent performance. In addition, they can be integrated into the existing manufacturing lines and circuitry for the RF front-end.</p> <p>Nonetheless, there are limitations in fabrication tolerances that PCB manufacturing could reach. Consequently, there are restrictions on the frequency bands that these devices can be manufactured as dimensions become smaller in higher bands. Moreover, EVA cavities have been proven to yield higher performance filters when compared to unloaded quality factors and power handling of currently used substrate integrated waveguide (SIW) based technologies. Specifically, EVA filters produced with silicon micro-manufacturing combined with MEMS actuators have been demonstrated with remarkable performance up to 100s of GHz. Also, cost limitations per unit built are significant compared to other technologies like injection molding.</p> <p>The research goal of this work is to investigate scalable, low-cost manufacturing processes and techniques while maintaining a high-performance device. Combining knowledge from silicon RF MEMS tuned EVA filters and the cost-effective mass manufacturing injection molding technology to deliver a high-Q, high power handling, low-cost tunable filter. Demonstrating these characteristics within the same manufactured prototype would be a unique solution within the existing literature on tunable filters.</p> <p>This thesis is organized into three parts. The first part is focused on design for manufacturing (DFM). Si micromachining has been used to produce tunable resonators and filters at lower bands, but higher bands have yet to be demonstrated. The low-cost batch fabrication of already established Si micromachining lines makes this an attractive technology to realize these devices. This section presents network densification’s challenges and the economics of scale-up manufacturing. Furthermore, using Si micromachining, the first high Q tunable W band RF resonator is demonstrated tuned with MEMS technology.</p> <p>In the second part, the focus is on design for performance (DFP). Si micromachining is optimized to demonstrate high-performance RF MEMS tunable filters up to 100s GHz. High Q, wide tuning range, and low actuation voltages for the MEMS tuners have been realized.</p> <p>In the third part, the focus is on design for cost (DFC), where injection molding manufacturing technology is proven to have significant advantages in low cost with respect to other large-scale manufacturing technologies. A high-performance tunable resonator and filter in the sub-6 GHz frequency band are manufactured. They prove that simultaneously high Q, widely tunable, high power capable filters can be produced with low-cost scalable manufacturing technology.</p>

The advanced handling of uncertainties arising from a wide range of sources is fundamental in quality control and dependability to reach advantageous decisions in different organizational levels of industry. Es-pecially in the competitive edge of production, uncertainty shall not be solely object of estimation but the result of a systematic management process. In this process, the composition and utilization of proper in-formation acquisition systems, capability models and propagation tools play an inevitable role. This thesis presents solutions from production system to operational level, following principles of the introduced con-cept of uncertainty-based thinking in production. The overall aim is to support transparency, predictability and reliability of production sys-tems, by taking advantage of expressed technical uncertainties. On a higher system level, the management of uncertainty in the quality con-trol of industrial processes is discussed. The target is the selection of the optimal level of uncertainty in production processes integrated with measuring systems. On an operational level, a model-based solution is introduced using homogeneous transformation matrices in combination with Monte Carlo method to represent uncertainty related to machin-ing system capability. Measurement information on machining systems can significantly support decision-making to draw conclusions on man-ufactured parts accuracy, by developing understanding of root-causes of quality loss and providing optimization aspects for process planning and maintenance. / <p>QC 20181015</p>

<p dir="ltr">The study aims to prove the need for higher quality production of weight plates which fall under US6746380B2 (expired May 10, 2021), assigned to USA Sports Inc. Literature justifies quality control standards. Selected literature validates posed hypotheses, and a product study is completed using weight plate specimens selected for physical quality testing to prove the common (repeated offense) existence of weight plates which fall out of the designated weight tolerance. Findings of physical product testing are collected and set against each other to determine differences in levels of quality control. Through extensive product testing (quantified within the study’s research methodology), novel quality control ideals are identified for product improvement in the study’s recommendations. Next steps are suggested to improve the understanding and utilization of quality control to work toward creating a sustainable and consistently high-quality product. Findings from the study are available to be used amongst companies in the fitness industry who produce weight plates.</p>