abstract: Honeycomb sandwich panels have been used in structural applications for several decades in various industries. While these panels are lightweight and rigid, their design has not evolved much due to constraints imposed by available manufacturing processes and remain primarily two-dimensional extrusions sandwiched between facings. With the growth in Additive Manufacturing, more complex geometries can now be produced, and advanced design techniques can be implemented into end use parts to obtain further reductions in weight, as well as enable greater multi-functionality. The question therefore is: how best to revisit the design of these honeycomb panels to obtain these benefits? In this work, a Bio-Inspired Design approach was taken to answer this question, primarily since the hexagonal lattice is so commonly found in wasp and bee nests, including the well-known bee’s honeycomb that inspired these panel designs to begin with. Whereas prior honeycomb panel design has primarily focused on the hexagonal shape of the unit cell, in this work we examine the relationship between the various parameters constituting the hexagonal cell itself, specifically the wall thickness and the corner radius, and also examine out-of-plane features that have not been previously translated into panel design. This work reports findings from a study of insect nests across 70 species using 2D and 3D measurements with optical microscopy and X-ray tomography, respectively. Data from these biological nests were used to identify design parameters of interest, which were then translated into design principles. These design principles were implemented in the design of honeycomb panels manufactured with the Selective Laser Sintering process and subjected to experimental testing to study their effects on the mechanical behavior of these panels. / Dissertation/Thesis / Masters Thesis Manufacturing Engineering 2020

abstract: In certain ant species, groups of ants work together to transport food and materials back to their nests. In some cases, the group exhibits a leader-follower behavior in which a single ant guides the entire group based on its knowledge of the destination. In some cases, the leader role is occupied temporarily by an ant, only to be replaced when an ant with new information arrives. This kind of behavior can be very useful in uncertain environments where robot teams work together to transport a heavy or bulky payload. The purpose of this research was to study ways to implement this behavior on robot teams. In this work, I combined existing dynamical models of collective transport in ants to create a stochastic model that describes these behaviors and can be used to control multi-robot systems to perform collective transport. In this model, each agent transitions stochastically between roles based on the force that it senses the other agents are applying to the load. The agent’s motion is governed by a proportional controller that updates its applied force based on the load velocity. I developed agent-based simulations of this model in NetLogo and explored leader-follower scenarios in which agents receive information about the transport destination by a newly informed agent (leader) joining the team. From these simulations, I derived the mean allocations of agents between “puller” and “lifter” roles and the mean forces applied by the agents throughout the motion. From the simulation results obtained, we show that the mean ratio of lifter to puller populations is approximately 1:1. We also show that agents using the role update procedure based on forces are required to exert less force than agents that select their role based on their position on the load, although both strategies achieve similar transport speeds. / Dissertation/Thesis / Masters Thesis Mechanical Engineering 2020

Compliant mechanisms are useful for improving existing machines and creating new ones that were not previously possible. They also help us to think of new methods and technologies needed to both improve existing systems as well as manufacture systems that have not been done before. The purpose of this thesis is to show novel implementations of compliant mechanisms into folding systems, and to show new methods for fabricating such mechanisms with nontraditional materials and on difficult scales. Folding systems are shown in furniture applications with chairs, stools, and childcare furniture applications as results of research into how such structures could be created with compliant mechanisms to be deployed from a flat state. Compliant mechanisms are also shown to be folded by a laser into simple mechanisms and into a potentially more complex parabolic reflector. Small-scale flexible (or compliant) mechanisms are valuable in replacing rigid components while retaining comparable motion and behavior. However, fabricating such mechanisms on this scale (from 0.01 to 10 cm thick) proves difficult, especially with thin sheet metals. The manufacturing method of laser forming, which uses a laser to cut and bend metal into desired shapes, could facilitate this fabrication. However, specific methods for designing mechanisms formed by lasers need to be developed. This work presents laser forming as a means for creating compliant mechanisms on this scale with thin sheet metal. The unique challenges for designing mechanisms to be laser-formed are explored, and new adaptations of existing designs are fabricated and discussed. The design of basic "building blocks" and features are developed for several mechanisms: a parallel-guided mechanism, a cross-axis flexural pivot, a LET joint array, a split-tube flexure, and a bi-stable switch. These mechanisms are shown to perform repeatable behavior and motion comparable to existing non-laser-formed versions. The further possibilities for fabricating compliant mechanisms with laser forming are explored, as advanced applications can benefit from using lasers to create compliant mechanisms from thin sheet metal. One such possible system is a parabolic reflector, which is useful for making solar collectors and antennas. Such shapes have been developed in various patterns and typically manufactured out of rigid components. Applications for these systems could benefit from paraboloids that can fold up and be deployed into a final shape. This work presents a conceptual method for designing a flat-foldable paraboloid and a means for its fabrication using laser forming.

In recent years, the field of Soft Robotics has grown exponentially resulting in a variety of different soft robot designs. A majority of the current soft robots can easily be split into two distinct categories: Navigation and Grasping. Navigation robots alter their body orientation to navigate around an environment. Grasping robots are designed to grasp a variety of unknown objects without damaging said object. However, only a few robots are able to demonstrate both aspects and even fewer robots are able to do both simultaneously. As thus, the goal of this thesis is to create a soft robot that is able to pick up and support an additional payload. This thesis will explore the challenges and difficulties that come with designing such a robot. For this thesis, we chose to simplify the manufacturing process making it easy to create and test different designs. We primarily used Pneumatic Network actuators for the majority of the soft robot. This allowed us to use a layered manufacturing approach to create the full robot. Finally, we split the robot into two main components which have their own purpose, which made it easy to test and design each component. Attached to this thesis are three different supplementary videos. The first one labeled "Walking Gaits" demonstrate how the robot is capable of moving forward. This video is comprised of several sections showing the full robot moving, just the base moving, and the full robot briefly moving as it supports a payload. The second video is labeled "Additional Walking". This video shows how the base can effectively move around a given environment. The final video if called "Grasping Method" which demonstrates the different grasping methods that the full robot uses to pick up objects. / 2021-06-03T00:00:00Z

<p>Insects and hummingbirds not only can perform long-term stationary hovering but also are capable of acrobatic maneuvers. At their body scale, such extraordinary flight performance remains unmatched by state-of-the-art conventional man-made aerial vehicles with fixed or rotary wings. Insects' and hummingbirds' near maximal performance come from their highly intricate and powerful wing-thorax actuation systems, sophisticated sensory system, and precise neuromotor control. Flapping Wing Micro Air Vehicles (FWMAVs) with bio-inspired flapping flight mechanisms hold great promise in matching the performance gap of their natural counterparts. Developing such autonomous flapping-wing vehicles to achieve animal-like flight, however, is challenging. The difficulties are mainly from the high power density requirements under the stringent constraints of scale, weight, and power, severe system oscillations induced by high-frequency wing motion, high nonlinearity of the system, and lack of miniature navigation sensors, which impede actuation system design, onboard sensing, flight control, and autonomous navigation. </p><p><br></p><p>To address these open issues, in this thesis, we first introduce systematic modeling of a dual-motor hummingbird-scale flapping wing robot. Based upon it, we then present studies of the onboard sensor fusion, flight control, and navigation method. </p><p><br></p><p>By taking the key inspiration from its natural counterparts, the proposed hummingbird robot has a pair of independently controlled wings. Each wing is directly actuated by a dc motor. Motors undergo reciprocating motion. Such a design is a severely underactuated system, namely, it relies on only two actuators (one per wing) to control full six degrees of freedom body motion. As a bio-inspired design, it also requires the vehicle close to its natural counterparts’ size and weight meanwhile provide sufficient lift and control effort for autonomy. Due to stringent payload limitation from severe underactuation and power efficiency challenges caused by motor reciprocating motion, the design and integration of such a system is a challenging task. In this thesis, we present the detailed modeling, optimization, and system integration of onboard power, actuation, sensing, and flight control to address these unique challenges. As a result, we successfully prototyped such dual-motor powered hummingbird robot, either with power tethers or fully untethered. The tethered platform is used for designing onboard sensing, control, and navigation algorithms. Untethered design tackles system optimization and integration challenges. Both tethered/untethered versions demonstrate sustained stable flight. </p><p><br></p><p>For onboard attitude sensing, a real-time sensor fusion algorithm is proposed with model-based adaptive compensation for both sensor reading drift and wing motion induced severe system vibration. With accurate and robust sensing results, a nonlinear robust control law is designed to stabilize the system during flight. Stable hovering and waypoint tracking flight were experimentally conducted to demonstrate the control performance. In order to achieve natural flyers' acrobatic maneuverability, we propose a hybrid control scheme by combining a model-based robust controller with a model-free reinforcement learning maneuver policy to perform aggressive maneuvers. The model-based control is responsible for stabilizing the robot in nominal flight scenarios. The reinforcement learning policy pushes the flight envelope to pilot fierce maneuvers. To demonstrate the effectiveness of the proposed control method, we experimentally show animal-like tight flip maneuver on the proposed hummingbird robot, which is actuated by only two DC motors. These successful results show the promise of such a hybrid control design on severely underactuated systems to achieve high-performance flight.</p><p><br></p><p>In order to navigate confined space while matching the design constraints of such a small robot, we propose to use its wings in dual functions - combining sensing and actuation in one element, which is inspired by animals' multifunctional flapping wings. Based on the interpretation of the motor current feedback which directly indicates wing load changes, the onboard somatosensory-like feedback has been achieved on our hummingbird robot. For navigation purposes, such a method can sense the presence of environmental changes, including grounds, walls, stairs, and obstacles, without the need for any other sensory cues. As long as the robot can fly, it can sense surroundings. To demonstrate this capability, three challenging tasks have been conducted onto the proposed hummingbird robot: terrain following, wall detection and bypass, and navigating a confined corridor. </p><p><br></p><p>Finally, we integrate the proposed methods into the untethered platform, which enables stable untethered flight of such a design in both indoor and outdoor tests. To the best of our knowledge, this result presents the first bio-inspired FWMAV powered by only two actuators and capable of performing sustained stable flight in both indoor and outdoor environment. It is also the first untethered flight of an at-scale tailless hummingbird robot with independently controlled wings, a key inspiration from its natural counterparts.</p><div><div><div><div><div> </div> </div> </div></div></div>

No description available.

Acoustic-structural interaction is the key to understand a wide range of engineering problems such as membrane-based dynamic pressure sensors, hearing devices for sound source localization, and acoustic absorbers for noise reduction. Despite tremendous developments in the last decades, there is still a fundamental size limitation in these areas. In the case of dynamic pressure sensors, sensitivity usually suffers for miniature sensors; the available acoustic directional cues proportionally decrease with size, which adversely affects the localization performance; thick panels are required to achieve superior sound attenuation, particularly for low-frequency sound. It is the motivation of this dissertation research to address the abovementioned size limitation that involves acoustic-structural interaction. The overall goal of this dissertation work is to achieve an enhanced understanding of the acoustic-structural interaction between diaphragms and air cavity and to apply this understanding to develop high-performance miniature acoustic sensors and noise reduction metamaterials. First, a finite element method (FEM) model and large-scale device are developed to understand how the interaction between the diaphragm and its backing air cavity affects the equivalent mass, stiffness, and damping of air-backed diaphragms. The numerical and experimental study shows that the complex interaction cannot be captured by the commonly used lump model. Then, air-backed graphene diaphragms are used to develop fiber optic sensors with sub-millimeters footprint and high sensitivity. Two different configurations are designed to enhance the sensor sensitivity limited by the backing air cavity. One is to increase the mechanical sensitivity by using a larger backing volume, the other is to increase the optical sensitivity by using silver-graphene composite diaphragm. Next, acoustic metamaterials with air-coupled diaphragms as unit cells are developed to achieve perfect acoustic absorption with thickness much smaller than the sound wavelength, which cannot be realized using natural materials. Finally, an expanded configuration of two diaphragms coupled by an air-filled tunnel is experimentally developed to mimic the hearing system of small vertebrates. The goal is to amplify the small directional cues available to the small animals so that a high angular resolution can be achieved. This dissertation provides a quantitative and mechanistic explanation for the interaction between the diaphragms and the sealed air cavity. It offers several frameworks for the development of miniature pressures, directional sensors, and thin sound absorbers. / Mechanical Engineering

Male cicada’s superior sound producing ability has been well studied by entomologists and ethologists. The secret behind the loud sound is the dual-resonator structure: the primary resonator is a series of buckled ribs/beams on its tymbal organ, while the secondary resonator is a large air cavity in the abdomen with a pair of openings. However, the understanding of the dual-resonator structure is incomplete, and few endeavors have been reported on developing cicada-inspired novel acoustic devices. To this end, this dissertation research aims to achieve a fundamental understanding of the cicada-inspired sound generating structures, and to apply the knowledge to develop a dual-resonator system with superior sound generating ability.First, a clamped-clamped buckled beam – the fundamental vibration source of the dual-resonator system – is modeled and tested for free vibration responses during the snap-through process between its bistable positions. It is found that the free vibration of the buckled beam is independent from actuation. In terms of the natural frequencies and the vibrational mode shapes, the free vibration is determined only by the geometry and material properties of the buckling beam. The experiment provides a comprehensive insight of the snap-through process and the induced free vibrations. Second, both analytical and experimental methods are used to investigate the buckling beam from an energy perspective, including the force needed for actuating the buckled beam, the work by the actuation force, the elastic energy of the buckling beam, and the sound radiation characteristics. Results show that although the actuation forces depend on its acting locations, the work by the force remains constant, which is equal to the elastic energy difference between the first symmetric buckling mode and the first anti-symmetric buckling mode. Acoustic analysis shows that the sound radiation is mostly generated from the first symmetric vibrational mode. Third, the dual-resonator system consisting of a buckling beam and a Helmholtz resonator is proposed. Considered as an equivalent two-degree-of-freedom vibration system, the dual-resonator system is modeled and studied for optimal sound output. Finally, a dual-resonator system is fabricated with the optimal parameters. Experimental characterization shows superior sound outputs of the dual-resonator system similar to what are observed in male cicadas. This dissertation sheds new lights on the structural-acoustic interaction of buckling beam and Helmholtz resonator that is found in the sound-producing organs of male cicadas and develops a cicada-inspired dual-resonator system for the first time. Findings from this research not only enhance the existing knowledge on male cicadas, but also pave the way for its engineering applications that require highly efficient sound radiation. / Mechanical Engineering

Continuum robots mimic the principle of a special biological structure known as the muscular hydrostat. These robots have an ability to bend at any location on along its backbone and have potential applications in disaster relief, medical surgeries and nuclear waste disposal. This thesis presents the modeling and verification of a multi-section continuum robot by applying the Cosserat theory of rods. Next, 2D verification is performed on a continuum robot based on a backbone composed of a nickel titanium alloy. In addition, the thesis develops the theoretical foundations for a cable-driven continuum robot by studying the effects of cable guide mass which cause additional deformation of the robot The results of this thesis show that the multi-section model is accurate within 3.4% in predicting the Cartesian tip coordinates, and the model with the cable guides accurate within 1.26% error in predicted versus the observed Cartesian tip coordinates of the backbone.

The purpose of this research is to develop fundamentals of compliant mechanisms in deployable space systems. The scope was limited to creating methods for thick origami, developing compliant deployable solar arrays, and developing methods for stowing and deploying the arrays. The research on actuation methods was focused on a one-time deployment of the array. Concepts for both passive and active actuation were considered. The primary objective of this work was to develop approaches to accommodate thickness in origami-based deployable arrays with a high ratio of deployed-to-stowed diameter. The HanaFlex design was derived from the origami flasher model and is developed as a deployable solar array for large arrays (150 kW or greater) and CubeSat arrays (60 W). The origami folding concept enables compact stowage of the array, which would be deployed from a hexagonal prism into a flat array with about a 10-times increase in deployed diameter as compared to stowed diameter. The work on the origami pattern for the solar array was also applied to the folding of 80-100 m2 solar sails for two NASA CubeSat missions, NEA-Scout and Lunar Flashlight. The CubeSat program is a promising avenue to put the solar array or solar sails into space for testing and proving their functionality. The deployable array concept is easily scalable, although application to CubeSats changes some of the design constraints. The thickness-to-diameter ratio is larger, making the issues of thickness more pronounced. Methods of actuation are also limited on CubeSats because of the rigorous size and weight constraints. This dissertation also includes the development of a compact, self-deploying array based on a tapered map fold design. The tapered map fold was modified by applying an elastic membrane to one side of the array and adequately spacing the panels adjacent to valley folds. Through this approach, the array can be folded into a fully dense stowed volume. Potential applications for the array include a collapsible solar array for military or backpacking applications. Additional compliant mechanism design was done in support of the HanaFlex array. This included a serpentine flexure to attach the array to the perimeter truss for deployment, and a bistable mechanism that may be used in the deployment of the array or sail.