Flexonics for Manufacturing and Robotics: Modeling, Design and Analysis Methods

205 Pages·2019·9.906 MB·English

by  Jiajie Guo, Kok-Meng Lee

Research on Intelligent Manufacturing
Jiajie Guo
Kok-Meng Lee
Flexonics
for Manufacturing
and Robotics
Modeling, Design and Analysis Methods
Research on Intelligent Manufacturing
Editors-in-chief
Han Ding, Huazhong University of Science and Technology, Wuhan, China
Ronglei Sun, Huazhong University of Science and Technology, Wuhan, China
Series editors
Kok-Meng Lee, Georgia Institute of Technology, Atlanta, GA, USA
Yusheng Shi, Huazhong University of Science and Technology, Wuhan, China
Jihong Liu, Beijing University of Aeronautics and Astronautics, Beijing, China
Hanwu He, Guangdong University of Technology, Guangzhou, China
Yuwang Liu, Chinese Academy of Sciences, Shenyang, China
Jiajie Guo, Huazhong University of Science and Technology, Wuhan, China
Haibin Yin, Wuhan University of Technology, Wuhan, China
Junzhi Yu, Chinese Academy of Sciences, Beijing, China
Wenfeng Li, Wuhan University of Technology, Wuhan, China
Jingjing Ji, Huazhong University of Science and Technology, Wuhan, China
ResearchonIntelligentManufacturing(RIM)publishesthelatestdevelopments
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This book series aims to address hot technological spots and solve challenging
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More information about this series at http://www.springer.com/series/15516
Jiajie Guo Kok-Meng Lee
(cid:129)
Flexonics for Manufacturing
and Robotics
Modeling, Design and Analysis Methods
123
JiajieGuo Kok-Meng Lee
Schoolof MechanicalScience and TheGeorge W. WoodruffSchoolof
Engineering MechanicalEngineering
HuazhongUniversity of Science and Georgia Institute of Technology
Technology Atlanta, GA,USA
Wuhan, China
ISSN 2523-3386 ISSN 2523-3394 (electronic)
Research onIntelligent Manufacturing
ISBN978-981-13-2666-0 ISBN978-981-13-2667-7 (eBook)
https://doi.org/10.1007/978-981-13-2667-7
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Preface
With the increasing demands for smart machines and intelligent equipment
adaptable to humans and environments, compliant structures and flexible elec-
tronics have been widely developed in robotics and thin-wall components with a
large strength-to-weight ratio are common in manufacturing. Among different
challenges in flexible mechatronics (flexonics), modelling, design and analysis are
still critical issues to be dealt with because of the nonlinear complexity of con-
tinuum. This book formulates distributed models in both time and spatial domains
using a geometric approach, along with practical field-based sensing methods for
robotics and manufacturing. Applications are illustrated by examples of exoskele-
tons,mobilesensornetwork,intelligentsensing,andsoon.Thisbookiswrittenfor
university researchers, R&D engineers and graduate students in engineering and
science, who wish to learn the core principles, theories, technologies, and appli-
cationsofflexonics.Itcanbeservedasatextbookorreferenceforagraduatelevel
course on mechatronics, which may require prerequisites of linear algebra,
mechanics of materials, ordinary and partial differential equations, numerical
methods, and vibrations.
The text is organized into seven chapters. Chapter 1 is an introduction to flex-
onics with basic concepts, problems and reviews of related work. Chapter 2 pre-
sentsfundamentalsofmathematicsformodelling,designandanalysisofflexonics.
Chapter 3 formulates the boundary value problems for basic flexible elements of
beamsandplates.Applicationexamplesaregiveninthelastfourchapters.Chapter
4illustratesthedesignofamobilenodeasanapplicationofflexonicsforstructural
health monitoring, where design concepts, functionalities, experimental validation
and demonstrative examples are included. Chapter 5 presents a distributed-
parameter method for intelligent sensing of displacement and strain distributions
across a flexible thin-wall workpiece and their field reconstruction for real-time
manufacturing applications. Chapter 6 provides a bio-joint model to capture the
kinematic and dynamic features of a biological joint, based on which an adaptive
exoskeleton is designed to eliminate negative effects associated with the closed
leg-exoskeleton kinematic chain on a human knee. Chapter 7 presentsa modelling
method to capture musculoskeletal deformations and its immediate application is
v
vi Preface
illustrated with poultry meat deboning in food processing. As a unified modelling
and analysis approach is developed in Chaps. 2 and 3, readers can find commons
among the various examples in subsequent chapters and may probably extend the
presentedmethodtoapplicationsthatarenotcoveredinthisbook.Chapters4–7are
somewhatindependentfromeachother,sosomeofthemcanbeskippedorchosen
based on readers’ application needs and interests.
Manyfindingsinthisbookarebasedonthelastdecadeofresearchconductedat
Georgia Institute of Technology and Huazhong University of Science and
Technology, and they were obtained under research grants supported by the
Georgia Agricultural Technology Research Program, National Science Foundation
(Grant CMMI-0928095) and more recently, the National Basic Research Program
of China (973 Program, Grant 2013CB035803) and the National Natural Science
Foundation of China (Grants 51505164, 51875221). The authors wish to
acknowledgewithgreat appreciationthecolleagues andgraduate studentsfor their
collaboration or suggestions in the presented research, like Prof. Yang Wang, Dr.
Dapeng Zhu, Dr. Xiaohua Yi and Yang Xie for Chap. 4, Prof. Kun Bai, Prof.
Jingjing Ji, Man Yu, Wuguang Liu, Ruochu Liuand Bo Wang for Chap. 5, Dr.
Donghai Wang for Chap. 6, and Dr. Jungyoul Lim and Mark Claffee for Chap. 7.
The writing of this book is funded by Hubei Academic Works Publishing Special
Fund and National Science and Technology Academic Works Publishing Fund.
The authors would also like to thank Daokai Yu from HUST Press and all the
committee members for their efforts to organize this book series which makes
publication of this book possible.
Wuhan, China Jiajie Guo
Atlanta, USA Kok-Meng Lee
Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Background and Motivation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Problem Description and Objectives . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Review of Related Work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3.1 Modeling of Compliant Mechanisms. . . . . . . . . . . . . . . . . 3
1.3.2 Joint Constraint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3.3 Numerical Methods for Boundary Value Problems . . . . . . 7
1.3.4 Flexible Robotics for Structural Health Monitoring . . . . . . 7
1.3.5 Human-Centered Equipment (Exoskeleton) . . . . . . . . . . . . 9
1.3.6 Process State Monitoring for Manufacturing . . . . . . . . . . . 10
1.3.7 Poultry-Meat Processing. . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.4 Book Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2 Fundamentals of Mathematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.1 Basics of Differential Geometry. . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.2 Curvature of a 3D Beam. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.3 Kinematics of a 3D Beam. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.4 Kinematics of an Annular Plate. . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.5 Multiple Shooting Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.6 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3 Flexible Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.1 Two-Dimensional Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.2 Three-Dimensional Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.3 Annular Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.4 General Constraint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.5 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
vii
viii Contents
4 Flexonic Mobile Node . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.1 Design Concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.1.1 Dimension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.1.2 Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.1.3 Flexibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.2 Functionalities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.2.1 Sensor Attachment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.2.2 Convex Corner Negotiation (2D) . . . . . . . . . . . . . . . . . . . 77
4.2.3 Convex Corner Negotiation (3D) . . . . . . . . . . . . . . . . . . . 80
4.2.4 Concave Corner Negotiation. . . . . . . . . . . . . . . . . . . . . . . 83
4.2.5 Environment Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . 83
4.3 Experimental Validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4.3.1 First Prototype of FMN . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4.3.2 Second Prototype of FMN . . . . . . . . . . . . . . . . . . . . . . . . 96
4.4 Structural Health Monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
4.4.1 Steel Frame Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
4.4.2 Space Frame Bridge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
4.5 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
5 Intelligent Manufacturing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
5.1 Dynamic Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
5.1.1 Parametric Effects on |A(xnm)| (DC1) . . . . . . . . . . . . . . . . 111
5.1.2 Illustrative Example (DC1). . . . . . . . . . . . . . . . . . . . . . . . 112
5.1.3 Numerical Verification (DC1 and DC2) . . . . . . . . . . . . . . 115
5.2 Parameter Identification and Sensing Configuration . . . . . . . . . . . 115
5.2.1 Modal Damping Ratios . . . . . . . . . . . . . . . . . . . . . . . . . . 118
5.2.2 Step Response. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
5.2.3 Robustness of Sensor Performance . . . . . . . . . . . . . . . . . . 120
5.2.4 Sensor Configuration Design . . . . . . . . . . . . . . . . . . . . . . 122
5.3 Formulation of Field Reconstruction . . . . . . . . . . . . . . . . . . . . . . 123
5.3.1 Field Reconstruction Algorithm . . . . . . . . . . . . . . . . . . . . 125
5.3.2 Numerical Verification. . . . . . . . . . . . . . . . . . . . . . . . . . . 126
5.3.3 Numerical Evaluation of Reconstruction Algorithm . . . . . . 129
5.4 Experiment Results and Illustrative Application . . . . . . . . . . . . . . 130
5.4.1 Free Vibration of Non-rotating Plate. . . . . . . . . . . . . . . . . 131
5.4.2 Field Reconstruction for Machining . . . . . . . . . . . . . . . . . 134
5.5 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
6 Bio-inspired Exoskeleton. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
6.1 Human Knee Kinematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
6.2 Knee Joint Dynamics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Contents ix
6.3 Knee-Exoskeleton Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
6.3.1 Coupled Kinematics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
6.3.2 Coupled Dynamics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
6.4 Experimental Investigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
6.4.1 Design Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
6.4.2 Experimental Test Bed. . . . . . . . . . . . . . . . . . . . . . . . . . . 152
6.4.3 Experimental Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
6.4.4 Results and Discussion . . . . . . . . . . . . . . . . . . . . . . . . . . 156
6.5 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
7 Musculoskeletal Modeling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
7.1 Musculoskeletal System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
7.1.1 Coordinates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
7.1.2 Bio-joint Constraint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
7.1.3 Clavicle Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
7.1.4 Soft Tissue Mechanics. . . . . . . . . . . . . . . . . . . . . . . . . . . 174
7.2 Experimental Investigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
7.2.1 Elastic Modulus of Clavicle . . . . . . . . . . . . . . . . . . . . . . . 176
7.2.2 Ligament Mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
7.3 Illustrative Application to Wing Manipulation . . . . . . . . . . . . . . . 183
7.4 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186