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ASME 2024 International Mechanical Engineering Congress and Exposition, IMECE 2024

作者： Peters, Julian Menning, Johannes D.M. Ewert, Arthur Prokopchuk, Artem Breimann, Richard Herbst, Felix Riehl, David Döllken, Markus Vorrath, E.-F. Markus Wallmersperger, Thomas Schlecht, Berthold Kirchner, Eckhard Kupnik, Mario Hofmann, Klaus Matthiesen, Sven Institute of Product Engineering Karlsruhe Institute of Technology Germany Institute of Solid Mechanics Technische Universität Dresden Germany Institute of Machine Elements and Machine Design Technische Universität Dresden Germany Institute of Semiconductors and Microsystems Technische Universität Dresden Germany Institute for product development and machine elements Technical University of Darmstadt Germany Measurement and Sensor Technology Group Technical University of Darmstadt Germany Integrated Electronic Systems Lab Technical University of Darmstadt Germany

ISBN: (纸本)9780791888599

In industrial digitization, data-driven analysis like condition monitoring and predictive maintenance relies on extensive measurement data. However, there’s often a lack of data on machine or system states. Sensor-integrating machine elements (SiME) can address this gap due to their widespread use, standardization, and in-situ measurement capability. Yet, integrating sensors typically compromises mechanical function. To ensure broad usability and retrofitting, maintaining mechanical functions to a defined degree is crucial. General procedures for systematically finding optimal design space solutions are lacking. In prior work, a procedure was developed for multi-axial force sensor integration into M20 bolts. This contribution demonstrates the procedure’s applicability to (1) M12 bolts for uni-axial force measurements using strain gauges, and (2) jaw couplings for torque measurement using capacitive sensors. Results indicate the procedure’s efficacy in both cases, yielding viable design space parameters. However, constructing an optimization function for jaw couplings in the final step was not feasible, as both mechanical and sensory function fulfillment indices pointed in the same direction. © 2024 by ASME.

关键词： Bolts

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High-ratio planetary gearbox with EC gearing for robot applications

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INTERNATIONAL JOURNAL OF INTELLIGENT ROBOTICS AND APPLICATIONS 2024年第4期8卷 1074-1084页

作者： Landler, Stefan Otto, Michael Vogel-Heuser, Birgit Zimmermann, Markus Stahl, Karsten Tech Univ Munich Munich Inst Robot & Machine Intelligence MIRMI Inst Machine ElementsGear Res Ctr FZG TUM Sch Engn & DesignDept Mech Engn Munich Germany Tech Univ Munich Munich Inst Robot & Machine Intelligence MIRMI TUM Sch Engn & Design Dept Mech EngnInst Automat & Informat Syst AIS Munich Germany Tech Univ Munich Munich Inst Robot & Machine Intelligence MIRMI TUM Sch Engn & Design Dept Mech EngnLab Prod Dev & Lightweight Design Boltzmannstr 15 D-85748 Garching Germany

The drive system of robots and robot-like systems (RLS) is often designed with a combination of an e-motor and a gearbox with a high transmission ratio to optimize performance. The various types of possible robot gearboxes can be selected based on their characteristics, which strongly influence the performance of the entire robotic system. Planetary gear drives have advantages due to their high efficiency and low design complexity. Disadvantageous is the low transmission ratio per stage and the resulting large design space required with the currently predominant involute gearing. Using special tooth profile shapes, such as the eccentric cycloid (EC) gearing, enables a high transmission ratio per stage to be achieved, thus reducing the design space required. In order to evaluate the design, a description of the geometry and characteristics of the EC gearing is necessary. The application-optimized design can be made accessible on an interdisciplinary basis using a suitable description language for the product development of the complete robotic system. The paper shows the design and analysis of a planetary gearbox with a high transmission ratio for applications in robotics. The planetary gear stage is designed with the EC gearing, which offers advantages compared to the involute gearing. The performance of the selected gearing is evaluated based on various characteristics. This allows advantages to be identified compared to the established types of transmission for robots and RLS. Overall, the paper presents a new robot gearbox with a comprehensive description and analysis directly accessible for simulation or production using additive manufacturing.

关键词： Planetary gearbox Robot transmission Robot drive system Eccentric cycloid EC gearing Special gearing

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Virtual special issue: Variable amplitude loading-Fracture mechanics and cumulative damage modeling

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FATIGUE & FRACTURE OF ENGINEERING MATERIALS & STRUCTURES 2023年第2期46卷 363-365页

作者： Heuler, Paul Savaidis, Georgios Newman, James C., Jr. DVM Ingolstadt Germany Aristotle Univ Thessaloniki Lab Machine Elements & Machine Design Thessaloniki Greece Mississippi State Univ Dept Aerosp Engn Starkville MS USA Gabriele Munter Str 5 D-85051 Ingolstadt Germany

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Static Modeling of the Stiffness and Contact Forces of Rolling Element Eccentric Drives for Use in Robotic Drive Systems

Static Modeling of the Stiffness and Contact Forces of Rolli...

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2024 International Conference on Intelligent Robots and Systems

作者： Fritsch, Simon Handler, Stefan Otto, Michael Vogel-Heuser, Birgit Zimmermann, Markus Stahl, Karsten Tech Univ Munich Munich Germany TUM Sch Engn & Design Dept Mech Engn Munich Germany Munich Inst Robot & Machine Intelligence MIRMI Munich Germany Gear Res Ctr FZG Inst Machine Elements Munich Germany Inst Automat & Informat Syst AIS Munich Germany Lab Prod Dev & Lightweight Design LPL Munich Germany

ISBN: (纸本)9798350377712;9798350377705

Rolling element eccentric drives promise to be an easy-to-manufacture and performant gear system for robotic actuators. They share characteristics with other eccentric drives, such as strain wave and cycloidal drives, but use rolling elements instead of an eccentric gear. They offer reduced manufacturing complexity and costs by using readily available standard parts. Little research into rolling element eccentric drives is available, and their characteristics are still underexplored. This work uses a contact-based model to investigate the previously unknown stiffness of rolling element eccentric drives. Such calculation methods are well established for structurally similar components, such as cycloidal drives and roller bearings, and provide a high-level and computationally efficient model. Good stiffness models are critical for accurately predicting robotic actuator behavior and enabling better control of robotic systems. Additionally, the proposed model is used to calculate the contact forces under load occurring in rolling element eccentric drives. Contact forces are critical to calculating a drive's load capacity, lifetime, and efficiency and serve as the foundation for further research. The mathematical description of the proposed model is derived, and the stiffness of a representative rolling element eccentric drive is calculated. Different manufacturing techniques, characterized by tolerance levels and material choices, are compared. Irrespective of manufacturing precision, similar stiffness curves result for drives made of steel, but higher contact forces result from less precise manufacturing. The stiffness of drives made from 3D printed plastic is considerably lower than that of drives made from steel. Additionally, the stiffness of rolling element eccentric drives is compared to similar eccentric drives, and a comparable twist-over-torque curve is shown.

关键词： Roller bearings

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Compatibility Assessment for Interfaces in Drivetrains of Robot-Like Systems 5

Compatibility Assessment for Interfaces in Drivetrains of Ro...

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5th International Conference on Industry 4.0 and Smart Manufacturing (ISM)

作者： Volpert, Marcus Vogel-Heuser, Birgit Hujo, Dominik Stahl, Karsten Zimmermann, Markus Tech Univ Munich TUM Sch Engn & Design Inst Automat & Informat Syst Garching Germany Tech Univ Munich TUM Sch Engn & Design Inst Machine Elements Garching Germany Tech Univ Munich Lab Product Dev & Lightweight Design TUM Sch Engn & Design Garching Germany

Due to the complexity of robot-like systems (RLS), new developments are often avoided, and most variants of the systems are designed. The primary determinant of an RLS is its drivetrain, which comprises purchased components, namely the controller, motor driver, motor, and gearbox. Each of these purchased parts has different interfaces that are not standardized. If the interfaces are sufficiently complex, the compatibility of the parts can no longer be guaranteed manually. Therefore, this paper presents a draft ontology that verifies the compatibility of purchased parts in RLS drivetrains. Classes and properties are obtained from expert knowledge, norms, data standards, and data sheets to build an ontology. The ontology design is evaluated using an application example for a motor-gearbox interface.

关键词： robot-like systems interface modeling ontology model-based systems engineering drivetrains

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Determination of the Characteristics of Gears of Robot-Like Systems by Analytical Description of their Structure

Determination of the Characteristics of Gears of Robot-Like ...

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IEEE/RSJ International Conference on Intelligent Robots and Systems (IROS)

作者： Landler, Stefan Blanco, Raul Molina Otto, Michael Vogel-Heuser, Birgit Zimmermann, Markus Stahl, Karsten Gear Res Ctr FZG Inst Machine Elements Munich Germany Inst Automat & Informat Syst AIS Munich Germany Lab Prod Dev & Lightweight Design LPL Munich Germany

ISBN: (纸本)9781665491907

The axes of robots and robot-like systems (RLS) usually include e-motor-gearbox-arrangements for optimal connection of the elements. The characteristics of the drive system and thus also of the robot depend strongly on the gears. Different gearbox designs are available which differ in stiffness, efficiency and further properties. For an application-optimal design of RLS a uniform documentation and a comparability of gearbox concepts is a decisive factor. The application-optimal design is supported by an interdisciplinary approach between mechanical engineering and software design, guided by adequate product development methodology. The quite heterogeneous characterization of gearboxes for RLS which is currently the state of the art is a relevant obstacle in the flexible and optimal design of RLS. The paper shows the analysis of the gear structure with unified symbols for specific machine elements and contact types. The introduced method gives insight into the mechanical structure of the gearboxes. Similarities between gear types can thus be revealed. This also enables the classification of new developments in the state of the art. Moreover, the developed method for analyzing the gear structure can be used to determine the characteristics of gears. Examples for these characteristics are backlash, efficiency or stiffness. Specifically, the stiffness of gears can be synthesized by the force action of individual contacts and the individual phenomena that occur with them. The representation by individual phenomena also makes it possible to extend the calculation to include influencing parameters such as temperature that have not been sufficiently taken into account so far.

关键词： Stiffness

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Chaotic behaviour in the dynamical response of coaxial magnetic gears during acceleration

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CHAOS SOLITONS & FRACTALS 2024年 187卷

作者： Tzouganakis, Panteleimon Gakos, Vasilios Papalexis, Christos Kalligeros, Christos Tsolakis, Antonios Spitas, Vasilios Univ West Attica Lab Machine Elements & Vehicles 250 Thivon & P Ralli Egaleo 12244 Greece Natl Tech Univ Athens Lab Machine Design 9 Iroon Polytech Zografos 15780 Greece

Slippage during acceleration has been a significant issue in coaxial magnetic and has been thoroughly investigated in the recent years. Depending on the applied outer load it is important to know the maximum acceleration that can be induced so that the system will not diverge. In the present work a non-dimensional analysis has been conducted in order to develop a stability criterion for the maximum acceleration that can be applied to the system as a function of the outer load. A closed-form relation for the period of the oscillations of the system that will be caused by the acceleration, has also been derived. Furthermore, the case of acceleration with ripple has been investigated. It was demonstrated that during acceleration with ripple under constant applied outer load, the system showcases a chaotic behaviour similar to the driven pendulum. In particular, a thorough analysis on the frequency of the ripple has been conducted. It was observed that when the ripple frequency was slightly lower than the frequency of the oscillation under steady acceleration, the system could potentially diverge even if the acceleration of the system was lower than the critical value. With the present work, a detailed nondimensional model has been derived that could be a useful tool for determining the stability of coaxial magnetic gears without the requirement of numerical solution of the governing equations. In addition, some interesting observations are made regarding the chaotic behaviour of the dynamical response of coaxial magnetic gears during acceleration with ripple.

关键词： Coaxial magnetic gear Non-linear dynamics chaos Poincare sections

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Formulation of a non-dimensional criterion for stable dynamical response in coaxial magnetic gears

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JOURNAL OF ENGINEERING MATHEMATICS 2024年第1期144卷 19-19页

作者： Tzouganakis, Panteleimon Gakos, Vasilios Kalligeros, Christos Papalexis, Christos Tsolakis, Antonios Spitas, Vasilios Univ West Attica Lab Machine Elements & Vehicles 250 Thivon & P Ralli Egaleo 12244 Greece Natl Tech Univ Athens Lab Machine Design 9 Iroon Polytech Zografos 15780 Greece

Coaxial magnetic gears have been investigated thoroughly in recent years. However, magnetic gears are prone to slippage that could be caused by overloading or acceleration of the drive. In the present work, the dynamical system of equations in coaxial magnetic gears was investigated in order to calculate the maximum operational characteristic of the drive. A non-dimensional condition was derived analytically that can determine the dynamical behaviour and whether the system will converge or diverge without the requirement of a numerical solution of the dynamical equation of the drive. A case study was performed where different values of acceleration and applied torque were considered. The convergence of the system was initially examined with the developed non-dimensional condition and then the equation was solved numerically in order to verify the prediction. The developed condition correctly predicted the behaviour of the drive in all cases. Finally, with the developed model the operational characteristics of a coaxial magnetic gear that yield a required transmission error can be calculated analytically. Therefore, with the developed model the maximum operational characteristics in coaxial magnetic gears can be determined analytically with a non-dimensional criterion without implementing iterative methods that would significantly increase the computational cost.

关键词： Analytical model Coaxial magnetic gear Dynamics Non-linear equations Stability

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An investigation of stress shot peening using a 2D FEM-based simulation approach

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INTERNATIONAL JOURNAL OF FATIGUE 2024年 181卷

作者： Gakias, C. Maliaris, G. Savaidis, G. Aristotle Univ Thessaloniki Sch Mech Engn Lab Machine Elements & Machine Design Univ Campus Thessaloniki 54124 Greece Int Hellen Univ Sch Sci Dept Chem Kavala 65404 Greece

In this study, a 2D Finite Element (FE) modeling approach is introduced for Stress Shot Peening (SSP), an enhanced version of Shot Peening (SP) widely used for fatigue life enhancement in leaf springs. The model incorporates the stochastic nature of peening particles and degraded surface properties, offering qualitative insights into the SSP process. Moreover, it reduces calculation time compared to a 3D approach, enabling the examination of multiple scenarios with limited computational resources. The approach is validated for both SP and SSP cases, providing a comprehensive overview of the SSP process, including parametrical studies on prestress level and peening angle.

关键词： Stress shot peening Finite element method Simulation Residual stresses Leaf spring

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Fast and efficient simulation of the dynamical response of coaxial magnetic gears through direct analytical torque modelling

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SIMULATION MODELLING PRACTICE AND THEORY 2023年 123卷

作者： Tzouganakis, Panteleimon Gakos, Vasilios Kalligeros, Christos Tsolakis, Antonios Spitas, Vasilios Univ West Attica Lab Machine Elements & Vehicles 250 Thivon & P Ralli Egaleo 12244 Greece Natl Tech Univ Athens Lab Machine Design 9 Iroon Polytech Zografos 15780 Greece

Coaxial magnetic gears have been of great interest amongst researchers and the industry since their introduction two decades ago. Although magnetic gears suffer from slippage at high torques and in general have lower torque density compared to their mechanical counterparts, they sur-pass their performance in terms of attained speeds, versatility, vibration attenuation, back-drivability and efficiency. Increasing the torque density is a major issue in magnetic drivetrains that has been extensively discussed in the literature. However, the calculation of the torque is typically performed through FEA and/or numerical methods, thus increasing the computational cost especially in dynamical simulations where the applied torques at the two rotors have to be calculated at each time step. The objective of this work is to introduce an analytical 2D model for fast and efficient calculation of the applied torques for every rotation angle, geometry configu-ration and constitutive parameters of the magnets using the Maxwell Stress Tensor. The results obtained from the model were compared against those obtained from FEA. The calculated torques at the inner and outer rotor were in perfect agreement with FEA, however the analytical model was more than two orders of magnitude faster. In addition, an analytical calculation of the torque ripple in coaxial magnetic gear drives is made possible using the proposed model. An investi-gation of the influence of the modulator ring on stall torque was performed illustrating that there is an optimum length value for the ferromagnetic segment to maximize torque density. Furthermore, the motion equations of the coaxial magnetic gear drive were formulated and a model was developed to simulate the dynamical response of the system without the requirement of torque calculation at each time step that significantly decreases computational cost. The slip effect was investigated and the resulting transmission error was determined.

关键词： Coaxial magnetic gear Analytical torque calculation Dynamical response Maxwell Stress Tensor Slip effect Torque ripple

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