Applied Sciences

Research

22 pages, 6071 KiB

Open AccessArticle

Advancements in Roundness Measurement Parts for Industrial Automation Using Internet of Things Architecture-Based Computer Vision and Image Processing Techniques

by Yazid Saif, Anika Zafiah M. Rus, Yusri Yusof, Maznah Lliyas Ahmed, Sami Al-Alimi, Djamal Hissein Didane, Anbia Adam, Yeong Hyeon Gu, Mohammed A. Al-masni and Hakim Qaid Abdullah Abdulrab

Appl. Sci. 2023, 13(20), 11419; https://doi.org/10.3390/app132011419 - 18 Oct 2023

Cited by 2 | Viewed by 2880

Abstract

In the era of Industry 4.0, the digital capture of products has become a critical aspect, which prompts the need for reliable inspection methods. In the current technological landscape, the Internet of Things (IoT) holds significant value, especially for industrial devices that require [...] Read more.

In the era of Industry 4.0, the digital capture of products has become a critical aspect, which prompts the need for reliable inspection methods. In the current technological landscape, the Internet of Things (IoT) holds significant value, especially for industrial devices that require seamless communication with local and cloud computing servers. This research focuses on the advancements made in roundness measurement techniques for industrial automation by leveraging an IoT architecture, computer vision, and image processing. The interconnectedness enables the efficient collection of feedback information, meeting the demands of closed-loop manufacturing. The accuracy and performance of assemblies heavily rely on the roundness of specific workpiece components. In order to address this problem, automated inspection methods are needed. A new method of computer vision for measuring and inspecting roundness is proposed in this paper. This method uses a non-contact method that takes into account all points on the contours of measured objects, making it more accurate and practical than conventional methods. The system developed by AMMC Laboratory captures Delrin work images and analyzes them using a specially designed 3SMVI system based on Open CV with Python script language. The system can measure and inspect several rounded components in the same part, including external frames and internal holes. It is calibrated to accommodate various units of measurement and has been tested using sample holes within the surface feature of the workpiece. According to the results of both techniques, there is a noticeable difference ranging from 2.9 µm to 11.6 µm. However, the accuracy of the measurements can be enhanced by utilizing a high-resolution camera with proper lighting. The results were compared to those obtained using a computer measurement machine (CMM), with a maximum difference of 8.7%. Full article

(This article belongs to the Special Issue Advanced Manufacturing Technologies: Development and Prospect)

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14 pages, 4911 KiB

Open AccessArticle

Options on Tooth Profile Modification by Hob Adjustment

by Jozef Mascenik, Tomas Coranic and Tibor Krenicky

Appl. Sci. 2023, 13(19), 10646; https://doi.org/10.3390/app131910646 - 25 Sep 2023

Viewed by 1065

Abstract

The presented contribution focuses its attention on the research on the influence of the angular setting in a hobbing mill on the adjustment of the tooth profile created by this technology. The aspect of influence from the angular settings in the hobbing mill [...] Read more.

The presented contribution focuses its attention on the research on the influence of the angular setting in a hobbing mill on the adjustment of the tooth profile created by this technology. The aspect of influence from the angular settings in the hobbing mill on the final shape of the gears is investigated. In this research, the effect of substituting the curvilinear profile of the cutting edges with a straight profile is analyzed, observing how this approach affects the final geometry of the gears. An important point of this research is also the comparison of different profiling methods using the hobbing mill, specifically when using a normal cut, which is perpendicular to the helix of the milling cutter, and also when cutting along the axial plane of the hobbing mill. Full article

(This article belongs to the Special Issue Advanced Manufacturing Technologies: Development and Prospect)

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20 pages, 7571 KiB

Open AccessArticle

Data Exchange with Support for the Neutral Processing of Formats in Computer-Aided Design/Computer-Aided Manufacturing Systems

by Piotr Kuryło, Peter Frankovský, Marek Malinowski, Tomasz Maciejewski, Ján Varga, Ján Kostka, Łukasz Adrian, Szymon Szufa and Svetlana Rusnáková

Appl. Sci. 2023, 13(17), 9811; https://doi.org/10.3390/app13179811 - 30 Aug 2023

Cited by 3 | Viewed by 1724

Abstract

This paper presents an analysis and the research results of system couplers in CAx systems that ensure the correct transfer of product data from the “supplier” system to the “recipient” system. This study presents the results of the compatibility tests between the systems [...] Read more.

This paper presents an analysis and the research results of system couplers in CAx systems that ensure the correct transfer of product data from the “supplier” system to the “recipient” system. This study presents the results of the compatibility tests between the systems based on the verification of geometric models and their attributes after importing/exporting 2D and 3D objects using neutral data exchange formats. The purpose of the research was to identify neutral formats that do not introduce errors after data transversion in certain types of geometry. Tests and analyses were carried out on selected formats depending on the type of object, such as 2D objects (DXF), solid objects (IGES, STEP, SAT, and PARASOLID), and surface objects (IGES, STEP, SAT, and X_T). One of the results of our research and analysis is the need for continuous development of CAD/CAE systems because current neutral formats are not 100% effective. Full article

(This article belongs to the Special Issue Advanced Manufacturing Technologies: Development and Prospect)

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18 pages, 4730 KiB

Open AccessArticle

Automation of the Edge Deburring Process and Analysis of the Impact of Selected Parameters on Forces and Moments Induced during the Process

by Karol Falandys, Krzysztof Kurc, Andrzej Burghardt and Dariusz Szybicki

Appl. Sci. 2023, 13(17), 9646; https://doi.org/10.3390/app13179646 - 25 Aug 2023

Cited by 2 | Viewed by 1674

Abstract

The article concerns the possibility of the automation and robotization of the process of deburring jet engine components. The paper presents the construction of a laboratory stand enabling the automation of selected production operations of typical low-pressure turbine blades. The work identifies important [...] Read more.

The article concerns the possibility of the automation and robotization of the process of deburring jet engine components. The paper presents the construction of a laboratory stand enabling the automation of selected production operations of typical low-pressure turbine blades. The work identifies important parameters and results of the technological process related to the removal of burrs that affect the exactness of the process. The results of the analysis of the impact of individual process parameters on the magnitude of forces and moments occurring during deburring were carried out and presented. The results of initial and detailed tests were presented. Based on the results obtained, it was noticed that doubling the rotational speed of the brush results in a linear increase in torque and an increase in the engagement of the detail in the disc brush, leading to a non-linear increase in torque. It has also been shown that with tool wear, the value of the torque generated by the rotating tool decreases. Based on the results of a comparison of manual and automated process and histogram analysis, results from an automated stand are centered more correctly inside of the required radius range. This means that the repeatability of the process is higher for an automated test stand, which is one of the key aspects of large-scale aviation component manufacturing. Additionally, it was confirmed by visual inspection that all burs had been removed correctly—the deburring operation for all tested work pieces was successful. Based on the results obtained, it was proven that introduction of an automated stand can improve working conditions (by the elimination of the progressive fatigue of employees and the possibility for injury) and allows for the elimination of the negative impact of the machining process on workers. Further areas in which the optimization of the process parameters of the edge deburring can be developed in order to reduce unit costs have also been indicated. Full article

(This article belongs to the Special Issue Advanced Manufacturing Technologies: Development and Prospect)

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14 pages, 9561 KiB

Open AccessArticle

Development of a Magnetic Levitation Wafer Handling Robot Transfer System with High-Accuracy and High-Cleanliness: Experimental Evaluation

by Chang-Wan Ha, Sungho Jung, Jinseong Park and Jaewon Lim

Appl. Sci. 2023, 13(16), 9482; https://doi.org/10.3390/app13169482 - 21 Aug 2023

Cited by 1 | Viewed by 2792

Abstract

Magnetic levitation can reduce particulate contamination that occurs during wafer transportation in the semiconductor manufacturing process. This technology radically eliminates contact between the wafer and the transport system, reducing friction, wear, and particle generation. Therefore, it is suitable for achieving high cleanliness in [...] Read more.

Magnetic levitation can reduce particulate contamination that occurs during wafer transportation in the semiconductor manufacturing process. This technology radically eliminates contact between the wafer and the transport system, reducing friction, wear, and particle generation. Therefore, it is suitable for achieving high cleanliness in the ultra-fine line-width semiconductor production process and solving the need for particle removal in a vacuum environment. In this study, the roller and linear motion guide components of the wafer transfer system were replaced with a magnetic levitation module, and a robot arm was installed on top to transport a single wafer. A posture controller and a current controller were designed, and test equipment simulating the wafer transfer system was also manufactured and tested. Regarding mover and system identification, a sine sweep test was performed on the motion axis of the five degrees of freedom. Through the obtained system identification, it was possible to design the posture controller more precisely. Moreover, through levitation in standstill experiments and high-speed operation experiments, the wafer transport system can be used to verify dust-free high-speed transport and accurate positioning performance. Full article

(This article belongs to the Special Issue Advanced Manufacturing Technologies: Development and Prospect)

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48 pages, 43804 KiB

Open AccessArticle

Measuring Procedures for Evaluating the Surface Roughness of Machined Parts

by Katarína Palová, Tatiana Kelemenová and Michal Kelemen

Appl. Sci. 2023, 13(16), 9385; https://doi.org/10.3390/app13169385 - 18 Aug 2023

Cited by 5 | Viewed by 5734

Abstract

This article deals with the problems that arise during the evaluation of the surface of the components, which can have a fundamental impact on the functionality and service life of the component as well as the entire product. A fast method for estimating [...] Read more.

This article deals with the problems that arise during the evaluation of the surface of the components, which can have a fundamental impact on the functionality and service life of the component as well as the entire product. A fast method for estimating the condition and maximum error of the surface tester used for assessing the surface roughness of components was proposed. Using the secondary surface roughness standard, a uniform distribution law of the measured data was experimentally identified as a suitable model, according to which it is then possible to determine the coverage factor for determining the measurement uncertainty. The design of surface roughness measurement methodology for Ra determination is critical when selecting optimal settings of conditions and measurement parameters for various types of component surface treatment technologies. This is mainly due to the effect of the selection of the evaluation standard, the effect of the measurement speed, and the effect of setting the cut-off filter for the evaluation of the quantity Ra. Etalon samples of surface roughness realized by different technologies were used for experimental verification of these phenomena. Large sets of measurements were carried out on selected samples from each technology, and, accordingly, a methodology was proposed for determining the optimal number of measurements for determining the surface roughness of the investigated component, which represents an important factor for achieving measurement results with minimal measurement uncertainties at low financial costs. Full article

(This article belongs to the Special Issue Advanced Manufacturing Technologies: Development and Prospect)

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14 pages, 3717 KiB

Open AccessArticle

The Difficulty of Measuring the Roughness of Glossy Surfaces Using the Triangulation Principle

by Juraj Ružbarský

Appl. Sci. 2023, 13(8), 5155; https://doi.org/10.3390/app13085155 - 20 Apr 2023

Cited by 8 | Viewed by 2501

Abstract

In the experiment, the roughness was measured on a machined surface with high gloss, which was also the main requirement for the test samples. For this reason, the samples made of stainless steel A304 and aluminum alloy AW 2017 were created by a [...] Read more.

In the experiment, the roughness was measured on a machined surface with high gloss, which was also the main requirement for the test samples. For this reason, the samples made of stainless steel A304 and aluminum alloy AW 2017 were created by a progressive laser using material-cutting technology. This article explains a contact-free measurement method that uses the triangulation principle, which constitutes the basis on which the device used in the experiment, i.e., the laser profilometry, works. The surface roughness of the cut surfaces was examined on the manufactured samples through the selected roughness parameters of Ra and Rz. These parameters are commonly used in industry to quantify the roughness of a surface. The values measured in a contact-free manner were then compared with the reference values measured in a contact manner. Data from individual experimental measurements were graphed as dependencies based on which problem areas of measuring the roughness of glossy material surfaces with laser profilometry were described. Laser profilometry is a non-contact method for measuring the roughness of surfaces, and given the presented results of the experimental measurements and selected roughness parameters of the cut surface using a laser, we do not recommend using it for materials that have a glossy surface. Full article

(This article belongs to the Special Issue Advanced Manufacturing Technologies: Development and Prospect)

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21 pages, 2343 KiB

Open AccessArticle

New Possibilities of Using DEMATEL and ERPN in the New PFMEA Hybrid Model

by Marián Bujna, Chia Kuang Lee, Milan Kadnár, Maroš Korenko and Juraj Baláži

Appl. Sci. 2023, 13(6), 3627; https://doi.org/10.3390/app13063627 - 12 Mar 2023

Cited by 3 | Viewed by 2184

Abstract

The aim of the paper is to examine the requirements of producers in post-communist countries with lower economic level. The first requirement was how to overcome the limitations of conventional PFMEA to propose measures effectively. The second requirement solved the economic effect of [...] Read more.

The aim of the paper is to examine the requirements of producers in post-communist countries with lower economic level. The first requirement was how to overcome the limitations of conventional PFMEA to propose measures effectively. The second requirement solved the economic effect of failure modes. The aim of the paper was to create a new hybrid PFMEA–DEMATEL–ERPN model to manage failure modes to resolve the requirements. The DEMATEL model overcame the limitations of PFMEA. DEMATEL data were used to estimate the functionality of the proposed models. Criteria such as the occurrence of defective products and the probability of their occurrence (O and RPN) were monitored. ERPN also overcame the limitations of PFMEA. Internal and external costs arise as effects of failure modes. The costs were included in the economic evaluation of the models. We validated the models in a transfer pressing process. The estimation of models’ functionality proved to be correct. The economic evaluation refined the research results and resolved the second requirement of the manufacturers. The DEMATEL and ERPN models (compared to PFMEA) proved their validity when the use of PFMEA was limited. By using DEMATEL, we registered the lowest number of defective products and the lowest costs. Full article

(This article belongs to the Special Issue Advanced Manufacturing Technologies: Development and Prospect)

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16 pages, 7489 KiB

Open AccessArticle

New Calculation Methodology of the Operations Number of Cold Rolling Rolls Fine Grinding

by Sergey Bratan, Zuzana Ságová, Milan Sága, Boris Yakimovich and Ivan Kuric

Appl. Sci. 2023, 13(6), 3484; https://doi.org/10.3390/app13063484 - 9 Mar 2023

Cited by 10 | Viewed by 1394

Abstract

This article considers the methods of calculating the number of operations for the fine grinding of cold rolling rolls which allows one to ensure the least labor-intensive processing of the part. Based on the analysis of the patterns in the operation of single [...] Read more.

This article considers the methods of calculating the number of operations for the fine grinding of cold rolling rolls which allows one to ensure the least labor-intensive processing of the part. Based on the analysis of the patterns in the operation of single abrasive grains, the dependence of the productivity of the fine-grinding process on the grain size of the wheel, the grinding allowance, the grinding mode, the size of the workpiece, and the wheel, is proposed. To analyze the productivity of the finishing grinding processes, a productivity indicator, independent of the size of the wheel and the workpiece, is analyzed, and the impact on the productivity indicator of the number of finishing grinding operations, as well as the following sequence of their optimization, is established. To simplify the calculation of the optimal number of operations, graphs and a nomogram are constructed. According to the proposed methodology, the calculation of the number of finishing operations of cold rolling rolls of various sizes was carried out. Experimental verification of the proposed theoretical dependencies and methods for calculating the optimal number of grinding operations was also carried out. Full article

(This article belongs to the Special Issue Advanced Manufacturing Technologies: Development and Prospect)

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17 pages, 3882 KiB

Open AccessArticle

The Use of Mobile Applications for Sustainable Development of SMEs in the Context of Industry 4.0

by Angelina Iakovets, Michal Balog and Kamil Židek

Appl. Sci. 2023, 13(1), 429; https://doi.org/10.3390/app13010429 - 29 Dec 2022

Cited by 7 | Viewed by 2216

Abstract

Sustainable development of technology in manufacturing motivates entrepreneurs to increasingly introduce technical innovations into their production process. In times of technical progress, the selection and support of qualified personnel are especially important. The process of introducing new technologies or innovations in an enterprise [...] Read more.

Sustainable development of technology in manufacturing motivates entrepreneurs to increasingly introduce technical innovations into their production process. In times of technical progress, the selection and support of qualified personnel are especially important. The process of introducing new technologies or innovations in an enterprise is closely related to the personnel involved in this process. Sustainable development of the enterprise is possible, subject to the sequence of processes, namely, ensuring the adaptation of personnel and collecting feedback. A mobile application can be innovative for a particular enterprise and ensure sustainable development and adaptation to Industry 4.0 technologies. Given the pressure of technology and the environment on small- and medium-sized manufacturing enterprises, it was proposed to conduct a practical study in the conditions of a typical enterprise of this category. To explore the attractiveness of mobile applications as a tool for enterprise sustainable development, an application with basic features that should help provide a framework for integrating Industry 4.0 technologies into the manufacturing process was proposed. In the course of the study, a cycle of innovations and a set of evaluation methods for some of them were proposed. With the help of the proposed assessment methods, as well as the practical use of the mobile application, it became clear that the proposed solution can create a positive effect. The success of this kind of innovation and the further sustainable development of the enterprise is possible if the gradual adaptation of employees will be ensured; it will enable further innovation. Full article

(This article belongs to the Special Issue Advanced Manufacturing Technologies: Development and Prospect)

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12 pages, 7113 KiB

Open AccessArticle

Tire Bubble Defect Detection Using Incremental Learning

by Chuan-Yu Chang, You-Da Su and Wei-Yi Li

Appl. Sci. 2022, 12(23), 12186; https://doi.org/10.3390/app122312186 - 28 Nov 2022

Cited by 6 | Viewed by 2184

Abstract

Digital shearography is a technique that has recently been applied to material inspections that cannot be performed by the naked eyes, including the detection of air bubble defects in tires. Although digital shearography detects bubbles that are not visible to the naked eyes, [...] Read more.

Digital shearography is a technique that has recently been applied to material inspections that cannot be performed by the naked eyes, including the detection of air bubble defects in tires. Although digital shearography detects bubbles that are not visible to the naked eyes, the process of determining tire defects still relies on field operators, with inconsistent results depending on the experiences of the field operator personnel. New or different types of bubble defects that AI models have not previously recognized are often missed, resulting in an inadequate quality detection model. In this paper, we propose a bubble defect detection method based on an incremental YOLO architecture. The data for this research was provided by the largest tire manufacturer in Taiwan. In our research, we classify the defects into six distinct categories, pre-process the images to allow better detections of less-noticeable defects, increase the amount of training data used, and generate an initial training model with the YOLO framework. We also propose an incremental YOLO method using small-model training for previously unobserved defects to improve the model detection rate. We have observed detection accuracy and sensitivity of 98% and 90% in the experimental results, respectively. The methods proposed in this paper can assist tire manufacturers in achieving semi-automatic quality inspections and labor cost reductions. Full article

(This article belongs to the Special Issue Advanced Manufacturing Technologies: Development and Prospect)

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15 pages, 3588 KiB

Open AccessArticle

Experimental Determination of the Coefficient of Friction on a Screw Joint

by Jozef Mascenik and Tomas Coranic

Appl. Sci. 2022, 12(23), 11987; https://doi.org/10.3390/app122311987 - 23 Nov 2022

Cited by 8 | Viewed by 2924

Abstract

This paper deals with the coefficient of determination of screw connection friction between the thread and the matrix. The coefficient of friction was measured using a laboratory device with an M20 screw connection without any grease and, subsequently, plastic grease was added (CX80 [...] Read more.

This paper deals with the coefficient of determination of screw connection friction between the thread and the matrix. The coefficient of friction was measured using a laboratory device with an M20 screw connection without any grease and, subsequently, plastic grease was added (CX80 silicone, lithium, and copper grease). When grease is added, the friction in the threads and screw heads is limited and consistently retained. When tightening by torque, which represents the prevailing assembly method in standard screwing practice, only part of the torque is effectively used to create axial force and pre-stress. The rest of the torque is employed in friction suppression between threads and converted into heat. In general, the coefficient of friction depends on diverse factors such as the roughness of the thread surface, the gradient angle of the helix, and the grease properties. The tightening torque represents a primary parameter in the experimental measurements, monitored using a digital torque spanner, and generates an axial force in the screw. Based on the aforementioned parameters, the objective of this paper was to monitor changes in the coefficient of friction between the thread of the screw and the matrix in the case of different grease types. The actual coefficient of friction was calculated through the exponential equation of the torque balance. First measured was the load of the bolted joint without the use of grease, where the average value of the coefficient of friction was 0.44732; this value served as a benchmark for comparison to the measurements with the use of grease. The measurements showed that the value of the friction coefficient was reduced by 30.57% when using lithium grease, by 40.56% when using silicone grease, and by 47.64% when using copper-based grease, making the latter the most suitable for the application. Without appropriate greasing, friction suppression was accompanied by extremely high torques, which resulted in insufficient screw prolongation. Full article

(This article belongs to the Special Issue Advanced Manufacturing Technologies: Development and Prospect)

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18 pages, 8668 KiB

Open AccessArticle

Method of Sequential Approximation in Modelling the Processes of Heat Transfer and Gas Dynamics in Combustion Equipment

by Miroslav Rimar, Oleksandr Yeromin, Grigoriy Larionov, Andrii Kulikov, Marcel Fedak, Tibor Krenicky, Olena Gupalo and Yana Myanovskaya

Appl. Sci. 2022, 12(23), 11948; https://doi.org/10.3390/app122311948 - 23 Nov 2022

Cited by 4 | Viewed by 1331

Abstract

The behavior of the processes taking place in furnaces determines the efficiency of fuel chemical energy utilization, the quality of the final products and the environmental safety of the production. Mathematical models of the processes of gas dynamics and heat transfer in the [...] Read more.

The behavior of the processes taking place in furnaces determines the efficiency of fuel chemical energy utilization, the quality of the final products and the environmental safety of the production. Mathematical models of the processes of gas dynamics and heat transfer in the working space of heating equipment are quite complex, and do not allow the establishment of a direct analytical relationship between the quality indicator of the process (F) and the influencing parameters (x_i). To simplify the procedure for obtaining the values of the function F depending on the change of parameters x_i, a method of successive approximation is presented in the article. The main idea of the method is that the representation of the function around a point from the domain of the function can be extended to the entire domain for many problems of mechanics. The relative error in the definition of the function acquires its maximum value at the border of the area, and a reasonable narrowing of it allows control of the size of the error. Thus, the advantages of using the method are obvious; it is able to provide approximation of the function in a multiplicative form with a controlled error. The distribution of the method to the field of heat transfer problems is presented in this paper. The successful implementation of this method for solving problems of this kind shows that the solution of practical problems may be generalized for the entire domain of the function, despite the fact that the errors of such a representation increase to 5–7% when approaching its limit, which, however, may be considered acceptable for engineering calculations. Full article

(This article belongs to the Special Issue Advanced Manufacturing Technologies: Development and Prospect)

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10 pages, 2145 KiB

Open AccessCommunication

Study of Anisotropic Friction in Gears of Mechatronic Systems

by Zuzana Ságová, Valerii Vasilevich Tarasov, Ivana Klačková, Alexander Ivanovich Korshunov and Milan Sága

Appl. Sci. 2022, 12(21), 11021; https://doi.org/10.3390/app122111021 - 31 Oct 2022

Cited by 1 | Viewed by 1543

Abstract

The article discusses the features of anisotropic friction, which can be used to refine the calculation of the efficiency in various friction and gear drives and transmissions in mechatronic systems. Friction processes are considered that determine the level of losses in friction and [...] Read more.

The article discusses the features of anisotropic friction, which can be used to refine the calculation of the efficiency in various friction and gear drives and transmissions in mechatronic systems. Friction processes are considered that determine the level of losses in friction and gear drives, which are complex and heterogeneous in a number of parameters: the contact patch, which depends on the quality of the contacting surfaces; the direction and intensity of sliding; load distribution, etc. A more complete understanding of the features of these processes requires the use of the concept of friction anisotropy, which is well known in tribology of mechatronics systems. The anisotropy effect is caused by the difference in the characteristics of the surface microgeometry and its physical and mechanical properties in relation to the direction of the tool marks remaining on the surface after machining. In the presence of anisotropic friction, in contrast to isotropic, the body moves at a certain angle to the direction of application of the perturbing (external) force. The situation is considered in detail within the framework of the tensor model of anisotropic friction. The model and methodological approaches considered in the paper to the estimation of friction anisotropy can be used to refine the calculations of friction losses. The aim of the work is to create mechanical and analytical models of frictional anisotropy for a more complete understanding of this phenomenon in relation to various friction pairs. This article may be of interest to specialists in the field of friction gears for solving problems related to improving the accuracy of calculations and quantifying friction losses. Full article

(This article belongs to the Special Issue Advanced Manufacturing Technologies: Development and Prospect)

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22 pages, 3608 KiB

Open AccessArticle

Large-Scale 3D Multi-Story Enterprise Layout Design in a New Type of Industrial Park in China

by Xuemin Liu, Guozhong Huang, Xuehong Gao, Haoxuan Li, Shengnan Ou and Ibrahim M. Hezam

Appl. Sci. 2022, 12(16), 8110; https://doi.org/10.3390/app12168110 - 12 Aug 2022

Cited by 2 | Viewed by 1768

Abstract

In the new-type clustered industrial park, the closer distance between enterprises leads to risk aggregation, and the layout of enterprises affects the safety and economy of the park. However, previous studies have often paid insufficient attention to safety, and few studies have considered [...] Read more.

In the new-type clustered industrial park, the closer distance between enterprises leads to risk aggregation, and the layout of enterprises affects the safety and economy of the park. However, previous studies have often paid insufficient attention to safety, and few studies have considered park profits. To address this issue, a bi-level three-dimensional layout optimization model was proposed to minimize the overall association risk of the park and maximize the rental profit. In particular, this article explained the enterprise association risks and provided calculation formulas, considering multiple risk types. To solve the proposed nonlinear model, a specific variable conversion method was presented to reduce the problem scale. Subsequently, an improved genetic algorithm was developed and applied to obtain the layout results. Furthermore, a case study of an industrial park was conducted, and the computational results indicated the validity of the model and methods. Finally, two different scenarios were implemented, and critical parameters were tested to provide valuable management insights. Full article

(This article belongs to the Special Issue Advanced Manufacturing Technologies: Development and Prospect)

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18 pages, 4803 KiB

Open AccessArticle

5G Digital Twin: A Study of Enabling Technologies

by Ramiro Ramirez, Chien-Yi Huang and Shu-Hao Liang

Appl. Sci. 2022, 12(15), 7794; https://doi.org/10.3390/app12157794 - 3 Aug 2022

Cited by 13 | Viewed by 5073

Abstract

5G networks require dynamic network monitoring and advanced security solutions. This work performs the essential steps to implement a basic 5G digital twin (DT) in a warehouse scenario. This study provides a paradigm of end-to-end connection and encryption to internet of things (IoT) [...] Read more.

5G networks require dynamic network monitoring and advanced security solutions. This work performs the essential steps to implement a basic 5G digital twin (DT) in a warehouse scenario. This study provides a paradigm of end-to-end connection and encryption to internet of things (IoT) devices. Network function virtualization (NFV) technologies are crucial to connecting and encrypting IoT devices. Innovative logistical scenarios are undergoing constant changes in logistics, and higher deployment of IoT devices in logistic scenarios, such as warehouses, demands better communication capabilities. The simulation tools enable digital twin network implementation in planning. Altair Feko (WinProp) simulates the radio behavior of a typical warehouse framework. The radio behavior can be exported as a radio simulation dataset file. This dataset file represents the virtual network’s payload. GNS3, an open-source network simulator, performs data payload transmission among clients to servers using custom NFV components. By transmitting data from client to server, we achieved end-to-end communication. Additionally, custom NFV components enable advanced encryption standard (AES) adoption. In summary, this work analyzes the round-trip time (RTT) and throughput of the payload data packages, in which two data packages, encrypted and non-encrypted, are observed. Full article

(This article belongs to the Special Issue Advanced Manufacturing Technologies: Development and Prospect)

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22 pages, 2460 KiB

Open AccessArticle

Model for Integrating the Electricity Cost Consumption and Power Demand into Aggregate Production Planning

by Camila Matos, Antônio Vanderley Herrero Sola, Gustavo de Souza Matias, Fernando Henrique Lermen, José Luis Duarte Ribeiro and Hugo Valadares Siqueira

Appl. Sci. 2022, 12(15), 7577; https://doi.org/10.3390/app12157577 - 27 Jul 2022

Cited by 10 | Viewed by 1905

Abstract

The constant increases in electricity tax costs and the mandatory contracting of power demand in advance by companies connected to the high-voltage electrical system drive organizations to improve energy planning in their production processes. In addition, market uncertainties make only stochastic methods insufficient [...] Read more.

The constant increases in electricity tax costs and the mandatory contracting of power demand in advance by companies connected to the high-voltage electrical system drive organizations to improve energy planning in their production processes. In addition, market uncertainties make only stochastic methods insufficient for forecasting future production demand. To fill this gap, this study proposes a model that integrates the cost with electricity consumption and power demand into the aggregate production planning, considering the market uncertainties. The model was empirically applied in the food industry, considering a family of potato chips products. From the collected data, a demand forecast was carried out for a later realization of the aggregate planning, using the Holt–Winters forecast model. Before modeling, the new energy demand was calculated, and finally, the model solution verification was performed. In the case study, after application, it was possible to reduce two workers and a cost reduction of R$ 14,288.00. Moreover, the proposal managed to define a power demand that minimized the costs of electric energy and the total costs of the aggregate production planning. Full article

(This article belongs to the Special Issue Advanced Manufacturing Technologies: Development and Prospect)

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19 pages, 8540 KiB

Open AccessArticle

An Analysis of Selected Technological Parameters’ Influences on the Tribological Properties of Products Manufactured Using the FFF Technique

by Gerhard Mitaľ, Ivan Gajdoš, Emil Spišák, Janka Majerníková and Tomáš Jezný

Appl. Sci. 2022, 12(8), 3853; https://doi.org/10.3390/app12083853 - 11 Apr 2022

Cited by 5 | Viewed by 1940

Abstract

This study investigates how layer deposition in printing 3D models made of polyetherimide (PEI) using the fused filament fabrication (FFF) technique affects resistance of these models to abrasive wear. Samples made by additive manufacturing with different setting of build orientation and path generation [...] Read more.

This study investigates how layer deposition in printing 3D models made of polyetherimide (PEI) using the fused filament fabrication (FFF) technique affects resistance of these models to abrasive wear. Samples made by additive manufacturing with different setting of build orientation and path generation strategy of extruded fibers were used in the experiment. The experiments were conducted on a tribometer according to the ASTM G65-16 standard. The friction force, normal force, and temperature in the contact area during the tribometer operation were measured using a strain gauge sensor. The tribometer allowed us to perform the tribological experiments using a rubber-coated or a metal disc without a lubricant in the so-called “dry” operation. Following the ASTM G65-16 standard, a rubber-coated disc and Fe₃Al₂ (SiO₄)₃ garnet abrasive were used for the wear resistance tests. The analysis of experimental data showed correlations among orientation selection, the strategy of layer deposition by the FFF technique, and the surface life in terms of abrasive wear. The results of this research also showed the suitability of the chosen building orientation and deposition strategy for part production by additive manufacturing, depending on the required tribological properties, such as the coefficient of friction (yield path) and wear behavior. Based on the results of the study, it is concluded that continuity of wear and friction force depends on the path traveled under the model production orientation. The size of wear (material loss) ranged from 0.451–0.809%. It was shown that the weight loss of the sample under loading was greater, on average, with the chosen fiber orientation strategy in the Z direction than in the X direction. Full article

(This article belongs to the Special Issue Advanced Manufacturing Technologies: Development and Prospect)

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15 pages, 4458 KiB

Open AccessFeature PaperArticle

Particle and Particle Agglomerate Size Monitoring by Scanning Probe Microscope

by Pavel Gulyaev, Tibor Krenicky, Evgeny Shelkovnikov and Aleksandr Korshunov

Appl. Sci. 2022, 12(4), 2183; https://doi.org/10.3390/app12042183 - 19 Feb 2022

Cited by 4 | Viewed by 2896

Abstract

In the present study, the use of a scanning probe microscope is described for monitoring the sizes of nanoparticles. Monitoring is the process of acquiring and analysing the set of overlapping images. The main analysis steps are image segmentation, determination of nanoparticles allocation [...] Read more.

In the present study, the use of a scanning probe microscope is described for monitoring the sizes of nanoparticles. Monitoring is the process of acquiring and analysing the set of overlapping images. The main analysis steps are image segmentation, determination of nanoparticles allocation and their sizes, determination of the overlap of images with one another, and exclusion of repeating measurements for the formation of the correct particle-size sampling. The thorough examination of commercial scanning probe microscopes, software, and image processing libraries showed that their capabilities are limited for image segmentation and determination of sizes in complex structured images. A method based on the surface curvature computation is proposed for the image segmentation (allocation of particles) and determination of particle sizes. The curvature is estimated using the surface area approximation with respect to the circumference. It is proposed to use sample displacement sensors as an aid for image stitching. Full article

(This article belongs to the Special Issue Advanced Manufacturing Technologies: Development and Prospect)

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16 pages, 4842 KiB

Open AccessArticle

Center of Gravity Coordinates Estimation Based on an Overall Brightness Average Determined from the 3D Vision System

by Radovan Holubek and Marek Vagaš

Appl. Sci. 2022, 12(1), 286; https://doi.org/10.3390/app12010286 - 28 Dec 2021

Cited by 2 | Viewed by 2392

Abstract

In advanced manufacturing technologies (including complex automated processes) and their branches of industry, perception and evaluation of the object parameters are the most critical factors. Many production machines and workplaces are currently equipped as standard with high-quality special sensing devices based on vision [...] Read more.

In advanced manufacturing technologies (including complex automated processes) and their branches of industry, perception and evaluation of the object parameters are the most critical factors. Many production machines and workplaces are currently equipped as standard with high-quality special sensing devices based on vision systems to detect these parameters. This article focuses on designing a reachable and fully functional vision system based on two standard CCD cameras usage, while the emphasis is on the RS 232C communication interface between two sites (vision and robotic systems). To this, we combine principles of the 1D photogrammetric calibration method from two known points at a stable point field and the available packages inside the processing unit of the vision system (as filtering, enhancing and extracting edges, weak and robust smoothing, etc.). A correlation factor at camera system (for reliable recognition of the sensed object) was set from 84 to 100%. Then, the pilot communication between both systems was proposed and then tested through CREAD/CWRITE commands according to protocol 3964R (used for the data transfer). Moreover, the system was proven by successful transition of the data into the robotic system. Since research gaps in this field still exist and many vision systems are based on PC processing or intelligent cameras, our potential research topic tries to provide the price–performance ratio solution for those who cannot regularly invest in the newest vision technology; however, they could still do so to stay competitive. Full article

(This article belongs to the Special Issue Advanced Manufacturing Technologies: Development and Prospect)

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14 pages, 6114 KiB

Open AccessFeature PaperArticle

Parametric Optimization of Combined Wind-Solar Energy Power Plants for Sustainable Smart City Development

by Pavel Kuznetsov, Miroslav Rimar, Boris Yakimovich, Olha Kulikova, Martin Lopusniak, Dmitry Voronin and Vladislav Evstigneev

Appl. Sci. 2021, 11(21), 10351; https://doi.org/10.3390/app112110351 - 4 Nov 2021

Cited by 6 | Viewed by 2603

Abstract

To minimize the existing risks associated with the energy production, distribution, and development of urban areas, the concept of sustainable development of smart manufacturing is being introduced everywhere. However, most of existing digital transformation technologies do not sufficiently take into account environmental, economic, [...] Read more.

To minimize the existing risks associated with the energy production, distribution, and development of urban areas, the concept of sustainable development of smart manufacturing is being introduced everywhere. However, most of existing digital transformation technologies do not sufficiently take into account environmental, economic, and social components. It requires the development of specialized solutions that, on the one hand, contribute to the development of the urban environment, and on the other, are focused on the use of innovative technologies that have a positive effect on the environment. However, in order to provide electric power to objects of a smart urban environment, we propose using autonomous power plants with renewable energy sources (wind and sun) instead of classical central power supply. The article describes the benefits of using combined wind-solar power plants to provide electricity to smart urban environments. The article considers advantages and disadvantages of this solution. We describe the design of the combined wind-solar installation with a vertical Darier rotor and photoelectric converters located on a common supporting structure. This solution allows getting a positive synergistic effect from the use of several renewable energy sources. The presented main advantages of this solution include increasing the energy efficiency of photovoltaic converters due to the intensification of heat removal from the surface of solar cells by the wind flow from the Darier rotor. In addition, this article considers the efficient use of the area and stability of electricity output. Digital aerodynamic modeling performed the parametric optimization of the Darier rotor having three blades with NACA 0021profile. The simulation demonstrated that the blades installed at an angle of 3.8° provide the maximum value of the wind utilization coefficient. This article also considers parametric optimization of a photovoltaic installation. In particular, the optimal installation angle of photovoltaic modules for Sevastopol is 34°. Full article

(This article belongs to the Special Issue Advanced Manufacturing Technologies: Development and Prospect)

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