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عدد المساهمات : 18928 التقييم : 35294 تاريخ التسجيل : 01/07/2009 الدولة : مصر العمل : مدير منتدى هندسة الإنتاج والتصميم الميكانيكى
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أخواني في الله أحضرت لكم كتاب Functional Reverse Engineering of Strategic and Non-Strategic Machine Tools Edited by Wasim Ahmed Khan, Khalid Rahman, Ghulam Hussain, and Ghulam Abbas
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Contents Foreword Preface xiii Acknowledgments xv Editors vii Contributors xix Section 1 Functional Reverse engineering Activities in Pakistan Chapter 1 3D Scanner: An Application of Functional Reverse Engineering Mohammad Zainullah Khan, Muhammad Hasan, Abdullah Haroon, Mohammad Shahrukh, and Wasim Ahmed Khan Chapter 2 Functional Reverse Engineering of Universal Testing Machine with Enhanced Positioning and Reduced Power Consumption 17 Ghulam Hussain, Salman Amin, Wasim Ahmed Khan, Sami Ullah, K. Rehman, Rafay Safdar, Ghulam Abbas, and Hamza Altaf Chapter 3 Design, Modeling, Analysis, and Characterization of a Pin-onDisk Tribometer with a Novel Spring Loading Mechanism 29 Ghulam Hussain, Shehroze Faisal, Iftikhar Ahmad, Wasim Ahmed Khan, M. Kamran Abbasi, K. Rehman, Sarmad Chohan, Ghulam Abbas, and Adeem Samad Chapter 4 Axes CNC Milling Machine .. 41 Sohaib Jabran, Shajee Ahmed, Sarmad Afzal, and Faizan Tariq Section 2 Sensors, transducers, Printed circuit Boards, and control Chapter 5 Sensors and Actuators: Selection and Interfacing 59 Memoon Sajid and Mazhar Javedviii Contents Chapter 6 PCB Design and Fabrication Fatima Mohsin Zakai, Muhammad Faizan, and Muhammad Faisal Khan Chapter 7 Vibration-Based Piezoelectric Energy Harvester for Wireless Sensor Node Application. 97 Muhammad Iqbal, Malik M. Nauman, Farid U. Khan, Asif Iqbal, Muhammad Aamir, A. E. Pg. Abas, and Quentin Cheok Chapter 8 Reverse Engineering the LQR Controller to Find Equivalence with PID Controller. 115 Ali Nasir Section 3 M achine tools and computational Analysis Chapter 9 Machine Tool Improvement through Reverse Engineering and Computational Analysis with an Emphasis on Sustainable Design 139 Kaan Buyuktas, Muhammad Suhaib, Waqar Joyia, Kemran Karimov, Ihtesham Khan, and Volkan Esat Chapter 10 A Coarse-to-Fine Classification Method for Aviation High-Similarity Sheet Metal Parts Based on Machine Vision 171 Lv Zhengyang, Li Xiaojun, Lin Yutao, and Zhang Liyan Chapter 11 Combustion Timing Control of a Recompression HCCI Engine Using Negative Valve Overlap through Reverse Engineering 191 M. Suleman, Muftooh Ur Rehman Siddiqi, and Sundus Tariq Chapter 12 Fabrication of Smart-Meter for Power Consumption Measurements of Machine Tools 227 Aqib Mashood khan, Ning He, Wei Zhao, Cheng Zhang, and Muhammad JamilContents ix Section 4 Modeling and Simulation Chapter 13 A Six Degree of Freedom Machining Bed: Kinematic Model Development, Verification, and Validation Muhammad Faizan Shah, Kamran Nazeer, Zareena Kausar, Muhammad Umer Farooq, Syed Saad Farooq, and Ghias Mahmood Khan Chapter 14 Learning Fault-Tolerant Control Using a Table Sat Platform 261 Ali Nasir and Ella M. Atkins Index Index Note: Bold page numbers refer to tables and italic page numbers refer to figures. actuators 59, 60 devices selection 66–8 shortlisting 63–4 signal conditioning and interfacing 72–5 thermal 64 algebraic Riccati equation (ARE) 120 AlN-based PEEH 106 ambient energy, kinetic 98 ambient mechanical vibration energy 98 ambient resources, characteristics of 100 ANSYS 52 ARE see algebraic Riccati equation (ARE) Astrom–Hagglund method 207 Autodesk Inventor ECO Material Adviser analysis 164 Autodesk INVENTOR environment 161 Autodesk Inventor Professional 2018 144, 147, 151 ECO material advisor feature of 155–6 Autodesk Nastran In-CAD 2018 151 axes CNC milling machine 41–2 analysis 52–3, 52–3 linear guides 53 concepts 43 design methodology electronics and software 45–6, 45–6 mechanical 44–5 development process of 53–4 equations and mathematical modelling load calculations 47–8, 48 torque calculation 48–51, 49, 50 geometric modeling and design 51 final design 51, 51 integration and instrumentation 54, 55 integration of 42 microprocessor in 43 physical model development and testing 53–4 prototype of 54–6 tools 42 design consideration 43–4, 44 band saw mechanism analysis 161–4, 163, 164 finite element analyses of 165, 165–6 bench-type drilling machine, improvement of 144–5, 145 biosensors, implantable 106 BoardMaster software 91, 93 bode plot 116 CAD see computer-aided design (CAD) cantilever-based PEEH 108 cantilever-type nonlinear PEEH 106 charge compress ion ignition (CCI ) engine, modelling for control 200 Choi, W.J. 105 CI engine see compression ignition (CI) engine CircuitCAM 91 classical control theory 116 CNN see convolutional neural network (CNN) coarse-to-fine classification method 177 coarse-grained classification 178–80 algorithm 182 fine-grained classification 181–2 algorithm 182–7 image acquisition and preprocessing 177–8 results 182–7 visual-guided part relocation 180–1 Cohen-Coon parameters technique 207 colorimetric transducer 60 combustion control by exhaust gas recirculation 201–2 homogenous charge ignition compression engine 196–7 by NVO 202–3 by variable compression ratio 200–1 by variable valve timing 202 compression engine, homogenous charge ignition 194–5 compression ignition (CI) engine 195 compression stroke engine 194 computed numerically controlled (CNC) machine, axes analysis 52–3, 52–3 linear guides 53 concepts 43 design methodology electronics and software 45–6, 45–6 mechanical 44–5 equations and mathematical modelling load calculations 47–8, 48 torque calculation 48–51, 49, 50 geometric modeling and design 51278 Index computed numerically controlled (CNC) machine, axes (cont.) final design 51, 51 integration and instrumentation 54, 55 microprocessor in 43 physical model development and testing 53–4 prototype of 54–6 tools 42 design consideration 43–4, 44 computer-aided design (CAD) model 8, 13, 30, 30, 141, 143, 147–8, 147–9 3D 144 solid model 140 computer aided design computer aided manufacturing (CAD-CAM) systems 42 computer aided engineering (CAE) tool 85 computer aided manufacturing (CAM) tool 85 conoscopic holography 5 contact scanners 143 conventional machining 41 convolutional neural network (CNN) 173, 175–6 creepage 89 Cuppin 230 Dahmus, J.B. 230 deep reactive ion etching (DRIE) 104 direct fuel injection 202 double-sided printed circuit board (PCB) 81 DRIE see deep reactive ion etching (DRIE) drilling machine bench-type, improvement of 144–5, 145 CAD modeling 147–8, 147–9 disassembly of 145, 146 dynamic analysis of the selected component of 149, 149–50 evaluation matrix approach for selecting the most feasible spindle model 157 FEA of spindle 151–4, 152–4 measurement techniques 146, 147 strength analysis of the spindle models 154–5, 156 strength of the spindle 154 sustainability and cost analyses of spindle models 155–6, 157 Ducas, C. 80 Eagle printed circuit board 83–5 electromagnetic energy harvesters (EMEHs) 99 electronics and software design 45–6, 45–6 electrostatic energy harvesters (ESEHs) 98–100 emissions, toxic 192 energy consumption of machine tool 229 model 230 monitoring system design 231 energy harvesters, vibration-based 100 energy harvesting devices 97 opportunities from different environmental sources 98 vibration-based 98 environmental impact, universal testing machine 24–6 environmental vibrations 103 Ertunc, H. M. 230 ESEHs see electrostatic energy harvesters (ESEHs) etching techniques, printed circuit board 89 dry etching 89–92 surface mount technology 92 wet etching 89, 90 ethanol 200 Euler’s method 265 exhaust gas recirculation (EGR) 198 combustion control by 201–2 exhaust stroke engine 194 experimental verification 257–8 fabrication 105 Fantoni, G.U. 142 fault detection 274–5, 275 FEA see finite element analyses (FEA) feedback sensors 267 fiberglass–epoxy laminate 87 finite element analyses (FEA) 141, 144 of band saw 165, 165–6 of flywheel 164, 164–5, 165 of flywheel pin 166 of spindle 151–4, 152–4 first-order systems, equivalence between LQR and PID 120 with PI control 122–6 with proportional control 120–2 flexible printed circuit board 81 flexural rigidity 34 flywheel, finite element analyses of 164, 164–5, 165 flywheel pin, finite element analyses of 166 four-stroke engine 194 compression stroke 194 exhaust stroke 194 intake stroke 194 power stroke 194 FR4 (fire retardant) 87 Francesco 105 “Free LSS” software 10 friction 29, 30, 34, 36, 37, 38, 163 fuel, compression of 195 functional reverse engineering 140, 142–3 Gammaitoni, L. 105 Garsthagen, R. 5 Gaussian smooth 178Index 279 general public license (GPL) 7 general purpose input/output (GPIO) pins 11 genetic algorithm (GA) 205 application of 209, 214 limitations 209 parameters settings 214 PID controller tuned with 213–18 PID tuning 207–8 geometric moment invariants 178 geometric reverse engineering 141–2 GPL see general public license (GPL) greenhouse gases 228 harvester, vibration energy 98 harvesting energy, from mechanical vibrations 98 HCCI engine see homogenous charge ignition compression (HCCI) engine heading control 265, 265–70 histogram of oriented gradient (HOG) 173, 175 holography, conoscopic 5 homogenous charge ignition compression (HCCI) engine 193–6, 202, 203 challenges 196 combustion control 196–7 control of 198 model 197–9, 203–5, 204, 205 open-loop response 211 proposed controller 205–7 recompression 205 states of the model 205 physics-based model of 198 Hook’s law 35 human motion-induced vibrations 103 humidity sensors 60, 62 Hu moments 178 ICs see integrated circuits (ICs) implantable biosensors 106 indicated mean effective pressure (IMEP) 199 intake stroke engine 194 integrated circuits (ICs) 82 internal combustion engines four-stroke engine 194 compression stroke 194 exhaust stroke 194 intake stroke 194 power stroke 194 Otto cycle 193 two-stroke engine 193 Internet of Things (IoT) 97, 231 water monitoring system 92 ion current sensing 202 isentropic process 193 ISI P20 tool 230 iterative closest point (ICP) algorithm 181 Kalman filter estimation 270–3, 272, 273 kinematic model 252–6, 253 verification of 256–7, 258 kinetic ambient energy 98 Laplace transform 115 laser filtering method 5 laser rangefinder 5–6 laser-type scanners 144 lead zirconate titanate (PZT) 101, 105 Li, N. 172 Li Congbo 230 linear quadratic (LQ) optimal system 116 linear quadratic regulator (LQR) 116, 119 equivalence between PID and 120–34 first-order systems 120–6 second-order systems 127–34 linear time-invariant (LTI) system 116 load calculations 47–8, 48 Load Controls Power Meter model (PPC-3) 243 low-amplitude bridge energy harvester 107 LPKF ProtoMat S series machine 89, 90, 93 LQR see linear quadratic regulator (LQR) machine control unit (MCU) 42–3 machine tool (MT) energy consumption of 229, 231 model 230 industrial application of 233 monitoring system design 231 advancement 233 functional structure 234, 234–5 objectives and requirements 232–3 practicality 233–4 scalability 233 working principle 232 software of the monitoring system 241, 242 system hardware 235 Raspberry Pi selection 237 sensor selection 236 Smart Pi expansion module 237–8, 238 system hardware circuit design 238–41 crystal oscillator circuit design 239 inter-board connection circuit 239–41, 240, 241 validation of measured results 241–5, 243–5 machining 251–2 magnetometer noise 268 Marzencki, M. 107 MathWorks proprietary algorithm vs. proposed controller 218–19 MATLAB 210, 218, 256, 259 proprietary algorithm 212 MCU see machine control unit (MCU) mechanical design 44–5 mechanical vibration energy 99 ambient 98 mechanical vibrations, harvesting energy from 98280 Index mechatronic system 59, 59 metal 88 metal pads 106 metal/wood cutting band saw band saw mechanism analysis 161–4, 163, 164 CAD solid modelling 160–1 FEA of band saw 165, 165–6 of flywheel 164, 164–5, 165 of flywheel pin 166 improvement of 159, 159–60, 160 results 166–8, 167, 168 METU NCC 144, 145, 159 microprocessor, in CNC machine 43 misfiring 198 model predictive control (MPC) 198 modern control theory 116 monitoring system design machine tool 231 advancement 233 functional structure 234, 234–5 objectives and requirements 232–3 practicality 233–4 scalability 233 working principle 232 MPC see model predictive control (MPC) MT see machine tool (MT) multilayer printed circuit board (PCB) 81 multiple input multiple outputs (MIMO) systems 197, 198 Multisim 83 NC see numerical control (NC) negative valve overlap (NVO) 196–7 combustion control by 202–3 90° miter gear system 31 node-RED 231, 241, 242 noncontact active 3D scanning 5 approaches to 5–7 phase shift 6 time-of-flight 5–6 triangulation 6, 6–7 noncontact scanners 143, 144 nonlinear cantilever type piezoceramic 105 nonlinear PEEH, cantilever-type 106 numerical control (NC) components 42 concept 41 milling machine 42 NVO see negative valve overlap (NVO) Nyquist plot 116 Olsen, T. 18 optimal system, linear quadratic 116 ORCAD PCB design software 82, 85–6 design features 85–6 design flow 86 Ottman, G.K. 107 Otto cycle 193 ozone 199 formation 192 parallel manipulators 252 PCB see printed circuit board (PCB) PEEHs see piezoelectric energy harvesters (PEEHs) phase shift 6 piezo-ceramic efficiency 107 piezoelectric energy harvesters (PEEHs) 98–108, 103, 109 AlN-based 106 cantilever-based 108 cantilever-type nonlinear 106 vibration-based unimorph-type 107 piezoelectric materials 101 classification 102 pin-on-disc tribometer 30, 30, 31 analysis 32, 33–4, 34, 37 design and configuration 30–3, 31 governing equations and mathematical modeling 34–5 physical model development and testing 35–6, 36 purpose of 36–8 Pin-on-Disk wear test 31 polytetrafluoroethylene (PTFE) 87 polyvinyl alcohol 60 power meters 233 power stroke engine 194 precision router 45 printed circuit board (PCB) case study 92 internet of things-based water monitoring system 92 ultrawideband vivaldi antenna 92–3 defined 80 double-sided 81 etching techniques 89 dry etching 89–92 surface mount technology 92 wet etching 89, 90 fabrication process 87–9 flexible 81 high-frequency 82 layer stack-up 88 multilayer 81 multilayer PCB fabrication advantages 88 popular software, features 84 rigid 81 rigid-flex 82 single-sided 81 software for PCB layouts 82 Eagle PCB 83–5Index 281 Multisim 83 ORCAD 82, 85–6 Proteus 82–3, 86–7 substrate/material 87–8 track distance 88–9 proportional-integral (PI) controller 120 proportional-integral-derivative (PID) equivalence between LQR and 120–34 first-order systems 120–6 second-order systems 127–34 parameters 214, 215 tuning 213 tuning 207–9 proportional-integral-derivative (PID) controller 205–6, 210 function of 197 mathematical preliminaries 117 classical control 117–18, 120 modern control 118–20 tuned with GA 213–18 proposed controller vs. MathWorks proprietary algorithm 218–19 Proteus PCB design software 82–3, 86–7 PTFE see polytetrafluoroethylene (PTFE) pulley and belt mechanism, motor connected to 150, 150 PZT see lead zirconate titanate (PZT) random access memory (RAM) 43 Raspberry Pi 7, 232, 233, 237 camera module 10 interaction unit 234–5 selection 237 read only memory (ROM) 43 Red Laser Diode 5V 10 Relay method 207 reverse engineering 140 functional 142–3 geometric 141–2 stages of 143–4 rigid-flex printed circuit board 82 rigid printed circuit board 81 ROM see read only memory (ROM) Routh Hurwitz stability criteria 116 SCADA system 92 scale-invariant feature transform (SIFT) 172, 173, 175 scanners contact 143 laser-type 144 noncontact 144 second-order systems, equivalence between LQR and PID 127 with proportional control 127–9 with PID control 132–4 with proportional-derivative control 129–32 sensing, ion current 202 sensors 59, 60 humidity 60, 62 selection of devices 64–6 shortlisting of devices 61–2 signal conditioning and interfacing 68–72 temperature 61–2 shape descriptors 178 shape invariants 178 sheet metal parts (SMP) 171–3, 172, 176, 179, 183, 184, 185 Shimomura, Y. 142 SI engine see spark ignition (SI) engine SIFT see scale-invariant feature transform (SIFT) single-input-single-output (SISO) models 197 system 119 single-sided printed circuit board 81 smart meter 230–1, 232 Smart Pi expansion-module (SPEM) 231–3 acquisition unit 235 SMP see sheet metal parts (SMP) SMT see surface mount technology (SMT) software, for PCB layouts 82 Eagle PCB 83–5 Multisim 83 ORCAD 82 Proteus 82–3 spark ignition (SI) engine 194, 195 SPEM see Smart Pi expansion-module (SPEM) spindle technology 252 state-space model 116 support vector machine (SVM) 173, 175 surface mount technology (SMT) 88 system hardware machine tool 235 Raspberry Pi selection 237 sensor selection 236 Smart Pi expansion module 237–8, 238 system hardware circuit design machine tool 228–41 crystal oscillator circuit design 239 inter-board connection circuit 239–41, 240, 241 Table Sat 261–3, 262 TEEHs see triboelectric energy harvesters (TEEHs) Teflon 87 temperature sensor 61–2 thermal actuator 64 thermodynamic energy model 230 3D CAD models 144 3D geometric model 143 3D scanners 4 analysis 11, 12 environmental impact 13–14282 Index 3D scanners (cont.) equations and mathematical modeling 8–11 camera 10 laser 10 motor 8–9, 9 power supply 10–11 geometric modelling and design 11, 11 hazard identification and safety measures 14 laser scanner, time-of-flight 5–6 limitations 14–15 social impact 13 sustainability analysis 13, 14 3D laser scanning 5 design methodology 7 3D scanning acquiring data 7 applications for 5 CAD Model 8 form of the data 7 noncontact active 5 processing of data 8 software 7 3D spindle solid models 154–5, 155 time-of-flight 3D laser scanner 5–6 torque calculation 48–51, 49, 50 toxic emissions 192 traffic-induced low-frequency 107 transducers 60 triboelectric energy harvesters (TEEHs) 99 tribology 29 tribometer 30, 30; see also pin-on-disc tribometer UI see user interface (UI) ultimate tensile strength (UTS) 162 ultrawideband vivaldi antenna 92–3 universal testing machine (UTM) 17–19 components of 19 electronic circuitry 20–1, 21 environmental impact 24–6, 25, 26 mechanical design and analysis 21–3, 22, 23 methodology 19–20, 20 testing 23–4, 24, 23–5 user interface (UI) 231 variable compression ratio, combustion control by 200–1 variable valve actuation 198 variable valve timing (VVT) 196 combustion control by 202 velocity control 263–5, 264 verification experimental 257–8 of kinematic model 256–7, 258 VGG-16 176 vibration-based unimorph-type PEEH 107 vibration energy harvester 98, 100 harvesting 98 mechanical 99 ambient 98 von Mises stress 153, 153, 164 distribution 150, 154 values 151 VVT see variable valve timing (VVT) wireless sensor network (WSNW) 109 wireless sensor nodes (WSNs) 97–8, 100, 109 Yau, H.T. 141 Zernike moments 178–9 Ziegler-Nichols method 207
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