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 |  موضوع: كتاب Functional Reverse Engineering of Strategic and Non-Strategic Machine Tools السبت 14 يناير 2023, 9:25 pm | |
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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
و المحتوى كما يلي :
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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