Cad, 3d modeling, engineering analysis, and prototype experimentation  industrial and research applications

Solar Energy System for Water Distillation

Access to clean drinking water is a challenge in many underdeveloped countries and disaster-stricken areas, where approximately 1.1 billion people lack safe drinking water, leading to 2.1 million deaths annually from contaminated sources (Anjaneyulu et al 2012; Badran et al 2005) The solar distillation process offers a sustainable solution by using sunlight to evaporate moisture and produce purified water, making it a viable method for water purification (Jabbar et al 2009) While the initial cost of solar distilling equipment can be high, the process itself incurs no fuel costs and remains more affordable than bottled water (Manikandan et al 2013; Lattemann and Höpner 2008) For those concerned about the quality of municipal water, solar distillation serves as a safe and energy-efficient alternative (Chakraborty et al 2004) As energy costs rise and freshwater resources become increasingly strained by population growth, solar desalination of seawater presents an economically and environmentally advantageous option (Jabbar et al 2009; Li 2011c).

The solar energy system for water distillation utilizes a solar still unit where impure water is evaporated by sunlight absorbed through a clear plastic panel The process involves pure water vapor passing through a condenser, cooling, and condensing into droplets that collect in a lower chamber, effectively removing impurities such as heavy metals and microorganisms (Tiwari and Tiwari 2007) This system is particularly beneficial in areas lacking access to rainwater, well water, or city water, and serves as an alternative clean water source during power outages caused by severe weather conditions A basic basin-type solar still consists of stones, a transparent panel, a condenser, and a collector for the condensed water (Yang et al 2011) Additionally, wick solar stills can distill salt water by allowing sunlight to heat salted water, causing evaporation and subsequent condensation on the underside of a transparent panel, with the purity of the distilled water depending on the efficiency of salt separation Enhancements such as more wicks and a fine grid can improve heat transmission and brine capture, while good sealing and darkened wicks can boost productivity (Jabbar et al 2009) Various solar still designs, including single-basin units with tilted glass or plastic plates, optimize sunlight capture, with glass models offering durability and plastic models providing cost-effective, easy installation (Anjaneyulu et al 2012).

Wind Power Turbine System

Wind power harnesses wind energy through turbines that convert it into mechanical energy This mechanical energy can then be utilized to generate electricity in wind power plants or to operate machinery and pump water in windmill or wind pump systems.

Wind power density, influenced by wind velocity and air density, is crucial for calculating the average annual energy produced per square meter of turbine area, with variations occurring at different heights In practical wind turbines, not all wind power can be harnessed due to some air escaping the system, necessitating consideration of the inlet and outlet wind velocity ratios in design The maximum efficiency of current turbines is approximately 60%, but power output is further diminished by losses in components such as the gear train, converter, rotor blades, and generator Turbines are typically positioned upwind of the structural tower, and rotor blades are engineered for high stiffness to prevent bending from strong winds Additionally, wind turbine systems are tailored to capture energy effectively at specific locations, with aerodynamic analysis employed to optimize tower height, control systems, and rotor blade design.

Solar Panel Tracking System

Global warming necessitates the exploration of alternative energy sources, particularly from green and renewable options like solar power Solar panel tracking systems are designed to follow the sun's movement, optimizing energy absorption These systems can involve photovoltaic or reflective panels, with tracking mechanisms reducing the angle between incoming sunlight and the panels to enhance energy capture In concentrated solar photovoltaic systems, tracking is critical for maximizing direct sunlight exposure The efficiency of solar panels is influenced by the angle of sunlight, as approximately 90% of solar energy comes from direct sunlight To maximize energy collection, it's essential for solar panels to maintain visibility of the sun, especially in cloudy conditions Advanced tracking systems can capture over 98.8% of direct sunlight and all diffusive sunlight Despite the sun's daily 360-degree movement, a stationary solar panel can only harness a limited portion of sunlight, underscoring the importance of tracking technology in solar energy systems.

A solar panel tracking system significantly enhances energy capture by optimizing the orientation of panels throughout the day The single-axial tracking system, which rotates around one axis, can be categorized into horizontal, vertical, inclined, and polar aimed systems Horizontal systems facilitate easy setup by maintaining parallel axes, while vertical systems offer improved efficiency at higher elevations by rotating panels from east to west Tilted single-axial systems feature two rotating axes to adjust for wind load, though care must be taken to minimize shading The polar aimed system aligns with the Earth's rotation, enhancing sunlight capture throughout the year For greater efficiency, a double-axial tracking system, which rotates around two perpendicular axes, allows for optimal solar energy reception by tracking the sun's movement in both vertical and horizontal planes When selecting a tracking system, factors such as environmental conditions, local latitude, weather patterns, electricity costs, and installation dimensions must be considered These systems utilize motor drivers and gearing units, controlled to follow the sun’s trajectory effectively.

Energy-Saving Cooling System

The cooling process involves transferring heat from one location to another, utilizing various energy sources such as mechanical, electrical, thermal, and magnetic energies Cooling systems are essential in diverse applications, including cryogenics, commercial freezers, residential refrigerators, and air conditioning units Currently, these systems are predominantly used in industrial cooling processes, air conditioning for residential and commercial spaces, medical treatments, surgical operations, and climate-controlled food preservation In industrial settings, cooling systems play a crucial role in gas liquefaction, air purification, oil refining, and metal tempering Various cooling methods exist, including cyclic cooling (vapor and gas cycles), magnetic cooling, and thermoelectric cooling.

The cyclic cooling process involves transferring heat from a lower temperature source to a higher temperature source using external energy In this system, the refrigerant circulates, absorbing and releasing heat There are two main types of cyclic cooling processes: the vapor cooling cycle and the gas cooling cycle The vapor cooling cycle compresses vapor without changing its entropy, resulting in a higher temperature and lower pressure as it exits the compressor The vapor condenses into liquid after passing through the condenser, and the liquid refrigerant absorbs heat through the evaporator, cooling the external environment In contrast, the gas cooling cycle maintains the gas phase during compression and expansion, with cooling capacity determined by the specific heat of the gas and the temperature rise at the lower temperature source This cycle is commonly used in gas turbine-driven aircraft Additionally, thermoelectric cooling systems utilize the Peltier effect to control temperatures in mobile cooling units for instruments and electronics Magnetic cooling systems employ paramagnetic salts, where multiple magnetic dipoles align under a magnetic field, lowering the entropy of the cooling media This process allows heat to be transferred to a thermal sink, and when the magnetic field is switched off, the system is insulated, completing the cooling cycle.

1.4 Energy-Saving Cooling System 7 raises thermal capacity of cooling media and reducing its temperature below thermal sink temperature (Gheisari et al 2012; Kagawa et al 2013).

The coefficient of performance (COP) is a vital metric for assessing the efficiency of cooling systems, defined as the ratio of cooling capacity to external energy input Additionally, the performance factor (PF), which measures the ratio of energy input to cooling capacity, plays a crucial role in evaluating system efficiency This book presents a newly developed cooling system aimed at enhancing energy savings and reducing manufacturing costs through its simplified design.

Automated and High-Speed Manufacturing Systems

Automated machinery systems utilize various control mechanisms to operate machinery with minimal human intervention, offering significant advantages such as reduced labor costs, energy savings, optimized material usage, improved quality, and enhanced accuracy and precision These systems are supported by technologies including computers, pneumatics, hydraulics, mechanics, and electronics Two primary control methods used are feedback control and sequential control Feedback control relies on continuous measurements from sensors to adjust operations, as seen in air-heating systems where temperature data is constantly relayed to maintain desired settings In contrast, sequential control executes a programmed sequence of operations, exemplified by relay logic in elevators, which controls the electric motor's operation Additionally, numerical control (NC) allows for the automated operation of machine tools, making automated machinery systems essential in various manufacturing and assembly processes, including petroleum refining, power generation, chemical production, plastic molding, steel making, and automobile manufacturing.

Automated machinery systems play a crucial role in various industrial applications, such as assembly, food processing, and welding, offering significant benefits including enhanced productivity, improved quality, and reduced labor costs These systems are particularly advantageous in environments requiring high accuracy, reduced cycle times, and safety for human workers The demand for flexibility in manufacturing has led to the adoption of numerical control (NC) technologies, allowing for seamless transitions between different product lines without extensive reconfiguration Additionally, computer-aided technologies like CAD, CAE, and CAM facilitate the development of complex industrial systems, while the integration of information technology with manufacturing processes enhances control system design through programmable logic controllers (PLC) Automated control systems are applicable across various sectors, including aerospace, food, automotive, and pharmaceuticals, emphasizing the need for integrating automated software with machinery to boost competitiveness in the market.

Robotic System for Industrial Applications

Robotic technology encompasses engineering design, manufacturing operations, automation, computational control, sensing feedback, and data processing It integrates computer science, mechanical engineering, electronic engineering, and manufacturing engineering to create effective robotic systems Mathematical expressions play a crucial role in controlling algorithms, allowing for the observation and management of various functioning processes.

1.6 Robotic System for Industrial Applications 9

Robotic systems have evolved from simulating human behavior to performing specialized tasks with advancements in automation technology and engineering design These systems excel in heavy-duty, hazardous, and monotonous jobs, demonstrating greater accuracy and reliability than humans Their applications span various industries, including manufacturing, space exploration, and surgery Actuators in robots convert stored energy into linear and angular movements, while sensors gather data about external conditions and the robot's status, facilitating informed decision-making Robotic arms, equipped with grippers, utilize advanced algorithms for 3D motion, focusing on kinematic and dynamic studies to optimize performance Kinematic analysis aids in calculating gripper positions and speeds, while dynamic studies assess the forces affecting motion This comprehensive understanding of robotic motion allows for enhanced control and adjustment of robotic algorithms, ensuring efficient operation across diverse applications.

Magnetic Sealing System

Magnetic sealing systems come in various types, with magnetic liquid seals being particularly effective for rotating machinery These seals utilize ferrofluid, which is held in place by a permanent magnet, enabling smooth rotation while maintaining a tight seal.

Magnetic liquid rotating seals serve as effective physical barriers to prevent leakage in various applications, requiring minimal maintenance and exhibiting low leakage rates (Gonza´lez-Jorge et al 2005; Mitamura et al 2008) These seals are typically integrated into mechanical assemblies featuring a centralized shaft, support bearings, and external housing The support bearings play a crucial role in maintaining the shaft's position and bearing external loads By utilizing an oil-distributive fluid magnetically contained between the rotary shaft and stationary wall, these seals enhance lifespan and reduce frictional torque (Cong et al 2005; Gonza´lez-Jorge et al 2007) Notably, they operate without electrical power due to the permanent magnet charge While magnetic rotary liquid seals are suitable for gaseous and vapor sealing, they are not designed for high-pressure fluid sealing due to vulnerabilities to temperature fluctuations, pressure variations, high speeds, and environmental changes (Hirsch 2003; Li 2010) Additionally, magnetic vacuum seals employ electromagnetic fields to secure metal components, effectively preventing hazardous material leakage and blocking impurities from compromising the seal mechanism (Topal et al 2003; Zydlo et al 2005; Ochonski 2005; Tusˇek et al 2011).

This article introduces an innovative magnetic sealing system designed for enhanced reliability, reduced manufacturing costs, and extended life cycles Traditional rotary machinery commonly employs conventional lip or labyrinth seals, which have been shown to experience significant wear and leakage of gases and liquids In contrast, magnetic seals offer a much longer life cycle, making them a superior choice for various engineering applications.

Automated and High-Speed Packaging

Packaging engineering and technology encompass the design of packing systems and the final placement of products, necessitating careful consideration of production line layouts (Fuge et al 2012; Han and Lee 2013; Jeon et al 2013) These systems are essential for ensuring reliable packaging that protects products from damage during storage and delivery (Cho et al 2013; Fusco and Russo 2013) Many advancements in packaging systems originated from military applications, where products must endure severe environments and challenging conditions (Chu and Chang 2005; Jeong et al 2013).

When designing packaging engineering systems, it is essential to focus on industrial and technical aspects such as production, marketing, logistics, and materials handling Effective packaging must prevent product damage while maintaining cost-efficiency and operational effectiveness Packaging techniques aim to protect products from external forces like compression, shock, temperature variations, and electrostatic discharge Transport packaging should adhere to standard logistics requirements to ensure protective strength and stability The design and testing of packaging can be conducted in-house or through external engineering firms Selecting appropriate packaging machinery involves considering capabilities, technical requirements, maintainability, reliability, safety, integration flexibility, layout, costs, energy efficiency, and ergonomic design Automated systems enhance packing quality and productivity, with various machinery available for processes like bottling and sealing Packaging materials can be hard or flexible and are designed to allow folding into specific shapes, using processes such as extrusion and thermoforming High-speed production processes for filling, packing, and shipping are increasingly common Additionally, structural and thermal analyses of packaging materials are crucial for quality evaluation and improvement A well-designed packaging system enhances product visibility, strengthens customer connections, and influences marketing strategies Understanding global marketing dynamics, customer needs, and cultural preferences is vital for effective engagement in a competitive landscape.

Biomedical and Surgical Systems

Newly developed biomedical and surgical instruments enhance complex surgeries and treatments through minimally invasive techniques and reliable functionality These instruments facilitate a wide range of medical procedures across various specialties, including gynecology, urology, cardiac surgery, and orthopedics It is essential for healthcare professionals to possess the necessary skills and knowledge to utilize these tools effectively in sterile environments The primary objective of these advancements is to enable smoother, safer, and more efficient medical operations, minimizing human error through precise control and manipulation Additionally, these innovative instruments improve upon traditional methods by offering better visualization, ergonomic design, and consistent performance, while addressing issues such as instrument drop-off and operational stability during procedures.

Energy Systems

Design of Solar Energy System for Water Distillation

Solar water distillation systems harness solar energy to produce clean water for drinking, cooking, and various commercial uses By utilizing solar stills, these systems evaporate water and capture the vapor through condensation on a cool surface The evaporation rate can be optimized by increasing water temperature and enhancing the contact area between water and air Individual solar distillation devices cater to residential needs, while larger systems serve industrial applications In regions lacking adequate water purification methods, concerns about environmental pollutants in the water supply arise Solar water distillation offers a viable solution, as it effectively eliminates potential threats associated with traditional filtration systems, which may struggle to remove certain inorganic materials During the distillation process, water is heated into steam, which is then cooled and condensed back into liquid form, leaving impurities behind.

J Zheng Li, CAD, 3D Modeling, Engineering Analysis, and Prototype

The innovative solar distillation process effectively separates dissolved salts from seawater, producing fresh drinking water while preserving beneficial organic minerals This cost-effective and user-friendly solar system is easy to install and requires minimal maintenance It optimizes water temperature at the unit entrance, ensures an adequate temperature difference between the input water and condensing surface, and reduces vapor leakage The systematic design maximizes radiation absorption and minimizes heat loss from the unit's floor and walls.

The innovative solar energy distillation system, illustrated in Fig 2.1, operates by allowing water to flow through an inlet tube, which lifts a small ball to open an internal channel for water collection in a basin Once the desired water level is reached, a larger ball rises, causing the small ball to descend and block the inlet, preventing additional water from entering The system utilizes sunlight, reflected onto an absorber, to heat the impure water, initiating evaporation As vapor ascends to the upper chamber, it condenses on the cooler internal walls, forming droplets that travel through a U-type channel, effectively transforming various types of impure water, including seawater, into purified water, which is then collected in an output container.

Fig 2.1 Newly developed green (solar) energy distillation system

18 2 Solar Energy System for Water Distillation

Computer-Aided Simulation of Solar Energy System

The sun's distance from the Earth allows its light to be nearly parallel to the Earth's surface, with solar energy measured at approximately 1,368 W/m² (Alloway 2000) As the Earth rotates and orbits the sun in an elliptical path, the distance between them fluctuates The solar energy captured by a solar distillation panel can be calculated using the equation Ncos(ψ), where ψ represents the angle between the perpendicular direction to the Earth's surface and the solar flux This angle ψ varies with latitude (ζ), declination (λ), hour angle, and zenith angle (Alloway 2000), with declination defined by the equation λ = 23.5sin(360).

In diffusion radiation, the tilt factor, denoted as ωF, quantifies the ratio of radiated diffusion flux arriving at a tilted surface compared to that on a horizontal surface, as described by Gevorkian (2007) using the formula ωF = 1 + cos(θ).

The computer-aided modeling and numerical simulation are applied to design and develop this new solar distillation system.

Figure 2.2shows the computer-aided FEA meshing in this new solar energy distillation system.

Figures 2.3 and 2.4 illustrate a computer-aided simulation of solar radiation intensity in an innovative solar energy distillation system, with the simulation revealing a peak solar radiation intensity of 2,388.50 W/m².

Figure2.4exhibits the distilled water output vs duration time in this new solar distillation system.

Figure 2.4 illustrates the relationship between distilled water output and basin temperature in a solar energy distillation system Increasing the solar basin temperature enhances water evaporation, resulting in a higher production of pure water from the system.

To ensure the structural integrity of a solar distillation system, it is crucial to assess its design against wind and snow loads, as detailed in the mathematical equations (2.3) and (2.4).

Velocity pressure (qz) in a solar distillation system can be determined using the equation from ASCE 7-05 (2005), expressed as qz = 0.00256KZKZTKDV²I In this formula, qz represents the effective velocity pressure, KD is the wind directionality factor, KZ is the exposure velocity pressure coefficient, KZT is the topographic factor, V denotes wind velocity, and I is the importance factor.

Snow load (PF) on solar distillation can be determined by the equation (ASCE 7-05 2005)

Fig 2.2 Computer-aided FEA meshing in new solar distillation system

Fig 2.3 Solar radiation intensity in this solar distillation system vs duration time

PFẳ0:7CECTISPSCS ð2:4ị wherePF—snow load,CE—exposure factor,CT—thermal factor,IS—importance factor,PS—50-year ground snow load, andCS—slope factor.

The wind and snow loads, derived from established mathematical models, are utilized in computer-aided modeling and numerical simulations to evaluate the performance of the new solar distillation system under extreme weather conditions The finite element analysis (FEA) simulation and structural assessment are illustrated in Figures 2.5 and 2.6.

The computer-aided simulation results demonstrate that the newly designed solar distillation system maintains structural integrity under various severe weather conditions With a maximum stress of 13,358.53 psi, which is significantly below the material yield strength of 36,300 psi, and a maximum deflection of 0.0106 inches, the system operates well within the allowable deformation limits This ensures that the solar distillation system can function effectively even in challenging environments, such as strong winds and heavy snowfall.

Experiment on Solar Energy System

The prototype of this new solar energy distillation system has been built and experiments have been conducted with all tested results being demonstrated as follows.

Table 2.1 displays the prototype testing result of solar radiation intensity vs experimental duration time.

Fig 2.4 Distilled water output vs duration time in new solar distillation system

2.3 Experiment on Solar Energy System for Water Distillation 21

Table 2.2 presents the prototype testing result of solar distilled water output vs experimental duration time.

The prototype testing confirms the system's functionality, as the experimental results for solar radiation intensity and solar distilled water output closely align with the findings from computer-aided modeling and numerical simulation.

Table 2.3 shows the experiment results of maximum stress and maximum deflection in this new solar distillation energy system.

The prototype experimental results presented in Table 2.3 validate the system's functionality, showing an average maximum stress of 13,358.51 psi and an average maximum deflection of 0.0111 in These findings closely align with the computer-aided modeling and simulation results, which indicate a maximum stress of 13,358.53 psi and a maximum deflection of 0.0106 in, as illustrated in Figs 2.5 and 2.6.

Fig 2.5 Computer-aided simulation of stress profile in new solar distillation system

Table 2.1 Prototype testing of solar radiation intensity vs experimental duration time

Fig 2.6 Computer-aided simulation of deflection profile in new solar distillation system2.3 Experiment on Solar Energy System for Water Distillation 23

Table 2.2 Prototype testing of solar distilled water output vs experimental duration time

Time (h) Distilled water output (ml)

Table 2.3 Prototype testing of maximum stress and maximum deflection in this new solar distillation energy system

Discussion and Future Improvement of Solar Energy

Energy System for Water Distillation

The filtration process effectively removes environmental pollutants from drinking water, particularly those resulting from industrial manufacturing and waste disposal Solar water distillation stands out as a leading technology for eliminating these contaminants However, the initial capital investment for solar distillation units can be a drawback To address this, planned modifications aim to reduce costs by simplifying the design, enhancing the heat exchanger's thermal efficiency, and selecting suitable materials, ultimately improving the affordability and effectiveness of solar water distillation systems.

2.4 Discussion and Future Improvement of Solar Energy System for Water Distillation 25

Design of New Wind Power Turbine System

Wind power turbines, available in horizontal and vertical axis designs, efficiently convert wind kinetic energy into mechanical energy for electricity generation Their applications range from small turbines for residential battery charging to large systems for commercial electricity production These turbines not only harness renewable wind energy but also contribute to environmental protection by reducing air pollution Advanced computer-aided aerodynamic modeling helps optimize turbine height, blade geometry, control systems, and the number of blades Key components include the rotor with blades for energy conversion, an electrical generator with a gearbox and controller for electricity generation, and structural elements that support the entire turbine system.

Recent research has led to the development of two innovative wind power turbine systems, utilizing advanced computer-aided modeling, numerical simulation, and prototype testing The 3D models of these turbines, along with key components such as the driver gear and blades, are illustrated in Figures 3.1, 3.2, 3.3, and 3.4.

In the design and development of wind power turbine systems, segmental element theory is utilized in computer-aided design to analyze the 3D complex geometry of turbine components This approach enables the examination of dynamic forces on a full turbine blade by segmenting it into smaller parts, allowing for a detailed load profile assessment across different blade elements and verification of turbine performance The total load on the rotor is calculated by integrating the segmental loads from all blade elements, with the maximum lifting force occurring when the turbine blade moves against the wind direction Critical parameters in turbine performance are essential for optimizing efficiency and functionality.

Fig 3.1 Wind power turbine system (new design 1)

Fig 3.2 Wind power turbine system (new design 2)

The design and development of the 28 3 Wind Power Turbine System focus on the angle β between incoming air and blade orientation, as well as the forces acting at the quarter chord from the blade's leading edge Key factors include the pitching torque generated by dynamic air forces, the tangential force that propels the blade, and the normal force that elevates it Subsequent chapters detail the computer-aided simulations and prototype testing of these innovative wind power turbine systems.

Computer-Aided Simulation of Wind Power

Computer-aided simulation and analysis of lifting and dragging forces in wind turbine energy systems enable precise determination of output forces by examining the aerodynamic performance around turbine blades The analytical results serve as a foundation for guiding wind turbine design, enhancing functionality, and optimizing system performance Specifically, Equation (3.1) can be utilized to calculate the lifting force acting on each turbine blade (Kundu and Cohen 2008).

Here,ρAIR—density of incoming air,ANET—net surface area of turbine blade,

DLIFT—lifting coefficient, andSRESULTANT—resultant speed.

Fig 3.3 Driver gear design in new wind power turbine system

Fig 3.4 Turbine blade design in new wind turbine system

3.2 Computer-Aided Simulation of Wind Power Turbine System 29

The full wind power can be determined by the following equation (Kundu and Cohen 2008):

Here,DPOWER—power coefficient,ASWEPT—swept area in wind power turbine, andSWIND—wind speed.

The turbine blade is constructed from a high-strength, low-density fiberglass composite Advanced computer-aided 3D modeling and aerodynamic analysis play a crucial role in designing the complex geometrical contours of wind power systems, helping to determine the turbine's lifting force Additionally, computational simulations and finite element analysis have been utilized to assess the turbine's full power capabilities An illustration of the computer-aided simulation of airflow over the wind turbine blade is shown in Figure 3.5.

Computer-aided design and analysis is a computational approach used to model system designs and simulate product functions, system structures, and stress and deflection profiles This methodology allows for the calculation of individual elements through computational simulations, ultimately leading to a comprehensive understanding of the entire system Figures 3.6 to 3.11 illustrate the stress and deflection profiles of key components in the innovative wind power turbine system, showcasing the effectiveness of computer-aided modeling and simulation.

The computer-aided simulations presented in Figures 3.6 and 3.7 illustrate the stress and deflection profiles of turbine blades in the newly designed system Additionally, Figure 3.5 showcases the airflow dynamics over the wind power turbine blade.

Fig 3.6 Computational modeling of stress profile in turbine blade

Fig 3.7 Computational modeling of deflection profile in turbine blade

3.2 Computer-Aided Simulation of Wind Power Turbine System 31

Fig 3.8 Computational modeling of stress profile in wind power turbine system 1

Fig 3.9 Computational modeling of deflection profile in wind power turbine system 1

Fig 3.10 Computational modeling of stress profile in wind power turbine system 2

Fig 3.11 Computational modeling of deflection profile in wind power turbine system 23.2 Computer-Aided Simulation of Wind Power Turbine System 33

The analysis indicates that the turbine blade experiences a maximum stress of 22,520.82 psi, which is below the material yield strength of 36,300 psi Additionally, the maximum deflection recorded is 0.01154 inches, remaining within the permissible deformation limits of the material.

The computer-aided simulation of the newly designed turbine system_1 reveals stress and deflection profiles, demonstrating that the maximum stress of 22,828.34 psi is below the material yield strength of 36,300 psi Additionally, the maximum deflection of 0.01198 inches remains within the allowable deformation limits for the material.

The computer-aided simulation results for the newly designed turbine system_2 indicate that the maximum stress of 25,005.59 psi is below the material's yield strength of 36,300 psi Additionally, the maximum deflection of 0.01243 inches remains within the allowable deformation limit for the material.

The computer-aided 3D modeling and numerical simulations indicate that the maximum stresses on critical components are below material strength limits, and all maximum deformations comply with material deflection specifications These analytical results demonstrate that the newly developed wind power energy system features an effective design, functional feasibility, and structural reliability for green and sustainable energy applications.

Experiment on Wind Power Turbine System

A new wind power energy system has been successfully prototyped and tested to validate the results of computer-aided analysis and numerical simulations The experimental results, detailed in Table 3.1, highlight the maximum stress and deflection observed on the turbine blade within this innovative wind power turbine system.

The prototype testing results for the turbine blade indicate normal functionality, with an average maximum stress of 22,520.85 psi and an average maximum deflection of 0.0112 inches These values closely align with the computer-aided modeling and numerical simulation results, which show a maximum stress of 22,520.82 psi and a maximum deflection of 0.0115 inches Additionally, Table 3.2 provides the testing results for the maximum stress and maximum deflection of Wind Power Turbine Energy System 1.

The prototype testing results for the new wind power turbine energy system 1 confirm its proper functionality, with an average maximum stress of 22,828.29 psi and an average maximum deflection of 0.0116 inches These values are closely aligned with the computer-aided modeling and numerical simulation results, which show a maximum stress of 22,828.34 psi and a maximum deflection of 0.0120 inches, as illustrated in Figs 3.8 and 3.9.

Table3.3expresses the experimental results of maximum stress and maximum deflection of wind power turbine energy system 2.

The prototype experimental results of new wind power turbine energy system

2 in Table 3.3 confirm the appropriate function of system 2 since the average

Table 3.1 Prototype experiment of maximum stress and maximum deflection on turbine blade in this new wind power energy system

Table 3.2 Prototype testing results of maximum stress and maximum deflection of wind power turbine energy system 1

3.3 Experiment on Wind Power Turbine System 35 maximum stress 25,005.62 psi and average maximum deflection 0.0128 in are almost equal to the results of maximum stress 25,005.59 psi and maximum deflection 0.0124 in that are depicted, respectively, in Figs 3.10 and 3.11 by computer-aided modeling and numerical simulation.

Discussion and Future Improvement on Wind Power

In the near future, wind energy is poised to become a leading source of cost-effective and environmentally friendly electricity This energy system utilizes turbines connected to mechanical generators to harness natural wind energy By employing piezoelectric materials shaped into various blade geometries and linked to piezoelectric actuators, electrical power can be generated from wind pressure As a passive system, wind power energy systems are less prone to breakdowns, resulting in reduced maintenance and repair costs Future improvements will focus on optimizing turbine blade structures for consistent wind flow and simplifying the overall design.

Table 3.3 Prototype testing results of maximum stress and maximum deflection of wind power turbine energy system 2

The innovative 36 3 Wind Power Turbine System is designed to minimize material usage, significantly reducing construction costs This new turbine system also aims to decrease energy consumption per unit operation, facilitating a more efficient energy production process Additionally, the design has been optimized for easier installation, streamlining the setup process Furthermore, enhancements to the airflow pathway near the turbine blades' diameter have been implemented to maintain a low-pressure region, thereby boosting wind flow and maximizing overall system efficiency.

3.4 Discussion and Future Improvement on Wind Power Turbine System 37

Design of Solar Panel Tracking System

A newly developed solar tracking system features an adjustable orientation angle that allows it to track sunlight in three dimensions, maximizing solar energy capture through systematic photovoltaic arrays This innovative system utilizes a gear train mechanism for east-west orientation and a rotating table for north-south alignment The prototype of this advanced solar tracking system is illustrated in Figures 4.1 and 4.2.

The prototype of the innovative solar tracking system, as depicted in Figure 4.1, features an orientation rack and base equipped with a stepper motor and gear reducer to enable the rotation of the solar panel frame along the eastern-western axis This system includes a motor driving mechanism, base plate, and orientation plate, allowing for continuous adjustment of the solar panel to align with the sun's annual movement in the north-south orbit Additionally, multiple detecting sensors are integrated to monitor sunlight, utilizing varying current signals from photodiodes to automatically control the solar panel's rotation in both eastern-western and northern-southern 3D directions.

Computer-Aided Simulation of Solar Panel

The innovative solar tracking system utilizes advanced computer-aided modeling and numerical simulation for its design Through 3D CAD software, detailed modeling is achieved, while Finite Element Analysis (FEA) techniques are employed to assess structural integrity This analysis ensures the effectiveness and durability of the driving system across both east-west and north-south orientations of solar panels.

Fig 4.1 Solar panel system front view

Fig 4.2 Solar panel system rear view

When designing a solar tracking system, it is crucial to account for wind load to ensure that all components—including the panel frame, lateral and longitudinal channel beams, orientation adaptor, rack, base, driver support, and link—function effectively under maximum wind conditions The wind load can be calculated using the equation provided by Mehta and Coulburne (2010).

FwindẳAprojectPwindDdrag ð4:1ị The wind pressurePwindcan be defined by the following equation:

Fwind represents the load induced by wind measured in pounds-force (lbf), while Aproject refers to the projected surface area of a solar panel at various orientations, expressed in square feet (ft²) Pwind indicates the pressure exerted by the wind, measured in pounds per square foot (psf) The coefficient of drag is denoted as Ddrag, and Vwind signifies the wind speed, measured in miles per hour (mph).

2 Calculation of gear-train force in solar panel orientation:

To protect the gears from damage during the operation of a solar panel tracking system, the gear train must effectively manage the combined forces from wind, the weight of the solar panels and associated hardware, as well as other frictional forces The resultant force can be calculated using methods outlined by Mehta and Coulburne (2010).

Tpanelðtorque to orientate the solar panelị ẳNd0:5dp ẳFR0:5Dgear ð4:3ị

The force required to drive gears (Nd) varies as solar panels adjust to different angles, which can be analyzed through computer-aided modeling and simulation Key parameters include the gear pitch diameter (d), orientation force (FR), outside gear diameter (DO), total weight of the solar panel system (WTW), and the friction coefficient (Cf) of various contact materials.

Figures4.3,4.4,4.5,4.6,4.7,4.8,4.9,4.10,4.11,4.12,4.13,4.14,4.15,4.16, 4.17,4.18,4.19,4.20,4.21,4.22,4.23,4.24,4.25,4.26,4.27,4.28, and4.29show the 3D part models, stress profile, and deflection profile of critical components in this new solar tracking system.

The computer-aided simulation and analysis of the newly designed solar panel system reveal key performance metrics, showing a maximum stress of 2,267.076 psi, significantly lower than the material yield strength of 36,300 psi Additionally, the system exhibits a maximum deflection of 0.00507 inches, which remains within the allowable deformation limits for the material.

4.2 Computer-Aided Simulation of Solar Panel Tracking System 41

Fig 4.4 Stress profile in solar panel

Fig 4.5 Deflection profile in solar panel

Fig 4.7 Stress profile in panel frame

Fig 4.8 Deflection profile in panel frame

Fig 4.10 Stress profile in lateral channel beam

Fig 4.11 Deflection profile in lateral channel beam

Fig 4.13 Stress profile in longitudinal channel beam

Fig 4.14 Deflection profile in longitudinal channel beam

Fig 4.16 Stress profile in orientation adaptor

Fig 4.17 Deflection profile in orientation adaptor

Fig 4.19 Stress profile in orientation rack

Fig 4.20 Deflection profile in orientation rack

Fig 4.22 Stress profile in orientation base

Fig 4.23 Deflection profile in orientation base

Fig 4.25 Stress profile in orientation driver support

Fig 4.26 Deflection profile in orientation driver support

Fig 4.28 Stress profile in orientation link

The computer-aided simulations reveal the stress and deflection profiles of both the lateral and longitudinal channel beams in the newly designed solar panel system For the lateral channel beam, the maximum stress measured is 15,877.88 psi, which is below the material yield strength of 36,300 psi, with a maximum deflection of 0.00828 inches that remains within allowable deformation limits Similarly, the longitudinal channel beam exhibits a maximum stress of 17,589.58 psi, also under the yield strength threshold, and a maximum deflection of 0.02748 inches, confirming compliance with material deformation standards.

The computer-aided simulation results for the newly designed solar panel system reveal the stress and deflection profiles of the orientation adaptor The analysis indicates that the maximum stress of 14,196.50 psi is significantly lower than the material yield strength of 36,300 psi, ensuring structural integrity Additionally, the maximum deflection of 0.00017 inches remains within the allowable deformation limit for the material.

The computer-aided simulation results for the newly designed solar panel system reveal the stress and deflection profiles of the orientation rack The analysis shows a maximum stress of 16,842.35 psi, which is below the material yield strength of 36,300 psi, indicating structural integrity Additionally, the maximum deflection recorded is 0.0511 inches, falling within the allowable deformation limits for the material.

The computer-aided simulation and analysis illustrate the stress and deflection profiles of the orientation base in the newly designed solar panel system The findings reveal that the maximum stress of 17,384.07 psi is below the material yield strength of 36,300 psi, and the maximum deflection of 0.00345 inches remains within the allowable deformation limit for the material.

The computer-aided simulations of the newly designed solar panel system reveal that the maximum stress and deflection profiles for key components, including the orientation driver support and orientation link, remain within safe limits Specifically, the orientation driver support experiences a maximum stress of 17,788.09 psi and a deflection of 0.00016 in., both below the material yield strength of 36,300 psi Similarly, the orientation link shows a maximum stress of 18,023.74 psi and a deflection of 0.01921 in., also within acceptable deformation limits Comprehensive analysis across various components indicates that all maximum stresses are below the material yield stress, and deflections are within allowable limits, demonstrating the effective performance of the newly developed solar tracking system.

Experiment on Solar Panel Tracking System

A new solar panel tracking system has been successfully prototyped and tested, allowing for a comparison and verification of computer-aided simulation results The experimental findings, presented in Table 4.1, highlight the maximum stress and maximum deflection experienced by the solar panels within this innovative tracking system.

The experimental results for the solar panel prototype, as shown in Table 4.1, confirm the effective performance of the new solar panel system The average maximum stress measured at 2,267.160 psi and the average maximum deflection at 0.00519 inches closely align with the computer-aided simulation results, which indicate a maximum stress of 2,267.076 psi and a maximum deflection of 0.00507 inches, as illustrated in Figures 4.4 and 4.5.

Table4.2expresses the experimental results of maximum stress and maximum deflection of solar panel frame in this new solar panel tracking system.

Table 4.1 Experimental results of maximum stress and maximum deflection of solar panel in this new solar panel tracking system

Table 4.2 Experimental results of maximum stress and maximum deflection of solar panel frame in this new solar panel tracking system

4.3 Experiment on Solar Panel Tracking System 57

The experimental results of the solar panel frame, as shown in Table 4.2, demonstrate its effective performance, with an average maximum stress of 14,343.15 psi and maximum deflection of 0.03126 in., closely matching the computer-aided simulation results of 14,343.03 psi and 0.03143 in Table 4.3 presents the lateral channel beam's experimental results, confirming its proper functionality, as the average maximum stress of 15,877.69 psi and maximum deflection of 0.00842 in are similar to the simulated values of 15,877.88 psi and 0.00827 in Furthermore, Table 4.4 outlines the longitudinal channel beam's experimental outcomes, which validate its performance, with average maximum stress recorded at 17,589.44 psi and maximum deflection at 0.02761 in., closely aligning with the simulation results of 17,589.58 psi and 0.02748 in.

Table 4.3 Experimental results of maximum stress and maximum deflection of lateral channel beam in this new solar panel tracking system

Table 4.4 Experimental results of maximum stress and maximum deflection of longitudinal channel beam in this new solar panel tracking system

Table 4.5 Experimental results of maximum stress and maximum deflection of orientation adaptor in this new solar panel tracking system

4.3 Experiment on Solar Panel Tracking System 59

Table4.5presents the experimental results of maximum stress and maximum deflection of orientation adaptor in this new solar panel tracking system.

The experimental results for the orientation adaptor, as shown in Table 4.5, demonstrate its normal functionality, with an average maximum stress of 14,196.38 psi and an average maximum deflection of 0.00011 in These findings closely align with the computer-aided simulation results, which report a maximum stress of 14,196.50 psi and a maximum deflection of 0.00017 in., illustrated in Figs 4.16 and 4.17 Additionally, Table 4.6 presents the experimental data on maximum stress and maximum deflection for the orientation rack within this innovative solar panel tracking system.

The prototype experimental results of the orientation rack demonstrate its effective functionality, with an average maximum stress of 16,842.22 psi and an average maximum deflection of 0.05118 in These values closely align with the computer-aided simulation results, which indicate a maximum stress of 16,842.35 psi and a maximum deflection of 0.05107 in, as shown in Figs 4.19 and 4.20.

Table4.7conveys the experimental results of maximum stress and maximum deflection of orientation base in this new solar panel tracking system.

The experimental results of the orientation base prototype, as shown in Table 4.7, demonstrate its normal functionality, with an average maximum stress of 17,384.20 psi and an average maximum deflection of 0.00331 inches, closely aligning with the expected outcomes.

Table 4.6 Experimental results of maximum stress and maximum deflection of orientation rack in this new solar panel tracking system

Table 4.7 Experimental results of maximum stress and maximum deflection of orientation base in this new solar panel tracking system

Table 4.8 Experimental results of maximum stress and maximum deflection of orientation driver support in this new solar panel tracking system

4.3 Experiment on Solar Panel Tracking System 61 maximum stress 17,384.07 psi and maximum deflection 0.00335 in that are recorded, respectively, in Figs.4.22and4.23by computer-aided simulation. Table4.8lays out the experimental results of maximum stress and maximum deflection of orientation driver support in this new solar panel tracking system. The prototype experimental results of orientation driver support in Table 4.8 verify the proper function of orientation driver support because the average maximum stress 17,788.20 psi and average maximum deflection 0.00025 in are almost same as the results of maximum stress 17,788.09 psi and maximum deflection 0.00016 in that are displayed, respectively, in Figs 4.25and4.26by computer- aided simulation.

Table 4.9 shows the experimental results of maximum stress and maximum deflection of orientation link in this new solar panel tracking system.

The experimental results of the orientation link, as shown in Table 4.9, validate its functionality, with an average maximum stress of 18,023.61 psi and an average maximum deflection of 0.01912 in These values closely align with the computer-aided simulation results, which indicate a maximum stress of 18,023.74 psi and a maximum deflection of 0.01921 in, as depicted in Figs 4.28 and 4.29.

Table 4.9 Experimental results of maximum stress and maximum deflection of orientation link in this new solar panel tracking system

Discussion and Future Improvement on Solar Panel

Solar power systems convert natural sunlight into electrical energy, offering safe and clean alternatives to traditional energy sources This chapter explores methodologies such as computational simulation and prototype testing to identify key factors influencing the performance of a solar panel tracking system Both methods demonstrate the system's reliability Future enhancements aim to optimize the solar tracking system through computer-aided modeling and analysis, focusing on achieving optimal operating conditions, reducing system weight to lower costs, and refining the gear train for quieter operation.

4.4 Discussion and Future Improvement on Solar Panel Tracking System 63

Design of Energy-Saving Cooling System

Recent advancements in energy-saving cooling systems have led to the development of a new automatically controlled prototype that enhances performance and reliability Key benefits of this innovative system include a simplified structure, compact design, and easy parameter adjustments, resulting in increased efficiency, quiet operation, and reduced frictional losses The system's gaseous pressure is regulated by two automatic valves managed through a PLC program, while proximity sensors monitor the free piston's motion to optimize performance by automatically adjusting operating parameters The prototype and its internal components are illustrated in Figs 5.1 and 5.2.

The new cooling system design allows for the transfer of partial compressive work from the middle chamber into useful motive work, unlike traditional systems like the Solvay system, which waste energy as heat This system enhances efficiency by providing cooling capacity at both ends of the cylinder and operates quietly due to reduced vibration and shock from its symmetrical design The systematic phase angle of thermal and mechanical functions can be easily adjusted through automatically controlled valves, optimizing performance Figures 5.1 and 5.2 illustrate the internal and external views of this innovative cooling system, featuring two symmetrically installed proximity sensors, compressive cylinders, expansive cylinders, and free pistons, along with a thin plate mounted in the cylinder's center.

The system features a symmetrical design with 65 small holes and two middle chambers, V mc and V 0 mc, which are crucial for analysis alongside the compressor piston H and free piston F To enhance machine functionality, two automatically controlled valves allow for the adjustment of air pressure in V mc and V 0 mc, optimizing the phase angles of all functional curves through PLC control Additionally, two electric sensors positioned at each end of the cylinder track the piston’s movement, providing feedback to the PLC unit for real-time adjustments of thermal parameters, ultimately improving system performance.

Fig 5.1 New energy-saving cooling system

Fig 5.2 Internal view of new energy-saving cooling system

Computer-Aided Simulation on Energy-Saving

The initial cyclic condition of the energy-efficient cooling system is illustrated in Fig 5.2, where piston H is positioned at the bottom of the compression chamber, and free piston F is situated at the right end of the expansion chamber The P–V cyclic diagram for the expansion chamber is presented in Fig 5.3.

During the final phase of the previous cycle, high-pressure gas (PẳPH) enters chamber V mc through a small orifice, causing it to mix with the low-pressure gas (PẳPL) already present This results in a mixed gas pressure, referred to as Pmix, within chamber V mc As the piston H ascends in the compressive chamber V c, it is assumed that the gas from chamber V mc does not flow into chamber V 0 mc due to the rapid movement of the free piston and the minimal diameter of the hole Consequently, the pressure on the left side of the free piston remains unaffected.

When the right-side gaseous pressure of F (PmcẳPave) exceeds the expansive chamber pressure (Pe), the free piston F remains stationary As a result, the gaseous pressure (Pe) in the expansive chamber escalates to a high pressure (PH), causing the gaseous volume (Ve) in the expansive chamber to increase from zero.

As the V2as piston H ascends, this motion is illustrated by curve 1–2 in Fig 5.3 Subsequently, the gas in chamber Vmc transitions into chamber V 0 mc Due to equal gaseous pressure on both sides of the free piston F, it moves to the left at a steady speed This occurs when the crankshaft rotates to an angle (θ) nearby.

In the expansive chamber, the gaseous volume increases from V2 to V3, illustrated by line 2–3 Initially, as piston H descends in chamber Vc, free piston F remains stationary because the gas in chamber V0 mc is not flowing into chamber Vmc Consequently, the pressure Pe in the expansive chamber decreases from P3 to P4, represented by line 3–1 As piston H continues its downward motion in the compressive chamber Vc, gas from chamber V0 mc begins to enter chamber Vmc through a small opening, allowing free piston F to move.

F moves to the right end in the expansive chamber with constant speed which can be represented by line 4–1 This concludes the full functioning cycle of this cooling system.

Fig 5.3 P–V cyclic diagram in expansive chamber

5.2 Computer-Aided Simulation on Energy-Saving Cooling System 67

The computer-aided simulations can be applied to verify the function of this new cooling system The piston H in compressive chamber moves in sine law (Kundu and Cohen 2008):

VẳVkỵVcỵVe ð5:2ị Here,Vkis the clearance volume:

As piston H in compressive chamber travels upwards with crankshaft rotating to angleω,

The differential equation of free piston motion can be derived based on the second Newton law: m d 2

Combine the above equations: d 2 V V e ð ị θ eo h i dθ 2 ẳPð ị ω hLWỵ V V c ð ị eo ω i m w 2 Y o

Here, pressureP(ω) can be determined by the following equation: d 2 Vcð ịθ dθ 2 ẳ0 ð5:9ị

The computer-aided simulation determines the stress and deflection profiles shown in Figs.5.4,5.5,5.6,5.7,5.8,5.9,5.10,5.11,5.12,5.13,5.14,5.15,5.16, 5.17, and5.18.

The computer-aided simulation of the compressive piston link assembly in the innovative energy-saving cooling system reveals critical stress and deflection profiles The analysis indicates that the maximum stress recorded at 25,698.25 psi is below the material's yield strength of 36,300 psi, ensuring structural integrity Additionally, the maximum deflection of 0.00169 inches remains within the permissible deformation limits of the material, confirming the design's reliability and efficiency.

The computer-aided simulation and analysis illustrate the stress and deflection profiles of the compressive chamber in the innovative energy-saving cooling system The findings reveal that the maximum stress of 26,088.02 psi is below the material's yield strength of 36,300 psi, while the maximum deflection of 0.00017 inches remains within the allowable deformation limits of the material.

The computer-aided simulation results reveal the stress and deflection profiles of the piston link in a newly designed energy-saving cooling system The analysis shows that the maximum stress experienced by the piston link is 23,242.99 psi, which is below the material's yield strength of 36,300 psi Additionally, the maximum deflection recorded is 0.00147 inches, remaining within the allowable deformation limits of the material.

Fig 5.4 Piston and link assembly in compressive chamber

Fig 5.5 Stress profile of compressive piston link assembly

Fig 5.6 Deflection profile of compressive piston link assembly

The computer-aided simulation and analysis of the newly designed energy-saving cooling system reveal the stress and deflection profiles of the crankshaft The findings indicate that the crankshaft experiences a maximum stress of 20,667.27 psi, which is below the material yield strength of 36,300 psi Additionally, the maximum deflection measured at 0.00019 inches remains within the allowable deformation limits of the material.

Fig 5.7 Piston head in compressive chamber

Fig 5.8 Stress profile of piston head in compressive chamber

Fig 5.9 Deflection profile of piston head in compressive chamber

Fig 5.10 Piston link in compressive chamber

Fig 5.11 Stress profile of piston link in compressive chamber

Fig 5.12 Deflection profile of piston link in compressive chamber

Fig 5.13 Crankshaft in compressive chamber

Fig 5.14 Stress profile of crankshaft in compressive chamber

Fig 5.15 Deflection profile of crankshaft in compressive chamber

Fig 5.16 Piston in expansive chamber

Fig 5.17 Stress profile of piston in expansive chamber

Fig 5.18 Deflection profile of piston in expansive chamber

The computer-aided simulation results demonstrate the stress and deflection profiles of a piston in a newly designed energy-saving cooling system The analysis reveals that the maximum stress experienced by the piston is 7,884.44 psi, which is significantly lower than the material yield strength of 36,300 psi Additionally, the maximum deflection measured is 0.00006 inches, remaining well within the allowable deformation limits of the material.

The computational simulation results indicate that the maximum stresses on critical components remain below the material yield stress, while the maximum material deflections are within permissible deformation limits These findings validate the effective and reliable performance of the newly developed energy-saving cooling system.

Experiment on Energy-Saving Cooling System

The newly developed energy-efficient cooling system has undergone prototyping and testing to validate the outcomes of computer-aided simulations The results of the prototype testing for the compressive piston link assembly in this innovative cooling system are presented in Table 5.1.

The prototype experimental results of compressive piston link assembly in Table 5.1 verify the proper function of this compressive piston link assembly

Table 5.1 Prototype testing of compressive piston link assembly in this new energy-saving cooling system

5.3 Experiment on Energy-Saving Cooling System 77 because the average maximum stress 25,698.50 psi and average maximum deflection 0.00145 in are approximately equal to the results of maximum stress 25,698.25 psi and maximum deflection 0.00169 in that are represented, respectively, in Figs.5.5and5.6by computer-aided modeling and numerical simulation. Table5.2expresses the prototype testing results of piston head of compressor chamber in this new energy-saving cooling system.

The experimental results for the piston head in the compressor chamber, as shown in Table 5.2, validate its effective performance, with an average maximum stress of 26,088.28 psi and an average maximum deflection of 0.00026 in These values are closely aligned with the computer-aided modeling and numerical simulation results, which indicate a maximum stress of 26,088.02 psi and a maximum deflection of 0.00017 in, as illustrated in Figs 5.8 and 5.9.

Table 5.3 records the prototype testing results of piston link of compressor chamber in this new energy-saving cooling system.

The prototype experimental results for the piston link of the compressor chamber demonstrate normal functionality, with an average maximum stress of 23,242.65 psi and an average maximum deflection of 0.00175 in These findings are closely aligned with the computer-aided modeling and numerical simulation results, which report a maximum stress of 23,242.99 psi and a maximum deflection of 0.00147 in, as illustrated in Figs 5.11 and 5.12.

Table 5.2 Prototype testing of piston head of compressor chamber in this new energy-saving cooling system

Table5.4states the prototype testing results of crankshaft of compressor chamber in this new energy-saving cooling system.

The prototype experimental results for the crankshaft of the compressor chamber confirm its proper functionality, with an average maximum stress of 20,667.43 psi and an average maximum deflection of 0.00013 in These findings align closely with the computer-aided modeling and numerical simulation results, which reported a maximum stress of 20,667.27 psi and a maximum deflection of 0.00019 in, as illustrated in Figs 5.14 and 5.15.

Table 5.5 demonstrates the prototype testing results of piston in compressor chamber of this new energy-saving cooling system.

The experimental results for the piston in the compressor chamber, as shown in Table 5.5, validate its effective performance, with an average maximum stress of 7,884.67 psi and an average maximum deflection of 0.00010 in These findings closely align with the computer-aided modeling and numerical simulation results, which report a maximum stress of 7,884.44 psi and a maximum deflection of 0.00006 in, illustrated in Figs 5.17 and 5.18.

Table 5.3 Prototype testing of piston link of compressor chamber in this new energy-saving cooling system

5.3 Experiment on Energy-Saving Cooling System 79

Table 5.4 Prototype testing of crankshaft of compressor chamber in this new energy-saving cooling system

Table 5.5 Prototype testing of piston in compressor chamber of this new energy-saving cooling system

Discussion and Future Improvement on Energy-Saving

Protecting the environment is crucial in combating global warming, and enhancing energy efficiency in cooling systems plays a significant role in this effort By improving performance and energy-saving capabilities, these advanced cooling systems not only contribute to environmental conservation but also enhance customer satisfaction Future advancements will focus on optimizing piston setups to minimize shock and vibration, ensuring quieter operation and increased efficiency Additionally, design simplifications, including a free piston glove cutoff, heat exchangers, and compressive crankshafts, are planned to further reduce costs while maintaining effectiveness.

5.4 Discussion and Future Improvement on Energy-Saving Cooling System 81

Automated Systems

Design of Automated and High-Speed

Automated production and manufacturing encompass the engineering disciplines focused on product manufacturing, production processes, and the development of machining equipment Utilizing computer-aided engineering (CAE) technology, design teams can efficiently iterate designs, enhancing quality and reliability without the need for physical prototypes until the design phase is complete Additionally, computer-aided manufacturing (CAM) integrates technology to facilitate the exchange of technical data, ensuring a qualified production process Recent research has led to the development of an advanced automated system for filling high-viscous liquids, as illustrated in Figures 6.1, 6.2, and 6.3.

The automated high-speed liquid filling system is engineered for efficiently filling various high-viscosity liquids across multiple industries, including chemical, pharmaceutical, dairy, cosmetic, and food production This innovative system utilizes a positive displacement pump for thick liquids like medical creams and food sauces, while a rotary gear pump is employed for heavy-duty applications such as oil products, construction tar, roofing bitumen, thick ink, and special wax The rotary gear pump features a specially designed jacket that enables operation at elevated temperatures, ensuring optimal performance in demanding environments.

The innovative pump system features 125 C and double-drive rotors, enabling efficient delivery of high-viscosity liquids To enhance filling speed, the system can incorporate multiple pumping nozzles of varying sizes Internally swaged nozzles are specifically designed for automated filling of bottles with narrow necks and complex shapes, ensuring optimal performance in diverse applications.

The 85 designed indexing conveyor effectively manages product movement within a specified tolerance range, ensuring that empty bottles or containers are accurately picked up and positioned in fixture holders These holders are securely integrated into the indexing conveyor through a specialized robotic system Additionally, the fixture holder in the liquid filling system is engineered to uphold precise dimensional standards.

Fig 6.1 Automated high-viscous liquid filling and sealing manufacturing system

Fig 6.2 Automated high- viscous liquid filling mechanism

Automated high-speed manufacturing systems ensure precise location tolerances between fixture holders and containers, enabling a reliable liquid filling process When an empty container reaches the filling position, a programmable logic control (PLC) system halts the indexing conveyor, guided by signals from an opposed mode sensor A horizontal air slider then moves the gripper pair to secure the container, while a vertical air slider lowers the filling nozzle to initiate the filling Upon completion, the sensor alerts the PLC to retract the nozzle, allowing the grippers to release the container for the next cycle This PLC-controlled system accurately manages the filling pump and nozzle, ensuring precise liquid volumes, particularly for high-viscosity products, while also facilitating cost-effective tooling changeovers Additionally, automated plastic welding methods, including ultrasonic, extrusion, and laser welding, are employed to efficiently join plastic parts, utilizing various techniques that apply heat or electromagnetic processes for effective sealing.

Fig 6.3 Automated ultrasonic sealing (welding) mechanism to fill high- viscous liquid

6.1 Design of Automated and High-Speed Manufacturing Systems 87 welding curves; the solvent welding process applies a melt or a liquefied method to weld components together; and the friction welding method utilizes the vibration among connecting surfaces by adjusting defined vibration frequencies and amplitudes (Wang et al 2013) The ultrasonic welding, with vibration produced from high-frequency sound energy to dissolve the plastic parts, is applied to the sealing mechanism in this new automated and high-speed production system since it is the quickest welding method suitable for high-speed production As the ultrasonic vibration stops, molten plastics become solidified and plastic components are welded Also the ultrasonic welding in this sealing system not only maintains high welding rate but also prevents the containers from usual damages by traditional sealing methods that relies on mechanical tolerance to control clearance between two mating parts The sequential operation of this automated and high-speed welding system using ultrasonic welding is described as follows As container stops at the accurate location below horn of welding mechanism, the fixture gripper travels forward to grab and secure the container for welding process The tooling gripper picks up a container cap from vibration bowl rail and vertically moves up by pneumatic air slider The pneumatic slider in horizontal setup drives cap gripper toward the center of container and pneumatic slider in vertical setup moves welding mechanism downward with pneumatic air rotary rotating cap gripper in 180 As container cap is brought to the center of container top entrance by horizontal slider, vertical slider moves top tooling gripper downward to finally insert the cap into container After cap being pressed down to the target position inside container, the top tooling gripper frees cap and travels back to pick up next cap in vibration bowl rail The newly developed mechanism drives the ultrasonic welding horn downward and quickly welds cap and container together to seal the product.

Figures6.4, 6.5, and 6.6 display newly developed automated and high-speed production system for chemical gas charging process based on author’s new research.

The design and development challenge in high-speed automated manufacturing lies in effectively sealing high-pressure chambers during the chemical gas charging process Traditional sealing methods, such as gel injection, often fail to provide adequate sealing under rapid gas charging conditions The innovative automated gas charging and plug sealing mechanism requires the plug to be swiftly inserted to seal the container entrance while chemical gas is simultaneously introduced through the air chamber, preventing gas escape This process is conducted within a confined gas chamber to enhance efficiency, with the sealing plug being automatically assembled at the container inlet, ensuring precise manufacturing tolerances for optimal gas charging and sealing The system's unit chamber comprises a plug delivery inlet, a central hole for plug insertion, and pneumatic valves and fittings As the empty container is automatically transported to the assembly station, the linear air actuator facilitates the process.

The automated high-speed manufacturing system efficiently moves the full plug assembly down until it contacts the container's inlet, while an automated delivery mechanism feeds plugs to the assembly station The sealing plug is then pressed through the air chamber's central hole by a top pusher, positioned 0.125 inches below the container's top surface Once the desired gas volume fills the chamber, the top pusher continues to move the plug down to achieve a complete seal on the container.

Fig 6.4 Automated and high-speed chemical gas charging and sealing system

Fig 6.5 Automated and high-speed sealing plug delivery mechanism

6.1 Design of Automated and High-Speed Manufacturing Systems 89

Fig 6.6 Automated and high-speed chemical gas charging and mechanical sealing mechanism

Fig 6.7 Confined air chamber with plug feeding and pusher mechanism

90 6 Automated and High-Speed Manufacturing System

To minimize gas leakage during automated high-speed production, a bronze metal ring is employed to seal the gap between the container entrance and the plug insert assembly mechanism This ring is precisely fitted and securely pressed into the bottom center hole of the assembly, ensuring an effective seal.

The friction force between the plug and the center hole in the plug assembly mechanism exceeds the gas pressure force, ensuring that there is no gas leakage from the upper area of the plug assembly unit.

Plug Pusher (Moves Up and Down)

Sealing Plug is being fed in

Chemical Gas is being filled in

Fig 6.8 Gas chamber and sealing plug mechanism in this new automated gas charging system

Fig 6.9 Bronze metal ring seal

6.1 Design of Automated and High-Speed Manufacturing Systems 91

Computer-Aided Simulation of Automated

and High-Speed Manufacturing Systems

Sections 3.2.1 and 3.2.2 detail the computer-aided modeling and numerical simulation of automated, high-speed systems for filling high-viscous liquids and charging chemicals with gas.

6.2.1 Computer-Aided Simulation on Automated

High-Viscous Liquid Filling System

The computational analysis and numerical simulation of the leaking rate of high-viscous liquids in automated, high-speed liquid filling systems can be expressed through a specific mathematical equation (Kundu and Cohen, 2008).

Here, V—liquid flow rate, E—constant, TE—average temperature, TP—basic temperature, DC—container inside diameter, EC—container filling efficiency,

PEntrance refers to the pressure at the entrance of a system, while PExit indicates the pressure at the exit The Darcy-Weisbach frictional coefficient (DW) is crucial for calculating pressure losses in fluid flow Specific gravity of liquids (LSG) plays a significant role in determining fluid behavior The length of the container (LC) affects the flow dynamics, and pressure base (PP) is essential for establishing reference pressure levels Additionally, the coefficient of compressibility (CF) is important for understanding how fluid density changes under pressure variations.

The mathematical equation (6.1) can be applied in computer-aided design and numerical simulation to analyze the leakage of high-viscous fluids during automated and high-speed filling processes This leakage is influenced by various factors, including the liquid flow rate (V) and the pressure difference (PEntrance - PExit) As shown in the computational simulation in Fig 6.10, the leakage of heavy viscous liquids in this advanced filling system is minimal, allowing it to be considered negligible.

Filling Plug Linear Speed (ft/ min)

Fig 6.10 Heavy viscous liquid leakage vs piston linear speed

Computer-aided structural and stress analysis has been conducted to aid in the design and development of a new automated, high-speed viscous liquid filling system The analysis focuses on key components, including the liquid filling mechanism and the ultrasonic welding (sealing) mechanism, with results illustrated in Figures 6.11, 6.12, 6.13, and 6.14.

The computer-aided simulation and analysis illustrate the stress and deflection of the liquid filling mechanism in a newly designed high-speed viscous liquid filling system The findings indicate that the maximum stress of 21,937.83 psi is below the material's yield strength of 36,300 psi, and the maximum deflection of 0.01324 inches remains within the acceptable limits for material deflection.

The computer-aided simulation and analysis reveal the stress and deflection characteristics of the ultrasonic welding mechanism in a new automated, high-speed viscous liquid filling system The findings indicate that the maximum stress of 24,973.92 psi is below the material's yield strength of 36,300 psi, while the maximum deflection of 0.01089 inches remains within the allowable limits for the material.

Utilizing advanced computer-aided modeling and numerical simulation, the innovative automated high-speed filling system effectively manages high-viscosity liquids This system demonstrates a sophisticated liquid filling mechanism, as illustrated in the stress profile computational modeling.

6.2 Computer-Aided Simulation of Automated and High-Speed 93 properly with good sealing capability and high production rates Also the manufacturing cost for this new liquid filling system is relatively low since the less tolerance control is required in this new liquid filling system design.

6.2.2 Computer-Aided Simulation on Automated

The mathematical modeling of gas leakage in chemical gas charging process can be expressed as follows (White 2003):

T ð6:2ị Here,VGL—leakage rate of gas, B—unit conversion constant,Δ P N ẳh N P F F P N I I i

The calculation for pressure change involves the final pressure divided by the final gas deviation constant, minus the initial pressure divided by the initial gas deviation constant Additionally, the time duration for the process is measured in minutes to establish the filling mechanism's deflection profile, as illustrated in the computational model.

94 6 Automated and High-Speed Manufacturing System stabilized pressure,VC—tubing string volume above container, andT—temperature in container.

The mathematical equation can be effectively modeled and analyzed using computer-aided 3D modeling and numerical simulation, as illustrated in Fig 6.15 The simulation results demonstrate that the newly designed chemical gas charging system exhibits excellent sealing capabilities, allowing for negligible gas leakage even under high-pressure conditions.

To perform computer-aided structural analysis, the following mathematic equation is applied to define the load or the force increment in the computational simulation (White 2003):

Here, FLoad—load or force applied to the component, PGas—maximum gas pressure, andSArea—gas charging area.

Computer-aided structural analysis plays a vital role in the design of the new system by providing analytical insights into key components such as the container fixture mechanism, plug delivery mechanism, plug insertion mechanism, and sealing plug feeding unit, as illustrated in Figures 6.16 to 6.23.

Fig 6.13 Computational modeling of stress profile in ultrasonic welding mechanism

6.2 Computer-Aided Simulation of Automated and High-Speed 95

Fig 6.14 Computational modeling of deflection profile in ultrasonic welding mechanism

Fig 6.15 Gas leakage vs gas pressure

The computer-aided simulation and analysis reveal the stress and deflection characteristics of the container fixture mechanism in the new automated high-speed viscous liquid filling system The findings indicate that the maximum stress of 24,692.52 psi is below the material yield strength of 36,300 psi, and the maximum deflection of 0.11857 inches remains within the allowable limit for the material.

The computer-aided simulation and analysis illustrate the stress and deflection of the plug delivery mechanism in a new automated, high-speed viscous liquid filling system The findings reveal that the maximum stress of 21,072.31 psi is below the material yield strength of 36,300 psi, and the maximum deflection of 0.08751 inches remains within the allowable limits for the material.

The computer-aided simulation and analysis reveal the stress and deflection characteristics of the plug insertion mechanism in a new automated high-speed viscous liquid filling system The findings indicate that the maximum stress of 13,766.81 psi is significantly below the material's yield strength of 36,300 psi, while the maximum deflection of 0.07182 inches remains within the allowable limits for the material.

Experiment on Automated and High-Speed

A new prototype for an automated, high-speed system designed for filling heavy viscous liquids and charging chemical gases is currently under testing This development aims to validate and compare the results obtained from computer-aided simulations.

6.3.1 Experiment on Automated and High-Speed Heavy

Table 6.1 records the prototype testing results of heavy viscous media leakage vs filling plug linear speed in this new automated and high-speed viscous liquid filling system.

The prototype experiment comparing viscous media leakage and plug linear speed confirms the effective operation of the liquid filling system, as illustrated in Fig 6.10 through computer-aided modeling and numerical simulation Additionally, Table 6.2 presents the experimental results regarding the maximum stress and maximum deflection of the liquid filling mechanism in this innovative, high-speed automated liquid filling system.

The prototype testing results validate the functionality of the liquid filling mechanism, as the average maximum stress measured at 21,937.78 psi and average maximum deflection of 0.0128 inches closely align with the computational simulation findings of 21,937.83 psi for maximum stress and 0.0132 inches for maximum deflection, as illustrated in Figs 6.11 and 6.12.

Table6.3demonstrates the prototype experimental results of maximum stress and maximum deflection of ultrasonic welding mechanism in this new automated and high-speed liquid filling system.

Table 6.1 Prototype testing of viscous media leakage vs filling plug linear speed

Filling plug linear speed (ft/min)

Heavy viscous media leakage (ml)

Table 6.3 Prototype experiment of maximum stress and maximum deflection of ultrasonic welding mechanism in this new heavy viscous liquid filling system

Table 6.2 Prototype testing of maximum stress and maximum deflection of liquid filling mechanism in this new heavy viscous liquid filling system

6.3 Experiment on Automated and High-Speed Manufacturing Systems 103

The experimental results for the ultrasonic welding mechanism, as shown in Table 6.3, confirm its normal functionality, with an average maximum stress of 24,973.96 psi and an average maximum deflection of 0.0112 inches These findings closely align with the computer-aided simulation results, which report a maximum stress of 24,973.92 psi and a maximum deflection of 0.0109 inches, as illustrated in Figs 6.13 and 6.14.

6.3.2 Experiment on Automated and High-Speed

Table 6.4demonstrates the prototype experimental results of gas media leakage vs filling gas pressure in this new automated and high-speed chemical gas charging system.

The prototype testing of gas media leakage compared to gas pressure confirms the effective operation of the gas filling system, as illustrated by the consistent results shown in Fig 6.15 through computer-aided modeling and numerical simulation Additionally, Table 6.5 presents the testing outcomes for maximum stress and maximum deflection of the container fixture mechanism within this innovative automated and high-speed chemical gas charging system.

The prototype testing results of container fixture mechanism in Table6.5con- firm the appropriate function of this container fixture mechanism since the average

Table 6.4 Prototype experimental results of gas media leakage vs filling gas pressure

Filling gas pressure (psia) Gas media leakage (cc/min)

The automated and high-speed manufacturing system demonstrated a maximum stress of 24,692.57 psi and an average maximum deflection of 0.1182 inches, closely aligning with the computational simulation results of 24,692.52 psi for maximum stress and 0.1186 inches for maximum deflection, as shown in Figures 6.16 and 6.17.

Table 6.6 records the prototype experimental results of maximum stress and maximum deflection of plug delivery mechanism in this new automated and high- speed chemical gas charging system.

The prototype experimental results demonstrate the effective functioning of the plug delivery mechanism, with an average maximum stress of 21,072.36 psi and an average maximum deflection of 0.0880 in These findings closely align with the computer-aided simulation results, which show a maximum stress of 21,072.31 psi and a maximum deflection of 0.0875 in, as illustrated in Figs 6.18 and 6.19.

Table6.7states the testing results of maximum stress and maximum deflection of plug insertion mechanism in this new automated and high-speed chemical gas charging system.

The prototype testing of the plug insertion mechanism, as detailed in Table 6.7, confirms its effective performance, with an average maximum stress of 13,766.88 psi and an average maximum deflection of 0.0722 in These values closely align with the computer-aided simulation results, which indicate a maximum stress of 13,766.81 psi and a maximum deflection of 0.0718 in, as illustrated in Figs 6.20 and 6.21.

Table 6.5 Prototype testing of maximum stress and maximum deflection of container fixture mechanism in this new automated chemical gas charging system

6.3 Experiment on Automated and High-Speed Manufacturing Systems 105

Table 6.7 Prototype experiment of maximum stress and maximum deflection of plug insertion mechanism in this new automated chemical gas charging system

Table 6.6 Prototype experiment of maximum stress and maximum deflection of plug delivery mechanism in this new automated chemical gas charging system

Table6.8demonstrates the experimental results of maximum stress and maximum deflection of plug feeding unit in this new automated and high-speed chemical gas charging system.

The prototype experimental results of the plug feeding unit demonstrate its effective functionality, with an average maximum stress of 7,216.19 psi and an average maximum deflection of 0.0177 in These values closely align with the computer-aided simulation results, which show a maximum stress of 7,216.139 psi and a maximum deflection of 0.0182 in, as illustrated in Figs 6.22 and 6.23.

Discussion and Future Improvement on Automated

and High-Speed Manufacturing Systems

Automation drives significant business growth by enabling real-time control of complex adaptive and multiprocessing systems Advanced control software facilitates communication among elemental nodes within these intricate systems Given the high costs associated with rebuilding automated production systems for design changes, it is essential that these systems are designed for flexibility and easy reconfiguration, allowing for the production of diverse products tailored to customized demands.

Table 6.8 Prototype testing of maximum stress and maximum deflection of plug feeding unit in this new automated chemical gas charging system

6.4 Discussion and Future Improvement on Automated and High-Speed 107

Modern automated and high-speed production technologies require skilled personnel to effectively address technical issues related to varying products, processes, and machinery These systems demand a workforce with fundamental production knowledge and hands-on experience to troubleshoot and maintain high-tech automated machinery, ensuring uninterrupted production flow Therefore, it is essential for these automated systems to be designed for reliability, quick maintenance, simple installation, cost-effective reconfiguration, and accessible technical training This book introduces two innovative automated systems for high-viscous liquid filling and chemical gas charging, which meet these professional design criteria The viscous liquid filling system can be easily adapted for chemical gas charging with minor modifications This cost-efficient design incorporates advanced quality diagnostic software and adaptable interfaces, ensuring high reliability and centralized control for effective error diagnosis and rectification Future enhancements will focus on reducing the weight of moving components to minimize vibration, optimizing the design layout for easier maintenance, sourcing more affordable high-viscous liquid pumps, and adjusting system tolerance controls for more economical manufacturing.

Design of Robotic System for Industrial Applications

Robotics research encompasses various disciplines such as mathematics, mechatronics, physics, automation, and mechanical engineering These robotic systems are essential in industrial applications, executing specialized, hazardous, and repetitive tasks with precision and efficiency The newly designed robotic prototype, as illustrated in Figure 7.1, is engineered for automated manufacturing and assembly processes, effectively handling tasks like picking and placing workpieces and products in industrial production settings.

Actuators in robotic systems function like human muscles, converting energy into motion, with electric motors being the most common type For applications requiring strong linear force, linear actuators are utilized, while piezo motors operate through piezo element vibrations Air wires change length based on internal air pressure, and electroactive polymers alter their dimensions with electrical input Sensors consist of a rigid central element surrounded by conductive liquids, which, when deformed by external contact, change resistance to detect forces Computer-aided vision technology enhances robotic systems by extracting numerical data from digital images Robotic arms enable flexible manipulation of objects for complex tasks, with mechanical grippers for small items and vacuum grippers for larger ones Kinematics helps analyze motion parameters such as velocity and acceleration, while dynamics assesses the external forces affecting robotic arm movement.

109 is an effective tool used in computational simulation to adjust and optimize the control algorithms of robotic systems.

The prototype illustrated in Fig 7.1 has undergone thorough analysis and validation via computer-aided 3D modeling, numerical simulations, and experimental testing in subsequent chapters The findings reveal that this innovative robotic system achieves maximum 3D movement distances of 8 feet in the x-direction, 12 feet in the y-direction, and 10 feet in the z-direction.

Computer-Aided Simulation on Robotic System

This chapter introduces and analyzes a novel robotic system developed for product handling in biomedical and surgical applications, as well as in automated production processes The robotic system has been meticulously 3D modeled, designed, and validated using computer-aided modeling, numerical simulation, and engineering analysis It features a specific mathematical model that precisely governs the movement of the robot arm An example of a basic double-link robot arm, characterized by its simpler mathematical model, is illustrated in Fig 7.2.

In a simplified double-lever arm system, the first lever A_B rotates around the origin point O within the M_N Cartesian coordinate system, while the second lever B_C pivots around the hinge point B that connects the two levers The angle ζ is defined between lever A_B and the horizontal axis O_M, and angle λ is established between the two levers.

Fig 7.1 Prototype of new robotic system

110 7 Robotic System levers A_B and B_C The robot arm is at the end places (M B , N B ) of lever A_B and (MC,NC) of lever B_C.

Three analytical methodologies can be utilized to evaluate robotic systems: kinematics, which determines the robot arm's position (MB, NB) given known angles ζ and λ; inverse kinematics, which calculates the angles ζ and λ based on the robot arm's position (MB, NB); and the application of these methods to enhance robotic functionality and precision in various tasks.

NB) is given; and trajectory generation—ascertain robot arm new position (MC,NC) by modifying anglesζandλwhile present position (MB,NB) is provided.

From Fig.7.2, the end point of lever B_C can be defined as follows (Gevorkian 2007):

MCẳðA Bị cosð ị ỵζ ðB Cị cosðζỵλị ð7:1ị

NCẳðA Bị sinð ị ỵζ ðB Cị sinðζỵλị ð7:2ị Here,

Fig 7.2 Double-lever model for robot arm

7.2 Computer-Aided Simulation on Robotic System for Industrial Applications 111

Based on kinematical equations (7.1) and (7.2), it needs a nonlinear solution to specify anglesζandλwhile end position (MC,NC) is provided.

The mathematical equations presented by Gevorkian (2007) demonstrate the relationships between angles α and β through cosine and sine functions, specifically in equations (7.3) and (7.4) By utilizing these algebraic models, one can effectively address the nonlinear problem by integrating the equations The resolution of these nonlinear equations leads to the derivation of a new mathematical expression to calculate angle λ, represented as λ = arccos[(MC² + NC² - (AB)² - (BC)²)].

The inverse kinematic problem can yield two solutions due to the equality cos(λ) = cos(λ), allowing lever B_C to rotate both clockwise and counterclockwise, as illustrated in Fig 7.3 The angles ζ can be determined once the angle λ is solved in the inverse kinematic model (Gevorkian 2007).

MCẳẵðA Bị ỵðB Cị cosð ịλ cosð ị ζ ðB Cị sinð ị λ sinð ị ðζ 7:6ị

NCẳðB Cị sinð ị λ cosð ị ỵζ ẵðA Bị ỵðB Cị cosð ịλ sinð ị ðζ 7:7ị

The angle λcan be specified by resolving the above nonlinear mathematical equations (7.6) and (7.7).

In double-levered robot arm applications, the arm's position (MB, NB) is linked to the lever angles ζB and λB When the robot arm moves to a new position (MC, NC), the angles ζC and λC can be determined through inverse kinematic analysis Various methods exist for manipulating the robotic arm's rotation, including adjusting angle ζ before λ, modifying angle λ prior to ζ, changing both angles simultaneously, and rotating the arm clockwise or counterclockwise An efficient robot system design reduces energy consumption and minimizes the time needed for mechanism transitions Figure 7.4 illustrates the robot arm following a trajectory curve while angle ζ rotates in a clockwise direction.

The two traveling trajectories of the robot arm, as depicted in Fig 7.4, illustrate the optimal movement scenario In the linear trajectory generation method, both straight and curved lines can be divided into numerous small segments, each linked to specific (Mi, Ni) coordinates.

The robotic system's elements are defined through computer-aided simulation, calculating targeted angle pairs ζi and λi for each coordinate pair (Mi, Ni) As new angle pairs are computed, the robot arm mechanisms are adjusted accordingly This computational simulation of the angle pairs ζi and λi is continuously executed along both straight and non-straight paths until the desired arm position is reached.

Complex robotic arm movements can be effectively simulated and analyzed using computational modeling and numerical simulation techniques The trajectory curve of the robot arm, illustrated in Figure 7.5, showcases critical data points along its travel path Notably, the movement becomes smoother when the angle pairs ζi and λi are adjusted simultaneously.

Fig 7.3 Inverse kinematical model for robotic arm

Fig 7.4 Robot arm in trajectory-generated move with clockwise change in angle ζ

Figure7.6records the robot arm traveling in an alternative trajectory path with smoother curve as angle pair’sζiandλiare manipulated simultaneously.

The robotic system operates as a nonlinear entity, necessitating the integration of advanced mathematical modeling, computer-aided analysis, and numerical simulation to effectively address robotic motion challenges By utilizing varying lever lengths, one can define the potential 3D travel ranges of robotic arms The inverse kinematic method can be adapted to follow trajectory-generated solutions, employing computational modeling and numerical simulations to examine the complex motions of the robotic arm system Figures 7.7 to 7.12 illustrate the computer-aided simulations and solutions of pulse-width modulation (PWM) values, which are essential for driving the motors and facilitating the robotic system's movement in various directions, ultimately aiding in the determination of its kinematic motion.

The travel paths of robotic systems, derived from computer-aided analysis of PWM values shown in Figs 7.7 to 7.12, can enhance robotic design optimization This process enables the achievement of targeted movement ranges through advanced computer modeling and numerical simulation techniques.

The angles ζi and λi for the coordinate pair are determined through computational modeling and numerical simulation to ensure optimal functionality The robotic arm mechanisms are promptly updated with each verified angle pair, and the computational solutions for ζi and λi are iterated until the robotic arm achieves the desired position The simulation results indicate the maximum 3D traveling ranges of the new robotic system, as illustrated in Fig 7.13.

8 ft (front to back), 12 ft (left to right), and 10 ft (top to bottom).

To verify if this newly developed robotic system has necessary strong structure to handle automated and high-speed manufacturing and production, the

Fig 7.5 Computational simulation of robotic arm traveling path upon multiple data points

114 7 Robotic System computer-aided structural analysis has been performed on some critical components, with stress and deflection profiles presented in Figs.7.14,7.15,7.16, 7.17,7.18, and7.19.

The computer-aided simulation and analysis in Figs.7.14 and 7.15 show the stress and deflection of arm in this new robotic system The analytic results tell that

Fig 7.6 Computational simulation of robotic arm traveling with an alternative moving path

Fig 7.7 Simulated PWM values—drive motor to move robot arm toward the front

Fig 7.8 Simulated PWM values—drive motor to move robot arm toward the back

Fig 7.9 Simulated PWM values—drive motor to move robot arm toward the left

Fig 7.10 Simulated PWM values—drive motor to move robot arm toward the right

Fig 7.11 Simulated PWM values—drive motor to move robot arm toward the upper direction

7.2 Computer-Aided Simulation on Robotic System for Industrial Applications 117 the maximum stress of 22,421.51 psi in this arm is less than the material yield strength of 36,300 psi and maximum deflection of 0.01045 in is within material allowable deflection limit.

Fig 7.12 Simulated PWM values—drive motor to move robot arm toward the lower direction

Fig 7.13 Simulated maximum 3D moving range of newly developed robotic system

The computer-aided simulation and analysis reveal the stress and deflection of the arm link in the new robotic system The findings indicate that the maximum stress of 22,634.97 psi is below the material's yield strength of 36,300 psi, ensuring structural integrity Additionally, the maximum deflection of 0.04469 inches remains within the allowable limits for the material, confirming the design's reliability.

The computer-aided simulation and analysis reveal that the new robotic system's arm base experiences a maximum stress of 19,097.23 psi, which is below the material's yield strength of 36,300 psi Additionally, the maximum deflection recorded is 0.23198 inches, remaining within the allowable deflection limits for the material.

Experiment on Robotic System for Industrial Applications

The kinematic motion of the robot arm in this robotic system is quantified using pulse-width modulation (PWM) techniques, which control the motors to achieve various orientations The subsequent tables illustrate the robot arm's movements in multiple directions, including forward, backward, left, right, upward, and downward.

Table7.1demonstrates the prototype testing results of PWM register as robot arm of this new robotic system moves to the front.

The prototype testing results of the PWM register confirm the proper functioning of the new robotic system's arm, as indicated in Table 7.1 The testing values align closely with the expected outcomes from computer-aided modeling and simulation, as illustrated in Fig 7.7.

Table7.2depicts the prototype experimental results of PWM register as robot arm of this new robotic system moves to the back.

Fig 7.15 Computer-aided simulation of deflection profile in the arm of new robotic system

The experimental results of the PWM register for the new robotic system confirm its functionality, as shown in Table 7.2, where the robot arm's movement to the back yields values consistent with those from computer-aided modeling and simulation, illustrated in Fig 7.8 Additionally, Table 7.3 presents the prototype testing results of the PWM register while the robot arm moves to the left.

Table 7.3 demonstrates that the robotic arm of the new system successfully moves to the left, with prototype testing results of the PWM register indicating normal functionality The testing values closely align with the simulated PWM register results obtained through computer-aided modeling and simulation, as illustrated in Fig 7.9.

Table7.4indicates the prototype experimental results of PWM register as robot arm of this new robotic system moves to the right.

Fig 7.16 Computer-aided simulation of stress profile in the link of new robotic system7.3 Experiment on Robotic System for Industrial Applications 121

The prototype experimental results for the PWM register confirm the effective operation of the robotic system, as the testing values closely align with the simulated results from computer-aided modeling and simulation Additionally, the testing outcomes indicate that as the robot arm moves upward, the PWM register performance remains consistent and reliable.

The experimental results of the PWM register for the new robotic system's arm, as shown in Table 7.5, indicate that the arm moves upward effectively The testing values align closely with the simulated PWM register results obtained through computer-aided modeling and simulation, as illustrated in Fig 7.11.

Table7.6displays the prototype experimental results of PWM register as robot arm of this new robotic system moves to the lower direction.

Fig 7.17 Computer-aided simulation of deflection profile in the link of new robotic system

The results in Table 7.6 indicate that as the robotic arm of the new system moves downward, the prototype testing of the PWM register confirms its normal functionality, with testing values closely matching the simulated PWM register results obtained through computer-aided modeling and simulation, as illustrated in Fig 7.12.

The kinematic motion of a newly prototyped robotic system demonstrates its ability to perform 3D movements, as evidenced by PWM register tracking Experimental results reveal that the robot arm can move 8.02 ft front to back, 12.05 ft left to right, and 10.04 ft top to bottom These findings closely align with previous computer-aided simulations, which indicated movements of 8 ft in the front-to-back direction, 12 ft left to right, and 10 ft top to bottom, showcasing the system's accuracy and reliability.

Fig 7.18 Computer-aided simulation of stress profile in the base of new robotic system7.3 Experiment on Robotic System for Industrial Applications 123

Fig 7.19 Computer-aided simulation of deflection profile in the base of new robotic system

Table 7.1 Prototype experimental results of

PWM register as robot arm moving to the front

Time (ms) PWM register 1 PWM register 2

The experiment aimed to evaluate the newly developed robotic system's structural integrity for various industrial applications, particularly in automated and high-speed manufacturing Rigorous strength and structure testing were conducted on key robotic components, with stress and deflection measurements detailed in the accompanying tables.

Table7.7demonstrates the experimental results of maximum stress and maximum deflection of robot arm in this new robotic system.

The prototype testing results for the robot arm, as shown in Table 7.7, demonstrate its normal functionality, with an average maximum stress of 22,421.56 psi and an average maximum deflection of 0.0110 in These values are in close alignment with the maximum stress recorded at 22,421.51 psi.

PWM register as robot arm moving to the back

PWM register as robot arm moving to the left

PWM register as robot arm moving to the right

7.3 Experiment on Robotic System for Industrial Applications 125

Table 7.5 Prototype testing results of PWM register as robot arm moving to the upper direction

Table 7.6 Prototype testing results of PWM register as robot arm moving to the lower direction

Table 7.7 Prototype testing results of maximum stress and maximum deflection of robot arm in this new robotic system

126 7 Robotic System maximum deflection 0.0105 in that are presented, respectively, in Figs.7.14and 7.15by computer-aided modeling and numerical simulation.

Table7.8demonstrates the experimental results of maximum stress and maximum deflection of robot arm link in this new robotic system.

The experimental results for the robot arm prototype, as shown in Table 7.8, confirm its functionality, with an average maximum stress of 22,634.93 psi and an average maximum deflection of 0.0452 in., closely matching the simulated values of 22,634.97 psi and 0.0447 in depicted in Figs 7.16 and 7.17 Additionally, Table 7.9 presents the experimental findings for the maximum stress and deflection of the robot arm base in this innovative robotic system.

The experimental results of the robot arm base, as shown in Table 7.9, validate its functionality, with an average maximum stress of 19,097.27 psi and an average maximum deflection of 0.2316 inches These values closely align with the computer-aided modeling and numerical simulation results, which report a maximum stress of 19,097.23 psi and a maximum deflection of 0.2320 inches, as illustrated in Figs 7.18 and 7.19.

Table 7.8 Prototype experimental results of maximum stress and maximum deflection of robot arm link in this new robotic system

7.3 Experiment on Robotic System for Industrial Applications 127

Discussion and Future Improvement on Robotic System

Increasingly, product companies are adopting robotic systems in their production processes due to the substantial business benefits they offer, despite some concerns about costs Robotic technology features advanced 3D visual manipulation and intuitive orientation with multiple degrees of freedom, which helps minimize human errors and enhances production quality However, improvements are still needed, particularly in operating complex systems across multiple quadrants and reducing overall costs To address these challenges, modifications should focus on creating cost-effective designs with easy maintenance, enhancing reliability, and utilizing computer-aided simulations to optimize energy and mechanical efficiency Ongoing prototype experiments aim to refine this robotic system, with plans for field evaluations to assess its performance.

Table 7.9 Prototype experimental results of maximum stress and maximum deflection of robot arm base in this new robotic system

Design of Magnetic Sealing System

Gas and lubrication oil leakages in reciprocating machinery, such as compressors and cooling units, significantly impact machine performance A novel magnetic sealing mechanism utilizing rare-earth magnet steel has been designed to effectively address these leakage issues Both computer-aided simulations and prototype tests confirm that this mechanism significantly reduces leaks compared to traditional sealing methods, including rubber seals, diaphragm seals, corrugated pipe seals, and magnetic fluid seals Visual representations of this innovative high-pressure gas compressive and filtration system are provided in Figures 8.1, 8.2, and 8.3, showcasing both 3D and 2D cross-sectional views.

The rare-earth magnet steel exhibits exceptional properties as a permanent magnet, characterized by a high density of magnetic flux (Br), a strong magnetic field (Hg), and a significant magnetism-energy product (BH) that effectively binds magnetic particles to its inner wall Key advantages of this magnetic sealing system include an increased Br in the magnetic circuit's working gap, enhanced durability and longevity in sealing performance, a compact design, lightweight configuration, improved efficiency, and reliable sealing functionality As the machine piston oscillates within the cylinder, lubricating oil is effectively sealed by the densely bonded magnetic particles on the magnet steel's inner surface This mechanism prevents oil droplets from entering the compressive gas cylinder, allowing them to settle by gravity in the crankshaft chamber, thereby minimizing gas leakage and ensuring optimal lubrication.

Designing an effective magnetic sealing system requires careful consideration of two key factors: magnetic flux density and material magnetic stability For optimal performance, the magnetic flux within the sealing mechanism's circuit must remain consistent over time, while the materials used should exhibit exceptional stability in their magnetic properties to ensure reliable functionality.

Fig 8.1 Full view of new high-pressure gas compressive and filtration system

Fig 8.2 3D cross-section view of new high-pressure gas compressive system

The innovative magnetic sealing system is designed to withstand external factors such as variations in magnetic fields, temperature fluctuations, mechanical vibrations, unexpected shocks, and severe environmental changes By optimizing the magnetic circuit design to achieve higher magnetic flux density (Br), increased magnetic field intensity (Hg), and a larger product of magnetism and energy (BH), the system ensures that these critical parameters remain at peak values for enhanced performance and reliability.

Computer-Aided Simulation on Magnetic

The magnetic circuit in the sealing mechanism operates under static conditions, allowing for the analysis of the functionality of rare-earth magnet steel through the ampere enclosed circuit and H–B curve This magnetic sealing system can be modeled as a series magnetic circuit, primarily comprising magnet steel and the sealing gap Relevant equations can be derived from the provided figure (Fig 8.3) as referenced by Ekren et al (2011).

The magnetic curve in magnetic circuit is shown in Fig.8.4.

To determine the magnetic flux in the sealing gap, identify the intersection point between the function {Fm(Φ)} and the line {[Lg/(U0Ag)]Φ} in the vertical coordinate system The sealing gap decreases from Lg to Lg' as additional magnetic particles are introduced into the magnetic circuit gap Furthermore, as the thickness of the magnetic particle layer between the contact surfaces of the magnet steel and the shaft varies from 0 to b, the operating point of the magnet steel also changes.

Fig 8.3 2D cross-section view of new high-pressure gas compressive system

8.2 Computer-Aided Simulation on Magnetic Sealing System 131 along the line QK and magnetic flux in sealing gap can be solved The coefficient of magnetic efficiencyηeff can be applied to verify if the magnetic field in sealing mechanism is correctly designed (Evans et al 2006): ηeffẳ Bg 2Vg

A higher ηeff value indicates a more reliable magnetic circuit design, with a standard ηeff value typically around 40% Computational simulations reveal that the ηeff value in the new magnetic sealing mechanism is 48.8%, confirming the effectiveness of the magnetic circuit design in this innovative system Additionally, the sealing capacity ΔP can be calculated using the energy balance law (Feil-Seifer et al 2007) Figure 8.5 illustrates the cross-section view of the magnetic steel used in this sealing system.

Based on diagram in Fig 8.5, R1ẳ sin 2 ð ị b α , R2ẳ sin 2 ð ị b β , S1ẳR1α, and

So, ΔSẳS2S1ẳh sin β ð ị β sin α ð ị α i

Since the work done by each magnetic force line equals to {TΔS}, total work done by all magnetic force lines in magnetic circuit is

And the work done by gaseous media pressure exerted to the body of magnetic particles is

Fig 8.4 Magnetic curve of circuit

According to the energy balance law, the work performed by magnetic force lines in a magnetic circuit must equal the work exerted by the pressure of gaseous media on magnetic particles This relationship highlights the equilibrium between magnetic forces and gas pressure in influencing magnetic particle behavior.

The equation can be effectively examined through computer-aided modeling and numerical simulation The stress and deflection profiles of key components in the innovative magnetic sealing system are illustrated in Figures 8.6 to 8.20.

The computer-aided simulation and analysis illustrated in Figs 8.7 and 8.8 reveal the stress and deflection characteristics of the aluminum adaptor in the innovative magnetic sealing system The findings indicate that the maximum stress experienced by the aluminum adaptor is 2,923.21 psi, which is below the material's yield strength, while the maximum deflection measured at 0.000016 inches remains within the permissible limits for material deflection.

The computer-aided simulation and analysis of the Armco iron ring in the new magnetic sealing system reveal that the maximum stress experienced is 2,428.89 psi, which is below the material's yield strength Additionally, the maximum deflection recorded is 0.00001 inches, remaining within the allowable deflection limits for the material.

The computer-aided simulation and analysis reveal the stress and deflection characteristics of the compressive unit in the innovative magnetic sealing system The findings show that the maximum stress of 19,376.24 psi is significantly below the material's yield strength of 36,000 psi, and the maximum deflection of 0.00105 inches remains within the allowable deflection limit for the material.

Fig 8.5 Cross-section view of magnetic steel

8.2 Computer-Aided Simulation on Magnetic Sealing System 133

The computer-aided simulation and analysis of the new magnetic sealing system demonstrate that the piston shaft experiences a maximum stress of 19,484.07 psi, which is below the material yield strength of 36,000 psi Additionally, the maximum deflection recorded is 0.00021 inches, well within the allowable deflection limit for the material.

Fig 8.7 Stress profile in aluminum adaptor

Fig 8.8 Deflection profile in aluminum adaptor

Fig 8.10 Stress profile in Armco iron ring

Fig 8.11 Deflection profile in Armco iron ring

Fig 8.13 Stress profile in compressive unit

Fig 8.14 Deflection profile in compressive unit

Fig 8.16 Stress profile in piston shaft

Fig 8.17 Deflection profile in piston shaft

Fig 8.18 Rare-earth magnetic steel

Fig 8.19 Stress profile in rare-earth magnetic steel

The computer-aided simulation and analysis illustrate the stress and deflection characteristics of rare-earth magnetic steel within a new magnetic sealing system The findings reveal that the maximum stress of 2,963.27 psi is below the material's yield strength, while the maximum deflection of 0.000005 inches remains within the allowable limits for the material.

The computational simulation results indicate that the maximum stresses on key components remain below the material yield stress, and the material deflections are within acceptable limits Additionally, the innovative magnetic sealing system effectively prevents oil leakage from the crankshaft chamber into the cooling system's gaseous chamber and reciprocating machinery These findings confirm that the newly developed magnetic sealing system performs efficiently, ensuring enhanced sealing functionality.

Fig 8.20 Deflection profile in rare-earth magnetic steel

Experiment on Magnetic Sealing System

The newly designed magnetic sealing system has been prototyped and tested, yielding results that closely align with computer-aided simulations As shown in Table 8.1, the prototype testing of the aluminum adaptor demonstrates an average maximum stress of 2,923.37 psi and an average maximum deflection of 0.00002 in., which are comparable to the simulated values of 2,923.21 psi and 0.00001 in presented in Figs 8.7 and 8.8 Additionally, Table 8.2 details the prototype testing results for the Armco iron ring within this innovative magnetic sealing system.

The prototype experimental results of the Armco iron ring, as shown in Table 8.2, validate its functionality, with an average maximum stress of 2,428.77 psi and an average maximum deflection of 0.00002 inches closely matching the computer-aided modeling results of 2,428.89 psi and 0.00001 inches, respectively, illustrated in Figs 8.10 and 8.11 Additionally, Table 8.3 presents the prototype testing results for the compressive unit in the new magnetic sealing system.

Table 8.1 Prototype testing of aluminum adaptor in this new magnetic sealing system

Table 8.2 Prototype testing of Armco iron ring in this new magnetic sealing system

Table 8.3 Prototype testing of compressive unit in this new magnetic sealing system

8.3 Experiment on Magnetic Sealing System 143

The prototype experimental results for the compressive unit demonstrate normal functionality, with an average maximum stress of 19,376.40 psi and an average maximum deflection of 0.00112 in., closely aligning with the computer-aided modeling and numerical simulation results of 19,376.24 psi and 0.00105 in., respectively Additionally, Table 8.4 presents the prototype testing results for the piston shaft within the new magnetic sealing system.

The experimental results of the piston shaft prototype confirm its proper functionality, with an average maximum stress of 19,484.22 psi and an average maximum deflection of 0.00015 in., closely aligning with the computer-aided modeling and numerical simulation results of 19,484.07 psi and 0.00021 in., respectively Additionally, Table 8.5 presents the testing outcomes for rare-earth magnetic steel used in the innovative magnetic sealing system.

The prototype experimental results of rare-earth magnetic steel demonstrate that the average maximum stress of 2,963.16 psi and average maximum deflection of 0.000012 in closely align with the computer-aided modeling and numerical simulation findings, which report a maximum stress of 2,963.27 psi and maximum deflection of 0.000006 in., as illustrated in Figs 8.19 and 8.20.

Table 8.4 Prototype testing of piston shaft in this new magnetic sealing system

Discussion and Future Improvement on Magnetic

A new magnetic sealing system has been developed to prevent liquid or gas leaks in machinery, enhancing performance and efficiency This innovative design features magnetic particles embedded in the gap between a rotating or reciprocating shaft and the internal wall of rare-earth magnetic steel, creating a dynamic seal that effectively prevents lubrication oil or gas leaks The system allows the shafts to operate with reduced friction in a non-contact manner, showcasing strong sealing capabilities in various machinery applications Additionally, the size of the sealing unit has been minimized due to fewer components Future enhancements will focus on optimizing the working gap geometry for improved magnetic flux, conducting computational simulations for design optimization, and exploring alternative materials to reduce costs.

Table 8.5 Prototype testing of rare-earth magnetic steel in this new magnetic sealing system

8.4 Discussion and Future Improvement on Magnetic Sealing System 145

Automated and High-Speed Packaging

Design of Automated and High-Speed Packaging

Automated packing machinery is gaining popularity across various industries as a means to reduce labor costs This innovative system streamlines the packaging process by automatically loading carton papers, forming them into square boxes, sealing both the bottom and top flaps after product insertion, printing labels, and offloading the packed boxes to the loading area on the production line The layout of this advanced automated packaging assembly system is illustrated in Figure 9.1, with a detailed description of the complete packaging production sequence provided.

Carton papers are transported via a loading channel where vacuum cups draw them into the production line A support plate aligns with the carton paper, ensuring it falls correctly for pickup The soft spring leaf on the support plate secures the carton while the square box opens Movable pushing plates then flatten the box flaps before sealing the bottom with a sealing mechanism After sealing, a left-side pushing plate advances the box to the next station for label printing, with a support plate ensuring labels are applied horizontally To seal the top flaps after product loading, a divider separates the long flaps, allowing the box to move towards the final curvature mechanism, which gradually closes the top flaps using front and rear curvatures.

The design features 147 long flaps that incorporate a combination of two vertical and one horizontal curvature, facilitating the gradual closure of short flaps Additionally, the rear curvature is utilized to ensure the gradual closing of the two long flaps The offloading mechanism efficiently transfers finished packing boxes to the product loading area, while the rejecting mechanism discards any packing boxes that exhibit defects during the packing process.

Computer-Aided Simulation on Automated

and High-Speed Packaging Machinery System

Automated packaging processes generate various loading forces such as vibration, insertion, and packing To ensure solid performance, computer-aided modeling and simulation are utilized to diagnose mechanism functions and verify component strength Vibration arises from multiple forces, including mass inertia and internal shock forces during kinematic movement Mathematical modeling provides critical insights into these dynamics, as demonstrated by the relevant equations (Isaev et al 2005; Kundu and Cohen 2008).

Here,M 0 ð ị ẳF B D OD P ð ị ð ị F F andM 00 ð ị ẳF B D BF P ð ị ð ị F F

DP(F)—Fourier transform of pushing device.

BOD(F)—Fourier transform of output delivery moving acceleration.

BBF(F)—Fourier transform of base frame acceleration.

Figures9.2,9.3,9.4,9.5,9.6,9.7,9.8,9.9,9.10,9.11,9.12,9.13,9.14,9.15,9.16, 9.17,9.18,9.19,9.20,9.21,9.22,9.23,9.24,9.25, and9.26display the computational simulation results in this new automated and high-speed packaging system. Fig 9.1 Fully automated packaging assembly system

148 9 Automated and High-Speed Packaging System

Fig 9.3 Stress profile in carton loading unit

9.2 Computer-Aided Simulation on Automated and High-Speed 149

Fig 9.4 Deflection profile in carton loading unit Fig 9.5 Carton separating unit

Fig 9.6 Stress profile in carton separating unit

Fig 9.7 Deflection profile in carton separating unit

Fig 9.9 Stress profile at base support in carton bottom closer

Fig 9.10 Deflection profile at base support in carton bottom closer

Fig 9.11 Stress profile at tension mechanism in carton bottom closer

Fig 9.12 Deflection profile at tension mechanism in carton bottom closer

Fig 9.14 Stress profile in labeling unit

Fig 9.15 Deflection profile in labeling unit

Fig 9.17 Stress profile at base support in carton top closer

Fig 9.18 Deflection profile at base support in carton top closer

Fig 9.19 Stress profile at tension mechanism in carton top closer

Fig 9.20 Deflection profile at tension mechanism in carton top closer

Fig 9.22 Stress profile in offloading unit

Fig 9.23 Deflection profile in offloading unit

Fig 9.25 Stress profile in rejecting unit

The computer-aided simulation and analysis depicted in Figs 9.3 and 9.4 illustrate the stress and deflection of the carton loading unit within the new automated, high-speed packaging system The findings reveal that the maximum stress of 16,596.73 psi is significantly below the material yield strength of 36,000 psi, while the maximum deflection of 0.00216 inches remains within the allowable deflection limit for the material.

The computer-aided simulation and analysis reveal that the carton separating unit in the new automated high-speed packaging system experiences a maximum stress of 18,255.09 psi, which is below the material yield strength of 36,000 psi Additionally, the maximum deflection recorded is 0.01607 inches, remaining within the allowable deflection limit for the material.

The computer-aided simulations presented in Figs 9.9 and 9.10 demonstrate the stress and deflection characteristics of the carton bottom closer in the new automated high-speed packaging system The analysis reveals that the maximum stress experienced by the carton bottom closer is 13,816.01 psi, which is below the material's yield strength, ensuring structural integrity during operation.

9.2 Computer-Aided Simulation on Automated and High-Speed 161 of 36,000 psi and maximum deflection of 0.00308 in is within material allowable deflection limit.

Computer-aided simulations reveal the stress and deflection characteristics of the tension mechanism in a carton bottom closer The analysis shows a maximum stress of 17,087.09 psi, which is below the material yield strength of 36,000 psi Additionally, the maximum deflection recorded is 0.00535 inches, well within the allowable limits for material deflection.

The computer-aided simulation and analysis of the labeling unit in the new automated high-speed packaging system reveal that the maximum stress is 17,615.54 psi, which is below the material yield strength of 36,000 psi Additionally, the maximum deflection of 0.00356 inches remains within the acceptable limits for material deflection.

The computer-aided simulation and analysis reveal that the maximum stress on the base support of the carton top closer in the new automated high-speed packaging system is 17,354.47 psi, which is below the material yield strength of 36,000 psi Additionally, the maximum deflection recorded is 0.00427 inches, well within the allowable deflection limit for the material.

The computer-aided simulation and analysis demonstrate the stress and deflection characteristics of the tension mechanism in the carton top closer of a new automated high-speed packaging system The findings reveal that the maximum stress of 17,270.99 psi is significantly lower than the material yield strength of 36,000 psi, and the maximum deflection of 0.00339 inches remains within the permissible deflection limits of the material.

The computer-aided simulation and analysis demonstrate the stress and deflection characteristics of the offloading unit in a new automated high-speed packaging system The findings reveal that the maximum stress experienced by the offloading unit is 17,964.43 psi, which is below the material's yield strength of 36,000 psi Additionally, the maximum deflection recorded is 0.00631 inches, well within the permissible limits for material deflection.

The computer-aided simulation and analysis of the rejecting unit in the new automated high-speed packaging system reveal that the maximum stress of 17,984.14 psi is below the material yield strength of 36,000 psi Additionally, the maximum deflection of 0.00421 inches is within the allowable limits for the material.

The computational simulation results indicate that the maximum stresses on critical components remain below the material yield stress, and the maximum deflections are within permissible deformation limits These findings validate the effectiveness of the newly developed automated high-speed packaging system for packaging applications.

Experiment on Automated and High-Speed Packaging

The newly developed automated high-speed packaging machinery system has undergone prototyping and testing to validate the outcomes of computer-aided simulations The results of the prototype testing for the carton loading unit in this innovative system are detailed in Table 9.1.

The prototype experimental results for the carton loading unit indicate proper functionality, with an average maximum stress of 16,595.84 psi and an average maximum deflection of 0.00242 inches, closely matching the computer-aided modeling results of 16,596.73 psi and 0.00216 inches, as shown in Figures 9.3 and 9.4 Additionally, Table 9.2 presents the testing results for the carton separating unit within this innovative automated high-speed packaging machinery system.

The prototype experimental results for the carton separating unit, as shown in Table 9.2, demonstrate its effective functionality, with an average maximum stress of 18,255.72 psi and an average maximum deflection of 0.01656 inches These values closely align with the computer-aided modeling and numerical simulation results, which indicate a maximum stress of 18,255.09 psi and a maximum deflection of 0.01607 inches, as illustrated in Figs 9.6 and 9.7 Additionally, Table 9.3 presents the testing outcomes for the base support of the carton bottom closer unit within this innovative automated and high-speed packaging machinery system.

Table 9.1 Prototype testing of carton loading unit in this new automated and high-speed packaging machinery system

9.3 Experiment on Automated and High-Speed Packaging Machinery System 163

Table 9.2 Prototype testing of carton separating unit in this new automated and high-speed packaging machinery system

Table 9.3 Prototype testing of base support of carton bottom closer unit in this new automated and high-speed packaging machinery system

The prototype experimental results for the carton bottom closer unit's base support demonstrate normal functionality, with an average maximum stress of 13,815.52 psi and an average maximum deflection of 0.00357 in These findings closely align with the computer-aided modeling and numerical simulation results, which indicate a maximum stress of 13,816.01 psi and a maximum deflection of 0.00308 in, as shown in Figs 9.9 and 9.10.

Table 9.4states the prototype testing results of tension mechanism of carton bottom closer unit in this new automated and high-speed packaging machinery system.

The prototype experimental results for the tension mechanism of the carton bottom closer unit confirm its proper functionality, with an average maximum stress of 17,087.60 psi and an average maximum deflection of 0.00486 in These values closely align with the computer-aided modeling and numerical simulation results, which indicate a maximum stress of 17,087.09 psi and a maximum deflection of 0.00535 in, as illustrated in Figs 9.11 and 9.12.

Table9.5demonstrates the prototype testing results of labeling unit in this new automated and high-speed packaging machinery system.

The experimental results of the labeling unit in Table 9.5 validate its functionality, with an average maximum stress of 17,616.12 psi and an average maximum deflection of 0.00314 inches, both closely aligning with the maximum stress results.

Table 9.4 Prototype testing of tension mechanism of carton bottom closer unit in this new automated and high- speed packaging machinery system

The computer-aided modeling and numerical simulation presented in Figs 9.14 and 9.15 show a maximum stress of 17,615.54 psi and a maximum deflection of 0.00356 in Table 9.6 details the prototype testing results for the base support of the carton top closer unit in the new automated, high-speed packaging machinery system The experimental results, with an average maximum stress of 17,354.02 psi and an average maximum deflection of 0.00468 in, closely align with the maximum stress of 17,354.47 psi and maximum deflection of 0.00427 in shown in Figs 9.17 and 9.18, confirming the normal function of the unit.

The prototype testing results for the tension mechanism of the carton top closer unit in the new automated high-speed packaging machinery system, as detailed in Table 9.7, confirm its effective performance The average maximum stress recorded is 17,270.49 psi, and the average maximum deflection is 0.00375 inches, which closely aligns with the computer-aided modeling and numerical simulation results of 17,270.99 psi for maximum stress and 0.00340 inches for maximum deflection, as shown in Figs 9.19 and 9.20.

Table 9.8 records the prototype testing results of offloading unit in this new automated and high-speed packaging machinery system.

Table 9.5 Prototype testing of labeling unit in this new automated and high-speed packaging machinery system

Table 9.7 Prototype testing of tension mechanism of carton top closer unit in this new automated and high-speed packaging machinery system

Table 9.6 Prototype testing of base support of carton top closer unit in this new automated and high-speed packaging machinery system

The prototype experimental results of the offloading unit, as shown in Table 9.8, validate its functionality, with an average maximum stress of 17,963.96 psi and an average maximum deflection of 0.00601 in These values are closely aligned with the computer-aided modeling and numerical simulation results, which indicate a maximum stress of 17,964.43 psi and a maximum deflection of 0.00631 in, as illustrated in Figs 9.22 and 9.23.

Table 9.9 states the prototype testing results of rejecting unit in this new automated and high-speed packaging machinery system.

The prototype experimental results for the rejecting unit demonstrate its normal functionality, with an average maximum stress of 17,984.53 psi and an average maximum deflection of 0.00455 in These values closely align with the maximum stress of 17,984.14 psi and maximum deflection of 0.00421 in obtained through computer-aided modeling and numerical simulation, as illustrated in Figs 9.25 and 9.26.

Table 9.8 Prototype testing of offloading unit in this new automated and high-speed packaging machinery system

Discussion and Future Improvement on Automated

and High-Speed Packaging Machinery Systems

Automated packaging machines are advanced multi-axis systems designed to efficiently manipulate components for final product packaging These machines significantly reduce the need for human labor, cutting costs while enhancing packing quality and boosting productivity Technological advancements have simplified the design of automatic packing machines, enabling precise and flexible operations Future developments will prioritize quick changeovers for different product packaging, streamlined tool and fixture adjustments, continuous workflow maintenance, balanced production lines, and easy equipment installation.

Table 9.9 Prototype testing of rejecting unit in this new automated and high-speed packaging machinery system

9.4 Discussion and Future Improvement on Automated and High-Speed 169

Biomedical Systems

Design of Biomedical and Surgical Systems

The innovative design of the open surgical instrument features an enhanced surgiclip delivery mechanism that surpasses traditional instruments The surgiclips are advanced to the front jaw pair via a distal movement of the surgiclip pusher, which is easily controlled by the instrument handles When surgeons operate the handles together, the surgiclip is propelled forward and fully formed as it is guided into the front jaw pair Upon releasing the handles, the surgiclip pusher automatically returns to its starting position, ready to load the next surgiclip for subsequent firing This streamlined advancing process reduces the need for precise dimensional tolerance in component manufacturing, preventing clip drop-off, simplifying production, increasing output, and lowering costs.

This innovative biomedical instrument is designed for precise placement on patient tissues, allowing surgeons to securely clamp them by manipulating the instrument's handles Once the handles are released, the front jaw pair opens, and the surgiclip pusher returns to its original position Unlike traditional mechanisms that rely on compression springs, which can lead to accidental dislodging of surgiclips, this new design ensures smooth and reliable movement of the surgiclip into the guiding track The driving mechanism, connected to the instrument's pivot point, effectively advances the surgiclip, enhancing control and accuracy during surgical procedures.

The newly designed biomedical instrument features a guiding track for the jaw pair, allowing surgeons to smoothly manipulate the surgiclip by bringing the instrument handles together Extensive prototype testing has confirmed the instrument's stability and reliability, with no instances of surgiclip drop-off Additionally, this innovative design requires less hand force to operate compared to traditional surgiclip instruments, enhancing surgical efficiency and safety.

Fig 10.1 New open surgiclip biomedical instrument

Fig 10.2 Internal structure of new open surgiclip biomedical instrument

The newly designed Endo Surgiclip biomedical instrument, illustrated in Figures 10.3, 10.4, and 10.5, is capable of delivering multiple surgiclips through a front jaw guiding channel The surgiclips, positioned lower within the instrument, are directed to move vertically along a curved channel by a moving block, which is activated by a surgiclip pusher To ensure there is no gap between the surgiclips, the moving block must maintain continuous contact with the last surgiclip, allowing for a one-way distal movement.

Fig 10.3 Endo surgiclip biomedical instrument—view 1

Fig 10.4 Endo surgiclip biomedical instrument—view 2

10.1 Design of Biomedical and Surgical Systems 175

The moving block comprises a block holder and two snaps, powered by top and bottom compression springs The top snap engages with the fixed gear rack, while the bottom snap interacts with a movable gear rack that allows vertical movement.

The movable gear rack initiates movement from right to left, with the bottom snap engaging the teeth of the gear rack while the top snap glides over them In step one, the moving block remains stationary relative to the gear rack, although the block holder shifts Step two sees the moving block advance distally as the gear rack halts When the gear rack reverses direction to the right, the top snap locks into the block holder's teeth, and the bottom snap moves distally over the gear rack's teeth In step three, the moving block remains still relative to the block holder, while the gear rack shifts in relation to the moving block Finally, in step four, the gear rack returns to its starting position, with both snaps engaging its teeth Throughout this cyclic process from steps one to four, the movable block travels one clip distance along the surgiclip track.

The innovative design of the driving mechanism allows for the one-way movement of the moving block along the distal motion of surgiclips Each surgiclip measures 0.256 inches in length, necessitating a travel distance of 0.276 inches for proper engagement As the surgiclips move distally by one clip distance, the foremost surgiclip is pushed into the guiding channel of the instrument's jaw pair for further processing The surgiclip pusher, driven by the mechanism, moves distally to deliver a surgiclip and then travels proximally to retrieve the next one In this design, the front section of the pusher delivers the surgiclip into the jaw pair, while the rear section connects to the driving mechanism, requiring a distal movement of 0.98 inches from its original position.

The biomedical and surgical systems are designed to accurately position each surgiclip within the guiding channel of the jaw pair, allowing for proximal movement back to its original position to retrieve the net surgiclip The driving mechanism provides a pusher movement of 0.98 inches and generates the necessary forces to counteract friction and the weight of all components, including the movable gear rack, moving block, block holder, and surgiclip pusher.

Computer-Aided Simulation on Biomedical

The computer-aided simulations on biomedical open surgiclip instrument and biomedical endoscopic surgiclip instrument are described as follows.

The mathematic equation of force and energy balance in this new biomedical open surgiclip instrument design can be demonstrated as follows (Kundu and Cohen 2008):

Referring the geometry design of this new instrument:

The different operation forcePfingercan be determined by combining different

Computer-aided simulations reveal that the optimal values for LR and W in the new biomedical instrument are 4.78 inches and 2.18 inches, respectively This combination is expected to enhance the instrument's performance significantly.

Pfinger4:78ẳPpivot2:1810.2 Computer-Aided Simulation on Biomedical and Surgical Systems 177

The ratio of angular speed to linear speed (Gangular/Glinear) can be effectively analyzed through computer-aided simulations to optimize instrument performance The mechanical advantage of this innovative biomedical instrument is assessed when the instrument handle is completely closed.

The study reveals that to fully form the biomedical surgiclip, a force of 20 lbf is necessary, while surgeons only need to apply 3.34 lbf to close the instrument handle, which is below the standard requirement of 4 lbf in surgical procedures This reduction in force simplifies the tasks for doctors and surgeons during medical treatments and surgical operations.

Figures10.6,10.7,10.8,10.9,10.10,10.11,10.12,10.13,10.14,10.15,10.16, 10.17,10.18,10.19,10.20,10.21,10.22,10.23,10.24,10.25,10.26,10.27,10.28, 10.29, 10.30, and 10.31 display the stress and deflection profiles of critical components in this new biomedical open surgiclip instrument.

Computer-aided simulations reveal the stress and deflection characteristics of the driving gear in a novel biomedical open surgical instrument The analysis indicates that the maximum stress experienced by the driving gear is 23,663.32 psi, which is below the material's yield strength of 36,000 psi Additionally, the maximum deflection measured at 0.00077 inches falls within the permissible limits for material deflection.

The computer-aided simulation and analysis of the new biomedical open surgical instrument demonstrate that the trigger experiences a maximum stress of 1,380.27 psi, which is below the material's yield strength Additionally, the maximum deflection recorded is 0.00077 inches, remaining within the allowable deflection limit for the material.

Fig 10.7 Stress profile of driving gear

Fig 10.8 Deflection profile of driving gear

Fig 10.10 Stress profile of trigger

The following diagram shows the stress profile of internal driving shaft when surgeon manipulates patient body tissues during surgical procedures.

The computer-aided simulation and analysis illustrated in Figures 10, 13, and 14 demonstrate the stress and deflection experienced at the front end of the internal shaft in this innovative biomedical open surgical instrument The analytical findings reveal that the maximum stress levels are critical for ensuring the instrument's performance and safety.

Fig 10.11 Deflection profile of trigger

Fig 10.12 Instrument front end of internal shaft

10.2 Computer-Aided Simulation on Biomedical and Surgical Systems 181

Fig 10.13 Stress profile of instrument front end of internal shaft

Fig 10.14 Deflection profile of instrument front end of internal shaft

Fig 10.16 Stress profile of instrument internal shaft

Fig 10.17 Deflection profile of instrument internal shaft

Fig 10.18 Instrument jaw in closing tissue

Fig 10.19 Stress profile of instrument jaw in closing tissue

Fig 10.20 Deflection profile of instrument jaw in closing tissue

Fig 10.21 Stress profile of instrument jaw in thick tissue manipulation

Fig 10.22 Deflection profile of instrument jaw in thick tissue manipulation

Fig 10.24 Stress profile of instrument surgiclip pusher

Fig 10.25 Deflection profile of instrument surgiclip pusher

Fig 10.27 Stress profile of instrument external shaft

Fig 10.28 Deflection profile of instrument external shaft

Fig 10.30 Stress profile of driving link

23,110.67 psi in this front end of internal shaft is less than the material yield strength of 36,000 psi and maximum deflection of 0.00144 in is within material allowable deflection limit.

The following diagram shows the stress profile of internal driving shaft when surgeon delivers surgiclips distally during surgical procedures.

The computer-aided simulation and analysis of the new biomedical open surgical instrument reveal that the internal shaft experiences a maximum stress of 22,542.71 psi, which is below the material yield strength of 36,000 psi Additionally, the maximum deflection recorded is 0.00152 inches, remaining within the allowable deflection limit for the material.

The following diagram shows the stress profile of instrument front jaw when surgeon forms the surgiclips during surgical procedures.

The computer-aided simulations presented in Figs 10.19 and 10.20 reveal the stress and deflection characteristics of the front jaw (closing tissue) in a novel biomedical open surgical instrument The analysis indicates that the maximum stress observed is detailed in Fig 10.31, which illustrates the deflection profile of the driving link.

16,300.16 psi in this front jaw (closing tissue) is less than the material yield strength of 36,000 psi and maximum deflection of 0.00421 in is within material allowable deflection limit.

The following diagram shows the stress profile of instrument front jaw when surgeon manipulates the thick tissues during surgical procedures.

The computer-aided simulation and analysis of the new biomedical open surgical instrument demonstrate that the front jaw, designed for thick tissue manipulation, experiences a maximum stress of 23,995.81 psi, which is below the material yield strength of 36,000 psi Additionally, the maximum deflection recorded is 0.00875 inches, well within the allowable deflection limits for the material used.

The following diagram shows the stress profile of instrument surgiclip driving pusher when surgeon delivers the surgiclip during surgical procedures.

The computer-aided simulations and analyses illustrated in Figs 10.24 and 10.25 reveal the stress and deflection characteristics of the surgiclip pusher in this innovative biomedical open surgical instrument The findings indicate that the maximum stress experienced by the surgiclip pusher is 21,389.27 psi, which is below the material's yield strength of 36,000 psi Additionally, the maximum deflection measured is 0.03106 inches, remaining within the allowable deflection limits for the material.

The following diagram shows the stress profile of instrument external shaft when surgeon manipulates patient tissues during surgical procedures.

Computer-aided simulations reveal that the external shaft of the new biomedical open surgical instrument experiences a maximum stress of 23,481.61 psi, which is below the material yield strength of 36,000 psi Additionally, the maximum deflection recorded is 0.00675 inches, well within the allowable limits for the material The accompanying diagram illustrates the stress profile of the instrument driver link during surgical operations, highlighting its performance under real-world conditions.

The computer-aided simulation and analysis illustrate the stress and deflection of the driving link in a new biomedical open surgical instrument The findings indicate that the maximum stress of 24,154.42 psi is below the material yield strength of 36,000 psi, while the maximum deflection of 0.00049 inches remains within the allowable deflection limit for the material.

The computer-aided simulation results indicate that the maximum stresses on critical components are below the material yield stress, and the maximum material deflections are within allowable deformation limits These analytic solutions validate the effective performance and reliable quality of the newly developed biomedical open surgiclip instrument.

Computer-aided kinematic simulations were conducted on the innovative biomedical endoscopic surgiclip instrument to identify the optimal system design, with the analytical results illustrated in Fig 10.32.

The analysis of various instrument setups, informed by computational simulations, indicates that the optimal system design is attained when the mechanical advantage of the new instrument reaches 2.878, as demonstrated in the equation presented by White (2003).

Tiêu đề	CAD, 3D Modeling, Engineering Analysis, and Prototype Experimentation Industrial and Research Applications
Tác giả	Jeremy Zheng Li
Trường học	University of Bridgeport
Thể loại	thesis
Năm xuất bản	2015
Thành phố	Bridgeport

Định dạng
Số trang	254
Dung lượng	12,51 MB