MECHANICAL SYSTEMS DESIGN HANDBOOK THE Modeling, Measurement, and Control © 2002 by CRC Press LLC The Electrical Engineering Handbook Series Series Editor Richard C. Dorf University of California, Davis Titles Included in the Series The Avionics Handbook, Cary R. Spitzer The Biomedical Engineering Handbook, 2nd Edition, Joseph D. Bronzino The Circuits and Filters Handbook, Wai-Kai Chen The Communications Handbook, Jerry D. Gibson The Control Handbook, William S. Levine The Digital Signal Processing Handbook, Vijay K. Madisetti & Douglas Williams The Electrical Engineering Handbook, 2nd Edition, Richard C. Dorf The Electric Power Engineering Handbook, Leo L. Grigsby The Electronics Handbook, Jerry C. Whitaker The Engineering Handbook, Richard C. Dorf The Handbook of Formulas and Tables for Signal Processing, Alexander D. Poularikas The Industrial Electronics Handbook, J. David Irwin The Measurement, Instrumentation, and Sensors Handbook, John G. Webster The Mechanical Systems Design Handbook, Osita D.I. Nwokah The RF and Microwave Handbook, Mike Golio The Mobile Communications Handbook, 2nd Edition, Jerry D. Gibson The Ocean Engineering Handbook, Ferial El-Hawary The Technology Management Handbook, Richard C. Dorf The Transforms and Applications Handbook, 2nd Edition, Alexander D. Poularikas The VLSI Handbook, Wai-Kai Chen The Mechatronics Handbook, Robert H. Bishop The Computer Engineering Handbook, Vojin Oklobdzija Forthcoming Titles The Circuits and Filters Handbook, 2nd Edition, Wai-Kai Chen The Handbook of Ad hoc Wireless Networks, Mohammad Ilyas The Handbook of Optical Communication Networks, Mohammad Ilyas The Handbook of Nanoscience, Engineering, and Technology, William A. Goddard, Donald W. Brenner, Sergey E. Lyshevski, and Gerald J. Iafrate © 2002 by CRC Press LLC CRC PRESS Boca Raton London New York Washington, D.C. OSITA D. I. NWOKAH YILDIRIM HURMUZLU Southern Methodist University Dallas, Texas MECHANICAL SYSTEMS DESIGN HANDBOOK THE Modeling, Measurement, and Control This book contains information obtained from authentic and highly regarded sources. Reprinted material is quoted with permission, and sources are indicated. A wide variety of references are listed. Reasonable efforts have been made to publish reliable data and information, but the authors and the publisher cannot assume responsibility for the validity of all materials or for the consequences of their use. Neither this book nor any part may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, microfilming, and recording, or by any information storage or retrieval system, without prior permission in writing from the publisher. All rights reserved. Authorization to photocopy items for internal or personal use, or the personal or internal use of specific clients, may be granted by CRC Press LLC, provided that $1.50 per page photocopied is paid directly to Copyright Clearance Center, 222 Rosewood Drive, Danvers, MA 01923 USA The fee code for users of the Transactional Reporting Service is ISBN 0-8493-8596-2/02/$0.00+$1.50. The fee is subject to change without notice. For organizations that have been granted a photocopy license by the CCC, a separate system of payment has been arranged. The consent of CRC Press LLC does not extend to copying for general distribution, for promotion, for creating new works, or for resale. Specific permission must be obtained in writing from CRC Press LLC for such copying. Direct all inquiries to CRC Press LLC, 2000 N.W. Corporate Blvd., Boca Raton, Florida 33431. Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are used only for identification and explanation, without intent to infringe. Visit the CRC Press Web site at www.crcpress.com © 2002 by CRC Press LLC No claim to original U.S. Government works International Standard Book Number 0-8493-8596-2 Library of Congress Card Number 2001043150 Printed in the United States of America 1 2 3 4 5 6 7 8 9 0 Printed on acid-free paper Library of Congress Cataloging-in-Publication Data The Mechanical systems design handbook : modeling, measurement, and control / edited by Osita D.I. Nwokah, Yildirim Hurmuzlu. p. cm. -- (The Electrical engineering handbook series) Includes bibliographical references and index. ISBN 0-8493-8596-2 (alk. paper) 1. Production engineering. 2. Manufacturing processes. I. Nwokah, Osita D. I. II. Hurmuzlu, Yildirim. III. Series. TS176 .M42 2001 658.5--dc21 2001043150 8596_frame_FM Page iv Monday, November 12, 2001 1:29 PM Preface This handbook is targeted as a reference for the use of engineers and scientists in industry. We have compiled a collection of selected topics that are directly related to the design and control of mechanical systems. The main motivation for the book is to present a practical overview of fundamental issues associated with design and control of mechanical systems. The reader will find four sections in the handbook: (1) Manufacturing, (2) Vibration Control, (3) Aerospace Systems, and (4) Robotics. Although the sections are arranged in a certain order, each contribution can stand alone to represent its subject. Thus, people can read the handbook in any order they see fit. The late Professor Osita Nwokah envisioned this project. Unfortunately, he could not see it through to completion. Professor Nwokah was the chairman of the mechanical engineering department at South- ern Methodist University and a distinguished member of the control community when he passed away on April 20, 1999. It was important to me to finish one of Professor Nwokah’s last projects. The reader will find a broad range of thoroughly covered important topics by well-known experts in their respective fields. Section I encompasses control issues related to manufacturing systems including several topics from precision manufacturing to machine vibrations. Section II deals with active vibration control including a diverse spectrum of topics such as suspension systems and piezoelectric networks. Section III touches upon aerospace systems, and the authors have presented a detailed analysis of tensegrity structures. Section IV covers robotics and is an encyclopedic review of most issues related to the control and design of robotic systems. It has been a pleasure to work with the four section editors, each a renowned international expert in his respective area. They, in turn, recruited very competent people who wrote chapters that, in my view, are individually important contributions to the design and control of mechanical systems. I also thank the people at CRC Press whose energy and constant support were essential to the completion of this handbook. I especially thank Nora Konopka who has spent numerous hours developing and producing this handbook. Yildirim Hurmuzlu Dallas, Texas 8596_frame_FM Page v Monday, November 12, 2001 1:29 PM © 2002 by CRC Press LLC Editors Yildirim Hurmuzlu currently serves as the Chairman of the Department of Mechanical Engineering at Southern Methodist University in Dallas, Texas. He has been with the department since 1987, and has served as assistant, associate, and full professor. Dr. Hurmuzlu's research interests are in the field of dynamic systems and controls, with particular emphasis on robotics and biomechanics. His research has been supported by the National Science Foundation, Whitaker Foundation, and Texas National Labora- tory Commission, and industrial corporations such as Bell Helicopter, Raytheon, Saudi Aramco, and Alcatel Corp. He has authored more than 50 articles in journals and conference proceedings and has organized sessions at national and international conferences. Dr. Hurmuzlu is an associate editor of the ASME Journal of Dynamic Systems Measurement and Control . He has also served as the chairman of IEEE Dallas–Fort Worth Control Systems Society and the ASME DSC biomechanics panel. Osita Nwokah was a leading international authority on the application of multivariable design methods for the control of high-performance, high-bypass ratio turbomachinery. As a graduate student at the University of Manchester Institute of Science and Technology (UMIST), Manchester, England, he was a member of the team that wrote the initial control algorithms for the regulation of the Rolls Royce Concordce Olympus 925 Engines using the inverse Nyquist array in 1971. After moving to the United States, Dr. Nwokah continued this line of work and developed fundamental methodologies to combine the inverse Nyquist array with the quantitative feedback theory (QFT) design method of Horowitz. At the time of his death, Dr. Nwokah was studying multivariable control design and implementation for the RASCAL Helicopter for NASA and U.S. Army at NASA Ames RC, Moffet Field, California. 8596_frame_FM Page vii Monday, November 12, 2001 1:29 PM © 2002 by CRC Press LLC Contributors Rajesh Adhikari Department of Mechanical and Aerospace Engineering University of California, San Diego La Jolla, CA Yusuf Altintas Department of Mechanical Engineering The University of British Columbia Vancouver, B.C., Canada Antal K. Bejczy Jet Propulsion Lab California Institute of Technology Pasadena, CA Branislav Borova´c Faculty of Technical Sciences University of Novi Sad Novi Sad, Yugoslavia Frederic Bossens Université Libre de Bruxelles Brussels, Belgium Waileung Chan Department of Mechanical and Aerospace Engineering University of California, San Diego La Jolla, CA Kourosh Danai Department of Mechanical and Industrial Engineering University of Massachusetts Amherst, MA Darren M. Dawson Electrical and Computer Engineering Clemson University Clemson, SC Richard J. Furness Advanced Manufacturing Technology Development Ford Motor Company Detroit, MI Martin Hägele Fraunhofer Institute Stuttgart, Germany David E. Hardt Professor of Mechanical Engineering Massachusetts Institute of Technology Cambridge, MA J. William Helton Department of Mathematics University of California, San Diego La Jolla, CA Martin Hosek University of Connecticut Storrs, CT S. Jack Hu Department of Mechanical Engineering University of Michigan Ann Arbor, MI Yildirim Hurmuzlu Department of Mechanical Engineering Southern Methodist University Dallas, TX Kenji Inoue Department of Systems and Human Science Osaka University Osaka, Japan Nader Jalili Department of Mechanical Engineering Clemson University Clemson, SC Elijah Kannatey-Asibu, Jr. Department of Mechanical Engineering University of Michigan Ann Arbor, MI 8596_frame_FM Page ix Monday, November 12, 2001 1:29 PM © 2002 by CRC Press LLC Branko Karan Mihajlo Pupin Institute Belgrade, Yugoslavia Dusko M. Kati´c Mihajlo Pupin Institute Belgrade, Yugoslavia David Kazmer Department of Mechanical and Industrial Engineering University of Massachusetts Amherst, MA P. P. Khargonekar Department of Electrical Engineering and Computer Science University of Michigan Ann Arbor, MI Nenad M. Kircanski University of Toronto Toronoto, Ontario, Canada Yoram Koren Department of Mechanical Engineering University of Michigan Ann Arbor, MI Willi Kortüm German Aerospace Research Establishment Wessling, Germany Thomas R. Kurfess The George W. Woodruff School of Mechanical Engineering Georgia Institute of Technology Atlanta, GA Robert G. Landers Department of Mechanical Engineering and Mathematics University of Missouri Rolla, MO Nicolas Loix Micromega Dynamics Angleur, Belgium M. G. Mehrabi Department of Mechanical Engineering University of Michigan Ann Arbor, MI D. L. Mingori Department of Mechanical and Aerospace Engineering University of California Los Angeles, CA Siddharth P. Nagarkatti Lucent Technologies Sturbridge, MA Osita D. I. Nwokah Department of Mechanical Engineering Southern Methodist University Dallas, TX Nejat Olgac Department of Mechanical Engineering University of Connecticut Storrs, CT Jean-Paul Pinaud Department of Mechanical and Aerospace Engineering University of California La Jolla, CA Veljko Potkonjak University of Belgrade Belgrade, Yugoslavia A. Preumont Université Libre de Bruxelles Brussels, Belgium Rolf Dieter Schraft Fraunhofer Institute Stuttgart, Germany Bruno Siciliano Universita degli Studi di Napoli Frederico II Naples, Italy Robert E. Skelton Department of Mechanical and Aerospace Engineering University of California La Jolla, CA Dragan Stoki´c ATB–Institute für Angewandte Systemtechnik Bremen, Germany Dragoljub ˇ Surdilovi´c Fraunhofer Institute Stuttgart, Germany Masaharu Takano Department of Industrial Engineering Kansai University Osaka, Japan D. M. Tilbury Department of Mechanical Engineering University of Michigan Ann Arbor, MI 8596_frame_FM Page x Monday, November 12, 2001 1:29 PM © 2002 by CRC Press LLC A. Galip Ulsoy Department of Mechanical Engineering University of Michigan Ann Arbor, MI Michael Valásˇ ek Czech Technical University Prague, Czech Republic Miomir Vukobratovic´ Mihajlo Pupin Institute Belgrade, Yugoslavia Kon-Well Wang Structural Dynamics and Controls Lab Pennsylvania State University University Park, PA Derek Yip-Hoi Department of Mechanical Engineering University of Michigan Ann Arbor, MI 8596_frame_FM Page xi Monday, November 12, 2001 1:29 PM © 2002 by CRC Press LLC Contents SECTION I Manufacturing 1 Manufacturing Systems and Their Design Principles 1.1 Introduction 1.2 Major Manufacturing Paradigms and Their Objectives 1.3 Significance of Functionality/Capacity Adjustments in Modern Manufacturing Systems 1.4 Critical Role of Computers in Modern Manufacturing 1.5 Design Principles of Modern Manufacturing Systems 1.6 Future Trends and Research Directions Selected References 2 Computer-Aided Process Planning for Machining Abstract 2.1 Introduction 2.2 What Is Computer-Aided Process Planning (CAPP)? 2.3 Review of CAPP Systems 2.4 Drivers of CAPP System Development 2.5 Characteristics of CAPP Systems 2.6 Integrating CAD with CAPP: Feature Extraction 2.7 Integrating CAPP with Manufacturing 2.8 CAPP for New Domains 2.9 Conclusions References 3 Discrete Event Control of Manufacturing Systems 3.1 Introduction 3.2 Background on the Logic Control Problems 3.3 Current Industrial Practice 3.4 Current Trends 3.5 Formal Methods for Logic Control 3.6 Further Reading Acknowledgments References 8596_frame_FM Page xiii Monday, November 12, 2001 1:29 PM © 2002 by CRC Press LLC [...]... Monitoring and Control 6.5 Other Process Phenomena 6.6 Future Direction and Efforts Acknowledgments References 7 Forming Processes: Monitoring and Control 7.1 Introduction: Process and Control Objectives 7.2 The Plant or Load: Forming Physics 7.3 Machine Control 7.4 Machine Control: Force or Displacement? 7.5 Process Resolution Issues: Limits to Process Control 7.6 Direct Shape Feedback and Control 7.7... and Welding Processes and Their Monitoring and Control 8.1 Assembly Processes 8.2 Monitoring and Control of Resistance Welding Process 8.3 Monitoring and Control of Arc Welding Processes References 9 Control of Polymer Processing 9.1 9.2 Introduction Process Description © 2002 by CRC Press LLC 8596_frame_FM Page xv Monday, November 12, 2001 1:29 PM 9.3 Process Variability 9.4 Modeling 9.5 Process Control. .. Dynamics and Vibrations 4.1 Introduction 4.2 Chatter Vibrations in Cutting 4.3 Analytical Prediction of Chatter Vibrations in Milling References 5 Machine Tool Monitoring and Control 5.1 Introduction 5.2 Process Monitoring 5.3 Process Control 5.4 Conclusion References 6 Process Monitoring and Control of Machining Operations 6.1 Introduction 6.2 Force/Torque/Power Generation 6.3 Forced Vibrations and Regenerative... Calculation of Transformation Matrices References 21 Actuators and Computer-Aided Design of Robots 21.1 Robot Driving Systems 21.2 Computer-Aided Design References 22 Control of Robots 22.1 Introduction 22.2 Hierarchical Control of Robots 22.3 Control of a Single Joint of the Robot 22.4 Control of Simultaneous Motion of Several Robot Joints References 23 Control of Robotic Systems in Contact Tasks 23.1 Introduction... Piezoelectric Network Treatments for General Modal Damping and Control 15.4 Active-Passive Hybrid Piezoelectric Network Treatments for Narrowband Vibration Suppression 15.5 Nonlinear Issues Related to Active-Passive Hybrid Piezoelectric Networks 15.6 Summary and Conclusions Acknowledgments References 16 Vibration Reduction via the Boundary Control Method 16.1 Introduction 16.2 Cantilevered Beam 16.3... Introduction 23.2 Contact Tasks 23.3 Classification of Robotized Concepts for Constrained Motion Control 23.4 Model of Robot Performing Contact Tasks 23.5 Passive Compliance Methods 23.6 Active Compliant Motion Control Methods 23.7 Contact Stability and Transition 23.8 Synthesis of Impedance Control at Higher Control Levels 23.9 Conclusion References 24 Intelligent Soft-Computing Techniques in Robotics... Neuro-Fuzzy Approach in Robotics 24.6 Genetic Approach in Robotics 24.7 Conclusion References 25 Teleoperation and Telerobotics 25.1 Introduction 25.2 Hand Controllers © 2002 by CRC Press LLC 8596_frame_FM Page xix Monday, November 12, 2001 1:29 PM 25.3 FRHC Control System 25.4 ATOP Computer Graphics 25.5 ATOP Control Experiments 25.6 Anthropomorphic Telerobotics 25.7 New Trends in Applications Acknowledgment... Dynamics of Mobile Robots 26.4 Control of Mobile Robots References 27 Humanoid Robots 27.1 Zero-Moment Point — Proper Interpretation 27.2 Modeling of Biped Dynamics and Gait Synthesis 27.3 Control Synthesis for Biped Gait 27.4 Dynamic Stability Analysis of Biped Gait 27.5 Realization of Anthropomorphic Mechanisms and Humanoid Robots 27.6 Conclusion References 28 Present State and Future Trends in Mechanical... Applications References 14 Active Vibration Absorption and Delayed Feedback Tuning 14.1 Introduction 14.2 Delayed Resonator Dynamic Absorbers 14.3 Multiple Frequency ATVA and Its Stability Acknowledgments References 15 Vibration Suppression Utilizing Piezoelectric Networks 15.1 Introduction 15.2 Passive and Semi-Active Piezoelectric Networks for Vibration Absorption and Damping 15.3 Active-Passive Hybrid Piezoelectric... Applied to Machine Tools 10.2 Basic Definitions 10.3 Motion 10.4 Sources of Error and Error Budgets 10.5 Some Typical Methods of Measuring Errors 10.6 Conclusion 10.7 Terminology References SECTION II 11 Vibration Control Active Damping of Large Trusses Abstract 11.1 Introduction 11.2 Active Struts 11.3 Active Tendon Control 11.4 Active Damping Generic Interface 11.5 Microvibrations 11.6 Conclusions . Limits to Process Control 7.6 Direct Shape Feedback and Control 7.7 Summary References 8 Assembly and Welding Processes and Their Monitoring and Control 8.1. The Measurement, Instrumentation, and Sensors Handbook, John G. Webster The Mechanical Systems Design Handbook, Osita D.I. Nwokah The RF and Microwave Handbook,