Energy Efficient Parallel Configuration Based Six Degree of Freedom Machining Bed

Abstract

The process of material removal from a workpiece to obtain the desired shape is termed machining. Present-day material removal technologies have high spindle speeds and thus allow quick material removal. These high-speed spindles are highly exposed to vibrations and, as a result, the accuracy of the final workpiece’s dimensions is compromised. To overcome this problem, the motion of the tool is restricted, and multiple degrees of freedom are given through the motion of the workpiece in different axes. A machining bed configured as a parallel manipulator capable of giving six degrees of freedom (DOF) to the workpiece is proposed in this regard. However, the proposed six DOF machining bed should be energy efficient to avoid an increase in machining cost. The benefit of using the proposed configuration is a reduction in dimensional error and computational time which, as a result, reduces the energy utilization, vibrations, and machining time in practice. This paper presents kinematics, dynamics and energy efficiency models, and the development of the proposed configuration of the machining bed. The energy efficiency model is derived from the dynamics model. The models are verified in simulation and experimentally. To minimize error and computation time, a PID controller is also designed and tested in simulation as well as experimentally. The resulting energy efficiency is also analyzed. The results verify the efficacy of the proposed configuration of the machining bed, minimizing position error to 2% and reducing computation time by 27%, hence reducing the energy consumption and enhancing the energy efficiency by 60%.

FI-NPI: Exploring Optimal Control in Parallel Platform Systems

“…There are two servo driving modes commonly used in a Six-Degrees of Freedom (6-DOF) parallel platform: a hydraulic rod [1,2] and a brushless DC motor with servo system [3][4][5]. Due to the high energy density of the hydraulic rod, the parallel platform driven by the hydraulic rod performs well in terms of dynamic performance, which is especially suitable for situations with high dynamic response requirements and heavy loads [6][7][8]. However, hydraulic platforms also have some disadvantages, such as their high cost, complex mechanical structure and hydraulic valve control structure, and the need for regular maintenance.…”

A Docking Mechanism Based on a Stewart Platform and Its Tracking Control Based on Information Fusion Algorithm

“…As the hardware equipment of the docking mechanism, the 6-DOF parallel motion platform is widely recognized at present. The advantages of the parallel structure, such as large relative stiffness, small inertia of the mechanism, precise position, high system bandwidth and strong relative load capacity, are irreplaceable for the series mechanism [ 12 , 13 , 14 ]. Therefore, the reconfiguration of docking technology based on the 6-DOF motion platform has been widely used in various carrier simulators, launch vehicle connector automatic docking, multi-degree-of-freedom parallel mechanical equipment, ultra-precision micro-nanometer systems and mobile robot equipment [ 15 , 16 , 17 , 18 , 19 ], which provides a technical and theoretical reference for the reconfiguration docking of ground unmanned vehicles.…”

Real Coded Mixed Integer Genetic Algorithm for Geometry Optimization of Flight Simulator Mechanism Based on Rotary Stewart Platform

“…Even after so many years (almost six decades) of research, there is still the opportunity to find a new or better way of practical use of this mechanism. Besides flight simulators, this mechanism is currently used, for instance, for machining tools [14], as part of medical instruments for precision surgeries [15], for high-precision vibration damping for spacecraft payload [16], within marine satellite tracking antenna stabilization system [17], for nondestructive inspection tool [18], for assembly of flaps [19], for testing of micro-electromechanical system dynamic inclinometer [20], for energy-efficient machining bed [21], gait rehabilitation [22,23], stabilization system for optoelectronic devices [24], docking mechanism [25] and even for helicopter floating helideck [26]; additional applications are shown in [27].…”