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Path planning and re-planning for serial 6 degree of freedom (DOF) robotic systems is challenging due to complex kinematic structure and application conditions which affects the robot's tool frame position, orientation and singularity avoidance. These three characteristics represent the key elements for production planning and layout design of the automated manufacturing systems. The robot trajectory represents series of connected points in 3D space. Each point is defined with its position and orientation related to the robot's base frames or predefined user frame. The robot will move from point to point using the desired motion type (linear, arc, or joint). The trajectory planning requires first to check if robot can reach the selected part(s). This can be simply done by placing the part(s) inside the robot's work envelope. The robot's work envelope represents a set of all robots' reachable points without considering their orientation.

The ‘boundary of space’ model representing all possible positions which may be occupied by a mechanism during its normal range of motion (for all positions and orientations) is called the work envelope. In the robotic domain, it is also known as the robot operating envelope or workspace. Several researchers have investigated workspace boundaries for different degrees of freedom (DOF), joint types and kinematic structures utilizing many approaches. The work envelope provides essential boundary information, which is critical for safety and layout concerns, but the work envelope information does not by itself determine the reach feasibility of a desired configuration. The effect of orientation is not captured as well as the coupling related to operational parameters. Included in this are spatial occupancy concerns due to linking multiple kinematic chains, which is an issue with multi-tasking machine tools, and manufacturing cells.

When performing trajectory planning for robotic applications, there are many aspects to consider, such as the reach conditions, joint and end-effector velocities, accelerations and jerk conditions, etc. The reach conditions are dependent on the end-effector orientations and the robot kinematic structure. The reach condition feasibility is the first consideration to be addressed prior to optimizing a solution. The ‘functional’ work space or work window represents a region of feasible reach conditions, and is a sub-set of the work envelope. It is not intuitive to define. Consequently, 2D solution approaches are proposed. The 3D travel paths are decomposed to a 2D representation via radial projections. Forward kinematic representations are employed to define a 2D boundary curve for each desired end effector orientation.

Biomechanical surrogates are used in various forms to study head impact response in automotive applications and for assessing helmet performance. Surrogate headforms include those from the National Operating Committee on Standards for Athletic Equipment (NOCSAE) and the many variants of the Hybrid III. However, the response of these surrogates to loading at the chin and how that response may affect the loads transferred from the jaw to the rest of the head are unknown. To address part of that question, the current study compares the chin impact response performance of select human surrogates to that of the cadaver. A selection of Hybrid III and NOCSAE based surrogates with fixed and articulating jaws were tested under drop mass impact conditions that were used to describe post mortem human subject (PMHS) response to impacts at the chin (Craig et al., 2008). Results were compared to the PMHS response with cumulative variance technique (Rhule et al., 2002).

Shell Elements based Parametric Frame Modeling is a powerful CAE tool, which can generate robust frame design concept optimized for NVH and durability quickly when combined with Taguchi Design of Experiments. The scalability of this modeling method includes cross members length/location/section/shape, frame rail segments length/section and kick in/out/up/down angle, and access hole location & size. In the example of the D. O. E. study, more than fifteen parameters were identified and analyzed for frequency and weight. The upper and lower bounds were set for each design parameter based on package and manufacturing constraints. Sixteen Finite Element frame were generated by parametrically updating the base model, which shows this modeling method is comparatively convenient. Sensitivity of these sixteen parameters to the frequency and weight was summarized through statics, so the favorable design alternative can be achieved with the major parameters' combination.

An iterative learning control (ILC) algorithm has been developed for a test cell electro-hydraulic, fully flexible valve actuation system to track valve lift profile under steady-state and transient operation. A dynamic model of the plant was obtained from experimental data to design and verify the ILC algorithm. The ILC is implemented in a prototype controller. The learned control input for two different lift profiles can be used for engine transient tests. Simulation and bench test are conducted to verify the effectiveness and robustness of this approach. The simple structure of the ILC in implementation and low cost in computation are other crucial factors to recommend the ILC. It does not totally depend on the system model during the design procedure. Therefore, it has relatively higher robustness to perturbation and modeling errors than other control methods for repetitive tasks.

Described in this paper is a component test methodology to evaluate the door trim armrest performance in an Insurance Institute for Highway Safety (IIHS) side impact test and to predict the SID-IIs abdomen injury metrics (rib deflection, deflection rate and V*C). The test methodology consisted of a sub-assembly of two SID-IIs abdomen ribs with spine box, mounted on a linear bearing and allowed to translate in the direction of impact. The spine box with the assembly of two abdominal ribs was rigidly attached to the sliding test fixture, and is stationary at the start of the test. The door trim armrest was mounted on the impactor, which was prescribed the door velocity profile obtained from full-vehicle test. The location and orientation of the armrest relative to the dummy abdomen ribs was maintained the same as in the full-vehicle test.

For the application of advanced clean combustion technologies, such as diesel HCCI/LTC, a compressor with high efficiency over a broad operation range is required to supply a high amount of EGR with minimum pumping loss. A compressor with high pitch of vaneless diffuser would substantially improve the flow range of the compressor, but it is at the cost of compressor efficiency, especially at low mass flow area where most of the city driving cycles resides. In present study, an ultra low solidity compressor vane diffuser was numerically investigated. It is well known that the flow leaving the impeller is highly distorted, unsteady and turbulent, especially at relative low mass flow rate and near the shroud side of the compressor. A conventional vaned diffuser with high stagger angle could help to improve the performance of the compressor at low end. However, adding diffuser vane to a compressor typically restricts the flow range at high end.

A new inter-disciplinary degree program has been developed at Lawrence Technological University: the Master of Science in Mechatronic Systems Engineering Degree (MS/MSE). It is one of a few MS-programs in mechatronics in the U.S.A. today. This inter-disciplinary program reflects the main areas of ground vehicle mechatronic systems and robotics. This paper presents areas of scientific and technological principles which the Mechanical Engineering, Electrical and Computer Engineering, and Math and Computer Science Departments bring to Mechatronic Systems Engineering and the new degree program. New foundations that make the basis for the program are discussed. One of the biggest challenges was developing foundations for mechanical engineering in mechatronic systems design and teaching them to engineers who have different professional backgrounds. The authors first developed new approaches and principles to designing mechanical subsystems as components of mechatronic systems.

Results of Computational Fluid Dynamic (CFD) analyses of different diesel fuel injector nozzle configurations using a commercial CFD code are presented here. The emphasis of this study is on comparing cavitation models available in the commercial code with respect to their mathematical approach. One of the models is a simple single-phase model based on the Barotropic equation of state, while the other model is a two-phase model based on the bubble dynamic considerations. Results are compared for various 3-D diesel injector nozzles using the two cavitation-modeling approaches. Simulation results are observed to substantiate some of the experimentally established facts like; nozzle efficiency improvements by using techniques like rounded orifice inlets and conical orifices. Also, simulation results agree well with the experimental results. Spray characteristics are predicted based on a primary breakup model.

Cavitating flows inside a two-dimensional valve covered orifice (VCO) nozzle were simulated by using the Space-Time Conservation Element and Solution Element (CE/SE) method in conjunction with a homogeneous equilibrium cavitation model. As a validation for present model, cavitation over a NACA0015 hydrofoil was predicted and compared with previous simulation results as well as experimental observations. The model was then used to investigate the effects on internal cavitating flows of different nozzle design parameters, such as the hole size, hole aspect-ratio, hydro-erosion radius, and orifice inclination. Under different conditions, cavitating flows through fuel injectors generated hydraulic flip, supercavitation, full cavitation, and cyclical cavitation phenomena, which are commonly observed in experiments.

A parametric study on the effects of critical injector design parameters of inwardly-opening pressure-swirl injectors was carried out using 3-D internal flow simulations. The pressure variation and the integrated momentum flux across the injector, as well as the flow distributions and turbulence structure at the nozzle exit were analyzed. The critical flow effects on the injector design identified are the swirler efficiency, discharge coefficient, and turbulence breakup effects on the spray structure. The study shows that as a unique class of injectors, pressure-swirl injectors is complicated in fluid mechanics and not sufficiently characterized or optimized. The swirler efficiency is characterized in terms of the trade-off relationship between the swirl-to-axial momentum-flux ratio and pressure drop across the swirler. The results show that swirl number is inversely proportional to discharge coefficient, and that hole diameter and swirler height is the most dominant parameters.

The nozzle configuration for an injector is known to have an important effect on the fuel atomization. A comprehensive experimental and numerical investigation has been performed to determine the influence of various internal geometries on the primary spray breakup and development using the electronically controlled high-pressure diesel injection systems. Different types of multi-hole minisac and VCO nozzles with cylindrical and tapered geometries, and different types of single-hole nozzles with defined grades of Hydro Grinding (HG) were investigated. The global characteristics of the spray, including spray angle, spray tip penetration and spray pattern were measured from the spray images with a high-speed drum camera. A long-distance microscope with a pulsed-laser as the optical shutter was used to magnify the diesel spray at the nozzle hole vicinity. A CFD analysis of the internal flow through various nozzle geometries has been carried out with a commercial code.

A dimensionless relationship that estimates the maximum bearing load of a 4-cylinder 4-stroke in-line engine has been found. This relationship may assist the design engineer in choosing a desired counterweight mass. It has been demonstrated that: 1) the average bearing load increases with engine speed and 2) the maximum bearing load initially decreases with engine speed, reaches a minimum, then increases quickly with engine speed. This minimum refers to a transition speed at which the contribution of the inertia force overcomes the contribution of the maximum pressure force to the maximum bearing load. The transition speed increases with an increase of counterweight mass and is a function of maximum cylinder pressure and the operating parameters of the engine.

The paper analyses the friction in the valve train of an internal combustion engine trying to separate the contribution of the different components to the total friction losses in the valve train. The measurements are performed on a running engine in order to avoid extraneous factors introduced by simulating rigs. The experimental engine is instrumented with strain gauge bridges on the rocker arm, the push rod and the camshaft to measure forces and moments acting on these components. Original techniques are developed to isolate and determine the friction forces between the valve stem and its guide, the friction force in the rocker arm bearing and the combined friction between cam/tappet and tappet/bore. It was found that the friction in the rocker arm bearing never reaches hydrodynamic conditions and that the friction coefficient between cam and tappet reduces with an increase in the engine speed.

An automotive powertrain system consists of several interactive and linked nonlinear systems. This research focuses on the coordination of Gasoline Direct Injection (GDI) engine, transmission and emission aftertreatment systems. The goal is to design an optimal control strategy for driving performance, emissions (HC, CO, NOX), fuel economy and smoothness when switching engine mode and when shifting gears, under both discrete and continuous limitations. A multivariable control strategy is used to compromise among all powertrain subsystems to achieve optimal overall performance. A nonlinear discrete dynamic programming approach is proposed for hybrid system optimization. The complex multivariable automotive control problem is then simplified into an optimization problem. The feasibility of automotive hybrid control via the discrete dynamic programming approach is demonstrated by results from many numerical simulations under different operating conditions.

This paper represents the development of a new design methodology based on data mining theory for decision making in vehicle crashworthy components (or parts) development. The new methodology allows exploring the big crash simulation dataset to discover the underlying complicated relationships between vehicle crash responses and design variables at multi-levels, and deriving design rules based on the whole vehicle safety requirements to make decisions towards the component and sub-component level design. The method to be developed will resolve the issue of existing design approaches for vehicle crashworthiness, i.e. limited information exploring capability from big datasets, which may hamper the decision making and lead to a nonoptimal design. A preliminary design case study is presented to demonstrate the performance of the new method. This method will have direct impacts on improving vehicle safety design and can readily be applied to other complex systems.

The purpose of the Institute for Manufacturing Research (IMR) is to enhance Wayne State University's existing technological strength in the areas of manufacturing research which have demonstrated potential benefits for the State's economy. IMR's faculty conduct basic and applied research in selected areas of manufacturing science. The research programs within the Institute are broadly interdisciplinary and industrially interactive, and are organized around the following areas: materials development, modification, and nondestructive evaluation; software technology for manufacturing and engineering; and product reliability and machine tool research. Faculty from eight departments within the Colleges of Science and Engineering participate in IMR.

Improvement of spray atomization and penetration characteristics of the gasoline direct-injection (GDi ) multi-hole injector is a critical component of the GDi combustion developments, especially in the context of engine down-sizing and turbo-charging trend that is adopted in order to achieve the European target CO₂, US CAFE, and concomitant stringent emissions standards. Significant R&D efforts are directed towards optimization of the nozzle designs, in order to improve the GDi multi-hole spray characteristics. This publication reports VOF-LES analyses of GDi single-hole skew-angled nozzles, with β=30° skew (bend) angle and different nozzle geometries. The objective is to extend previous works to include the effect of nozzle-hole skew angle on the nozzle flow and spray primary breakup. VOF-LES simulations of a single nozzle-hole of a purpose-designed GDi multi-hole seat geometry, with three identical nozzle-holes per 120° seat segment, are performed.

Lean Six Sigma is an approach that is gaining momentum both in manufacturing and service industries. Design for Lean Six Sigma (DFLSS) is an outgrowth of the DFSS and Lean Six Sigma approaches. The essence of DFLSS is to ensure design quality and predictability during the early design phases and the approach employs a structured integrated product development methodology and a comprehensive set of robust tools to drive product quality, innovation, faster time to market, and lower product costs. When it comes to automotive Product Development, applying lean principles and DFSS together becomes more of a challenge within the existing PD system. While the benefits of DFLSS present an attractive proposition in a fiercely competitive market it brings its own challenges as to how to deploy it for maximum benefits. This paper examines the challenges, potential and opportunities for DFLSS in the automotive industry and presents a vision for integrating it in to the Product Development System.