Virtual prototyping and digital twin

Efficient management of the power and energy output of a high voltage battery pack requires a precise estimation of the State of Energy (SOE). For the accurate estimation of SOE, this work presents two data-driven methods as Deep Neural Network (DNN) and a regression model, i.e. Support Vector Regression (SVR). The effectiveness of the SOE estimation was compared, analysed, and studied through these models under similar conditions. For performance enhancement of estimation, a modified algorithm based on the grid search of optimized hyperparameters was proposed and evaluated in both the models. For training of the model at subsequent thermal ranges, two case studies were performed using US06, UDDS, LA92, and HWFET drive cycles and at four different temperature levels (−10, 0, 10, and 25 °C), for each cycle. The results indicate that the DNN method has provided enhanced performance for State of Energy Estimation as compared to the regression models of ML, i.e. SVR. This work highlights the prevailing challenges in the industry and proposes the potential recommendation for Battery Management System (BMS) development and SOE estimation in next-generation EV applications.

Keywords: Deep neural network , Hyperparameters optimization , Regression , Support vector regression , The State of Energy

Exosuits are emerging as promising in assisting with activities of daily living. In the design phase of an exosuit, it is fundamental to maximize its portability. The goal of this work was to identify the best cable routing configuration for an upper limb cable-driven exosuit to assist elbow flexion. Simulations were run in OpenSim. Different cable configurations were evaluated. The goal was to minimize the overall tension of the cables to reduce the device's power consumption and torque requirements. The optimal configuration was evaluated in simulation for different percentages of assistance to study its effects in terms of muscle activation and joint reaction forces. We then tested three different configurations on a test bench to both evaluate the motor current and their effect on the pronation/supination of the elbow. Simulation results suggested that a double cable configuration might help to lower the motor torque and power consumption. This conclusion was supported by the experimental results, in which the motor current was reduced by 12.5% with respect to the single cable configuration. Simulation results also showed that the optimal configuration lowered muscle activation without greatly affecting joint reactions at the elbow, even though it might cause unwanted pronation/supination, as experimental results confirmed. However, since a double configuration results in greater complexity and reduced efficiency, single-cable solutions still represent a good option.

Keywords: Chemical activation , Electric power utilization , Joints (anatomy) , Muscle

Nowadays, mechatronic systems are used in every field and all around us, going through micro, small, medium and large power systems. Due to their widespread use, mechatronic system design plays an important role in energy sustainability.Mechatronic systems are generally complex systems from a modelling point of viewdue to the presence of several domains and a set of related interfaces for energy exchanges. Such a context needs a multi-domain and integrated design to correctlyevaluate mechatronic system performances. Modelling and simulation tasks are generally adopted to evaluate the behaviour of mechatronic systems in order to meet system requirements. Unfortunately, energy saving is not always considered among the set of primary requirements, while it is tackled only after reaching the expected system behaviour. The present chapter tackles themulti-domainmodelling and simulationof mechatronic systems according to V-model steps and using the RFLP approach driven by sustainability requirements. The key idea is to perform a concurrent evaluation of energy and domain performances. It summarises a case study, by using Matlab/Simscape environment, to illustrate the used approach. Moreover, it introduces the design of mechatronic systems pulled by environmental sustainability as a new paradigm in opposition to the design pushed by system performances.

Measurement and monitoring systems (MMSs) are intrinsically part of 4.0 and, in particular, of cyber-physical systems (CPSs). However, by introducing the 4.0 enabling technologies into MMSs, also the vice versa can be accomplished, and MMSs can evolve into a cyber-physical measurement system (CPMS). Starting from this consideration, in the present work, a preliminary case study of a CPMS is presented: an innovative robotic platform to be used for measurement systems in confined and constrained remote environments. The proposed system is a soft growing robot that includes a robot base, to be placed outside the remote environments, and a robot body that accesses the site through growth. A pneumatic actuation mechanism enables the controllable growth of the system (through lengthening at its tip), as well as its controllable steering. The system can be equipped with sensors to enable remote monitoring tasks, or can be used to transport sensors in remote locations. The ultimate goal is to achieve a self-adapting, fully-autonomous, reliable and safe system for monitoring applications, particularly useful for the remote inspection of unknown and/or constrained environments.

Keywords: 4.0 , Inspection , Monitoring systems , Remote monitoring , Soft continuum robots , Soft growing robots

Purpose: To evaluate the effect of different substrate stiffness [sound dentin (SD), resin composite core (RC) or metal core (MC)] on the stress distribution of a zirconia posterior three-unit fixed partial denture (FPD). Methods: The abutment teeth (first molar and first premolar) were modeled, containing 1.5 mm of axial reduction, and converging axial walls. A static structural analysis was performed using a finite element method and the maximum principal stress criterion to analyze the fixed partial denture (FPD) and the cement layers of both abutment teeth. The materials were considered isotropic, linear, elastic, homogeneous and with bonded contacts. An axial load (300 N) was applied to the occlusal surface of the second premolar. Results: The region of the prosthetic connectors showed the highest tensile stress magnitude in the FPD structure depending on the substrate stiffness with different core materials. The highest stress peak was observed with the use of MC (116.4 MPa) compared to RC and SD. For the cement layer, RC showed the highest values in the molar abutment (14.7 MPa) and the highest values for the premolar abutment (14.4 MPa) compared to SD (14.1 and 13.4 MPa) and MC (13.8 and 13.3 MPa). Both metal core and resin composite core produced adequate stress concentration in the zirconia fixed partial denture during the load incidence. However, more flexible substrates, such as composite cores, can increase the tensile stress magnitude on the cement.

3D tooth models were virtually restored: flowable composite resin + bulk-fill composite (A), glass ionomer cement + bulk-fill composite (B) or adhesive + bulk-fill composite (C). Polymerization shrinkage and masticatory loads were simulated. All models exhibited the highest stress concentration at the enamel–restoration interfaces. A and C showed similar pattern with lower magnitude in A in comparison to C. B showed lower stress in dentine and C the highest cusps displacement. The use of glass ionomer cement or flowable composite resin in combination with a bulk-fill composite improved the biomechanical behavior of deep class II MO cavities.

Keywords: Adhesion , class II MO , loading , operative dentistry , polymerization shrinkage

Background and objective: The aim of the present study was to review the literature concerning the analysis of periprosthetic bone remodeling through finite element (FE) simulation. Methods: A systematic review was conducted on 9 databases, taking into account a ten-year time period (from 2009 until 2020). The inclusion criteria were: articles published in English, publication date after 2009, full text articles, articles containing the keywords both in the abstract and in the title. The articles were classified through the following parameters: dimensionality of the simulation, modelling of the bone-prosthesis interface, output parameters, type of simulated prosthesis, bone remodeling algorithm. Results: Sixty-seven articles were included in the study. Femur and tooth were the most evaluated bone segment (respectively 41.8% and 29.9%). The 55.2% of the evaluated articles used a bonded bone-prosthesis interface, 73% used 3D simulations, 67.2% of the articles (45 articles) evaluate the bone remodeling by the bone density variation. At last, 59.7% of the articles employed algorithms based on a specific remodeling function. Conclusions: Increasing interest in the bone remodeling FE analysis in different bone segments emerged from the review, and heterogeneous solutions were adopted. An optimal balance between computational cost and accuracy is needed to accurately simulate the bone remodeling phenomenon in the post-operative period.

Keywords: Biological processes , Bone remodeling , Computational analysis , FE simulations , Prosthesis , Systematic review

The protection of artistic and cultural heritage is a major challenge due to its peculiarities and its exposure to significant natural hazards. Several methodologies exist to assess the condition of artistic heritage and to protect it from exceptional actions. Moreover, novel digital technologies offer many solutions able to deliver a digital replica of artifacts of interest, so that a reduction in the uncertainties in the analysis models can be achieved. A rational approach to the preservation and protection of artistic heritage is based on traditional approaches supported and integrated by novel technologies, so that qualitative and quantitative indicators of the current condition of artistic heritage can be defined and validated in an interdisciplinary framework. The present paper reports the results of an approach to the maintenance and preservation of art objects housed in a museum complex based on a comprehensive digital path towards a Historical Digital Twin (HDT). A workflow aimed at estimating the stress regime and the dynamic properties of two sculptures, based on the detailed three-dimensional model resulting from a laser scanner survey, is illustrated and dis-cussed. The results highlight the great advantages resulting from the integration of traditional and novel procedures in the field of conservation of artistic assets.

Keywords: 3D simulation , Conservation , Cultural heritage , Digital twin , Laser scanning , Maintenance

In this paper we show an overview of the preliminary strategy planned for remote maintenance of neutron–activated and contaminated components of DTT machine, in the 2019 reference configuration. The remote maintenance of such a complex machine has impact on different aspects of the DTT machine: layout of the tokamak hall, vacuum vessel and cryostat structures, in–vessel components. To date, the number and size of vacuum vessel ports as well as the segmentation and size of in–vessel mechanical components of DTT have been established by a compromise between operational and maintenance needs. An extensive multidisciplinary work has been done in deriving the requirements for the DTT remote maintenance strategy. Each vacuum vessel sector is divided into five ports: in the current configuration, the top and bottom divertor cassettes are expected to be removed, respectively, from four lower lateral ports and from four equatorial horizontal ports; the first wall modules at the inboard side are expected to be installed/removed from all the upper ports; the first wall modules at the outboard and upper sides are segmented such that they can be removed from four equatorial horizontal ports. The work describes the current strategies for divertor and first wall remote maintenance systems, as well as a first conceptual design of the remote maintenance equipment of DTT machine.

Keywords: DTT , Remote maintenance

This paper introduces a novel upper limb robotic exoskeleton designed to assist industrial operators in a wide range of manual repetitive tasks, such as tool handling and lifting/moving of heavy items. Due to its reduced size and high maneuverability, the proposed portable device may also be employed for rehabilitation purposes (e.g. as an aid for people with permanent neuromuscular diseases or post-stroke patients). Its primary function is to compensate the gravity loads acting on the human shoulder by means of a hybrid system consisting of four electric motors and three passive springs. The paper focuses on the exoskeleton mechanical design and virtual prototyping. After a preliminary review of the existent architectures and procedures aimed at defining the exoskeleton functional requirements, a detailed behavioral analysis is conducted using analytical and numerical approaches. The developed interactive model allows to simulate both kinematics and statics of the exoskeleton for every possible movement within the design workspace. To validate the model, the results have been compared with the ones achieved with a commercial multibody software for three different operator's movements.

Keywords: Computer aided design , Gravity balancing , Robotic arm , Upper limb exoskeleton , Virtual prototyping

In this paper, the concept of isotropic compliance is extended to the field of compliant mechanisms. Starting from the design of a rigid-body mechanism, a planar compliant system is determined by applying the rigid-body replacement method. The static behaviour of the isotropic compliant mechanism is validated by finite element simulations and experimental tests. The extension of the proposed method to the Euclidean Space E(3) is discussed.

Keywords: Compliant mechanism , Isotropic compliance , Pseudo-rigid body model , Rigid body replacement

Beam-based Compliant Mechanisms (CMs) are increasingly studied and implemented in precision engineering. Straight beams with uniform cross section are the basic modules in several design concepts, which can be deemed as standard CMs. Their behavioral analysis can be addressed with a large variety of techniques, including the Euler–Bernoulli beam theory, the Pseudo-Rigid Body (PRB) method, the beam constraint model and the discretization-based methods. This variety is unquestionably reduced when considering nonstandard CMs, namely design problems involving special geometries, such as curve/spline beams, variable section beams, nontrivial shapes and contact pairs. The 3D Finite Element Analysis (FEA) provides accurate results but its high computational cost makes it inappropriate for optimization purposes. This work compares the potentialities of computationally efficient modeling techniques (1D FEA, PRB method and chained-beam constraint model), focusing on their applicability in nonstandard planar problems. The cross-axis flexural pivot is used as a benchmark in this research due to its high configurable behavior and wide range of applications. In parallel, as an attempt to provide an easy-to-use environment for CM analysis and design, a multi-purpose tool comprising Matlab and a set of modern Computer-Aided Design/Engineering packages is presented. The framework can implement different solvers depending on the adopted behavioral models. Summary tables are reported to guide the designers in the selection of the most appropriate technique and software framework. Lastly, efficient design procedures that allow to configure nonstandard beam-based CMs with prescribed behavior are examined with two design examples.

Keywords: CAD/CAE software framework , Compliant Mechanisms , Cross-axis flexural pivot , Design methods , Shape optimization , Virtual Prototyping

This paper reports about the design of a bio-inspired compliant wrist, whose mobility (i.e. ulnar-radial deviation and flexion-extension) has been realized by employing two pairs of contact-aided Cross-Axis Flexural Pivots (CAFPs), actuated via remotely-placed servo-motors and tendon transmissions. The human wrist behaves differently when deflecting in clockwise or anticlockwise direction, both in terms of maximum angular deflection and passive stiffness. The device proposed hereafter aims at mimicking such natural asymmetry, while withstanding unexpected external loads. In order to fulfill these requirements, two contacts are included: (i) a pure rolling contact (named passive contact), achieved via a cam mechanism guiding the CAFP deflection and ensuring the wrist resistance to compressive loads; (ii) a purposely shaped contact pair (named active contact), acting on one beam of the CAFP so as to increase its stiffness. The design procedures and tools specifically developed for the wrist optimization are described. In the first step, a CAFP shape optimization is performed, followed by the synthesis of the active contact pair. In the second step, the centrodes are computed and then used to generate the passive contact profiles. At last, the third step focuses on the definition of the tendons routing. To prove the validity of the numerical models, a physical prototype of the wrist is produced and tested. Direct comparisons between simulations and experiments confirm the efficacy of the proposed design method.

Keywords: CAD/CAE multi-software framework , Compliant mechanism , Cross-axis flexural pivot , Robotic wrist , Shape optimization , Virtual prototyping

This article reports the preliminary analysis and design of a novel 6 degrees of freedom, passive, upper limb exoskeleton for industrial applications. The aim is to conceive a wearable device to support workers in a vast range of repetitive tasks, offering an effective strategy to reduce the risk of injuries in production lines. The exoskeleton primary purpose is to compensate for the gravity loads acting on the human upper limb via the action of five springs. By reaching the static balancing through the use of passive elements only, several advantages in terms of reduced weight and cost can be provided. In this scenario, a detailed analytical approach has been developed to study the exoskeleton statics and synthesize the springs within the human upper limb workspace. In particular, a 3R balancer is designed for the exoskeleton shoulder joint and a set of computationally efficient optimization studies are carried out to determine the optimal coefficients and positions of the springs. The obtained results have been validated with a commercial multibody tool.

Keywords: Design Optimization , Gravity Balancing , Upper Limb Exoskeleton , Virtual Prototyping , Wearable Devices

Servo-Actuated Mechanisms (SAM) are capable of improving the flexibility and reconfigurability of modern automatic machines. On one hand, as compared to fully mechanical drives, SAM may suffer from non-negligible positioning inaccuracies, whose effect can become unacceptable in case of undesired part deformations during high dynamic motions. On the other hand, it may be the case that parts of the system are purposely designed to provide an highly compliant behaviour, so as to potentially increase the device safety in case of interaction with humans. In both cases, practical strategies to reduce the SAM positioning errors are necessary. As a possible solution to such issue, in this paper, an integrated approach to improve the accuracy of a partially compliant SAM in position-controlled tasks is described. The method exploits a multi-software framework comprising Matlab and RecurDyn, namely a commercial Computer-Aided Engineering (CAE) tool that can be used to simulate the motion of systems comprising both rigid and flexible bodies. Starting from an initial, sub-optimal, motion law of the input link, a trajectory optimizer iteratively runs the CAE solver and automatically computes an optimal, compensated, position profile. The obtained results show that the method may represent a useful tool for analyzing/designing partially compliant SAM, whenever analytical models are either too complex or not readily available.

The following sections are included: • Introduction • Related Works • VR Maintenance Training: A Case Study • Implementation of the VR Application • Experimental Setup and Testing • Analysis of Test Results • Discussion and Conclusion • References.

Principal components analysis is a powerful technique which can be used to reduce data dimensionality. With reference to three-dimensional bone shape models, it can be used to generate an unlimited number of models, defined by thousands of nodes, from a limited (less than twenty) number of scalars. The full procedure has been here described in detail and tested. Two databases were used as input data: the first database comprised 40 mandibles, while the second one comprised 98 proximal femurs. The “average shape” and principal components that were required to cover at least 90% of the whole variance were identified for both bones, as well as the statistical distributions of the respective principal components weights. Fifteen principal components sufficed to describe the mandibular shape, while nine components sufficed to describe the proximal femur morphology. A routine has been set up to generate any number of mandible or proximal femur geometries, according to the actual statistical shape distributions. The set-up procedure can be generalized to any bone shape given a sufficiently large database of the respective 3D shapes.

Keywords: 3D model generator , Comparative anatomy , Mandible anatomy , Mesh morphing , PCA , Proximal femur anatomy , Stochastic bone models

The tyre-suspension-seat dynamic system, driveline and engine vibrations are generally considered in the vibrational field as the main factors that influence the particular feeling of comfort perceived by passengers on a vehicle. Hence, the development of several criteria and models for the optimal estimation of the design parameters of such systems. Among these parameters, the most detrimental impacting on the passenger comfort are undoubtedly acceleration and its variation. The two types of suspension systems (conventional passive suspension system and active suspension system) differ as the first foresees the spring-damper characteristics to be adjusted so that only one of several conflicting objectives (such as passenger comfort, road holding, and suspension deflection) is followed. In active suspension systems, instead, these objectives are balanced by the designer in a more efficient manner thanks to the feedback-controller actuator assembly. However, this approach presents some limitations linked to the extremely wide spectrum of magnitude and frequency of external forces that the tyre-suspension-seat system has to efficiently control and mitigate. It remains that in the existing optimisation models and systems time exposure limits established by unification agencies and road authorities are not generally considered. This paper illustrates the development of an active tyre-suspension-seat system control for passenger cars, using both a non-linear multibody model and Genetic Algorithm (GA) controls. A benefit of the proposed active tyre-suspension-seat system control is also to consider various time exposure limits and an active damping element. The main innovative element introduced by this work consists in having coupled an active control to passive mechanical parameters in order to minimize the seat acceleration. The 3 DoF multibody model, applied to a quarter body for symmetry reasons, treated road roughness as an input variable in the GA control so as to determine the vertical component of acceleration. The numerical and experimental applications of the proposed model to a specific case study allowed to validate the effectiveness of the active system towards the vibrations transmitted to the passenger.

Keywords: Acceleration variation , Active suspension system , Genetic algorithm , Passenger comfort , Vibrations

Traditional analytical methods are approximate and need to be validated when it comes to predict the tensional behavior of thread coupling. Numerical finite element simulations help engineers come up with the optimum design, although the latter depends on the constraints and load conditions of the thread couplings which are often variable during the system functioning. The present work illustrates a new method based on Radial Basis Functions Mesh Morphing formulation to optimize the stress concentration in thread couplings which is subject to variable loads and constraints. In particular, thread root and fillet under-head drawings for metric ISO thread, which are the most commonly used thread connection, are optimized with Radial Basis Functions Mesh Morphing. In metric ISO threaded connection, the root shape and the fillet under the head are circular, and from shape optimization for minimum stress concentration it is well known that the circular shape becomes seldom optimal. The study is carried out to enhance the stress concentration factor with a simple geometric parameterization using two design variables. Radial Basis Functions Mesh Morphing formulation, performed with a simple geometric parameterization, has allowed to obtain a stress reduction of up to 12%; some similarities are found in the optimized designs leading to the proposal of a new standard. The reductions in the stress are achieved by rather simple changes made to the cutting tool.

Keywords: Feature-based modeling , Fillet under-head , Metric ISO thread , Radial basis functions , Thread root

In the presented paper it has been proposed a methodology that translates the customer conditions in terms of electric power into thermo-mechanical variables correlated with power module failure mechanisms. An initial analysis of power module failure modes will be presented, then the module temperature during inverter load profile will be numerically estimated. The so-obtained time-temperature during inverter operation will be converted using Rainflow-like approach into a pre-defined number of loading conditions. According to the time and temperature dependency of the typical failure mechanism, the mentioned loading cases will be characterized by different temperature swing and time duration. The extrapolated equivalent history will be a starting point to set durability tests aimed to predict reliability performances.