Oleksandr Dyshev

A comprehensive numerical method was developed to ensure energy-efficient operating modes of a linear motion module powered by an induction motor. The proposed approach is based on minimizing inertial torque, accounting for the inertial properties of the drive components and the load carriage, followed by structural-parametric optimization and dynamic modeling. For the optimization of the drive system, comprising an intermediate gear stage and a primary ball screw mechanism, a normalization-based method combined with numerical parameter sweep was employed. The optimization process yielded optimal values of the screw lead and the number of gear teeth, which were further validated in terms of Pareto optimality. The carriage design was optimized with respect to mass, strength constraints, and dynamic stiffness using the finite element method. For the developed linear motion module, dynamic behavior was simulated by means of a system of nonlinear differential equations, taking into account the electromagnetic characteristics of the induction motor and the nonlinearities of the gear mesh. As a result of the comprehensive approach, the kinematic, force, and energy characteristics of the linear motion module, which was optimized at the design stage, were determined.

Problem statement. Modern design of robotic technological complexes (RTCs) for machine part manufacturing requires reproducible engineering methods for evaluating layout efficiency at the design stage. Existing approaches do not sufficiently formalize the relationships among the reachable, accessible, actually used, and unused parts of the industrial robot (IR) workspace, which complicates quantitative comparisons of alternative layouts and rational robot selection. Purpose. The purpose of this study is to develop a two-parameter model to evaluate the implementation efficiency of RTC layouts by combining spatial assessment of the industrial robot working zone with kinematic assessment of the workpiece transfer cycle time. Methodology. The study applies systems analysis, structural decomposition, geometric modeling, kinematic analysis, and layout parameter optimization. The workspace is represented through accessible and used areas, while motion trajectories between technological positions are evaluated using trajectory lengths and average end-effector speed. Findings. Practical validation for an RTC that includes metal-cutting machine tools, a conveyor, and a KUKA KR 60-3 industrial robot confirmed that a rational spatial arrangement of equipment reduces trajectory lengths and work-cycle duration while increasing the working-zone utilization coefficient and reducing unused workspace. Originality. The scientific novelty lies in formalizing the structural-parametric synthesis of RTCs as a coordinated selection of spatial layout parameters, trajectory characteristics, and workspace constraints. Technological positions are considered as an interconnected system of coordinate-geometric parameters that affect reachability, maneuverability, travel distance, cycle time, and workspace utilization. Practical value. The proposed model can be integrated into CAD, simulation, and virtual commissioning environments to verify layouts, assess reachability, identify unused workspace, compare alternative trajectories, and select a rational industrial robot before physical implementation of the complex. Future research directions. Further development should account for energy consumption, dynamic loads, positioning accuracy, the probability of singular configurations, multi-criteria optimization algorithms, and RTC digital twins.

The problem of optimizing the drive design parameters for a high-speed linear system is solved based on minimizing the inertial torque. New analytical expressions are obtained for determining the optimal gear ratio of the intermediate transmission, taking into account the moments of inertia of rotating masses, the carriage mass, and the screw pitch. An optimization problem is proposed to determine the number of gear teeth and the screw pitch by minimizing a function that includes the relative error between the actual and calculated gear ratio, as well as the total number of teeth required to ensure the specified travel speed of a carriage. At the next calculation stage, the number of gear teeth is refined based on the nearest standard screw pitch values. The resulting parameters are evaluated using a transient dynamic analysis according to key kinematic and energy characteristics.

The simulation modeling of cutting processes represents a powerful scientific instrument for investigating stress-strain and thermodynamic processes in machined materials. Nevertheless, the principal obstacle to the extensive deployment of this scientific approach is inadequate precision of the resulting research outcomes. This is due to the complexity of formalizing the physical and mechanical forming pattern, considering all the dominant factors in building a high-quality cutting model. Additionally, there is a need for professional experience from the researcher to correctly describe the physical model of the material, as well as a logical selection of fracture criteria, among other factors. One of the most significant challenges in ensuring the accuracy of cutting modeling processes is formalization of the description of a rigid-plastic or elasto-plastic FEA model for analyzing the behavior of materials during machining. The article presents a scientifically based argument for the practicality of using these techniques in simulation modeling systems. It also provides practical recommendations for researchers on constructing an accurate FEA simulation model in DEFORM 2D. The conclusions drawn from the analysis of simulation studies of cutting-induced residual stresses for heterogeneous materials are confirmed by experimental investigations.

The paper considers the design parameters that must be provided during the practical implementation of small-sized reversible vibratory conveyors with an electromagnetic drive. The proposed conveyor is developed on the basis of a classical two-mass oscillatory system. Two oscillating masses are connected by symmetrically assembled round-shaped rods. In order to avoid angular (torsional) oscillations of the vibratory conveyor, the geometrical centers of mass and stiffness of the spring system are aligned at the same point. The analysis of kinematic characteristics is performed by means of numerical solving of the system of nonlinear Lagrange-Maxwell differential equations. The influence of the phase shift angle between the electromagnetic excitation of horizontal and vertical oscillations on the trajectories of the mass center of the conveying member is analyzed. The first two frequencies and forms of natural oscillations of the vibratory conveyor are determined for estimating its dynamic characteristics. The novelty of this study lies in the development of a new design of a vibratory conveyor with a controllable independent electromagnetic drive that provides the conveying reversibility and efficiency.

Nowadays, the machine-building complex is actively saturated with high-tech equipment, without which an enterprise cannot enter the global market or keep up with its competitors. And it's not just about using systems with artificial intelligence elements as scientific and technical solutions to improve quality and reduce production costs. It is also about reducing the time required to prepare products for production and bringing them to the consumer ahead of schedule. Today, the most preferred method in the competitive struggle is to equip CAD/CAM production with computer-aided design systems. With their help, engineering and technology services cannot only design models of new products but also generate CNC control software for manufacturing parts on CNC machines. At the same time, program frames composed in G-codes have several drawbacks, the main one being a "rigid" algorithm of action, i.e., the lack of variability for final solutions when the required accuracy is achieved by correcting the numerical values of the coordinates of the points of formation of individual surfaces in the PC. In this case, the operator largely intuitively corrects individual program frames based on his or her own experience, which is almost impossible without appropriate calculations for controllers with linear-circular and angular motions. In addition, after some such changes, the program loses its geometric adequacy to the part drawing, and by correcting one element of the shaped profile, we invariably violate the laws of contact with neighboring elements specified in the drawing. The paper considers the analytical geometry apparatus that allows a line on a double curvature surface, the theoretical trajectory of tool movement, to be represented not as a set of scalar points but in a vector representation, considering its possible torsion. This approach is ensured by parametric programming with computational frames of point coordinates and logical transitions, determining the angles of inclination of the cutter axis relative to the normal to the surface in the case of multi-axis machining. However, the main advantage of this method is the ability to correct processing errors not by local changes in the numerical values of the coordinates, but by introducing correction coefficients into the equation of the shape formation trajectory - reactors for the appearance of errors in the shape or location of surfaces, arising, for example, from elastic movements. The value of the coefficients per group of personnel can be set in the process of research and industrial production and change depending on the properties of the blanks. For example, according to the current standards, variations in hardness of up to 10-12% were allowed for the blanks of rolling mill rolls. The article presents the experimental data of the research of the correction task in a parametric form and the results of their application for machining parts with radius cutters in real production..