Sensing pressure at the physical interface between the robot and the human has important implications for wearable robots. On the one hand, monitoring pressure distribution can give valuable benefits on the aspects of comfortability and safety of such devices. Additionally, on the other hand, they can be used as a rich sensory input to high level interaction controllers. However, a problem is that the commercial availability of this technology is mostly limited to either low-cost solutions with poor performance or expensive options, limiting the possibilities for iterative designs. As an alternative, in this manuscript we present a three-dimensional (3D) printed flexible capacitive pressure sensor that allows seamless integration for wearable robotic applications. The sensors are manufactured using additive manufacturing techniques, which provides benefits in terms of versatility of design and implementation. In this study, a characterization of the 3D printed sensors in a test-bench is presented after which the sensors are integrated in an upper arm interface. A human-in-the-loop calibration of the sensors is then shown, allowing to estimate the external force and pressure distribution that is acting on the upper arm of seven human subjects while performing a dynamic task. The validation of the method is achieved by means of a collaborative robot for precise force interaction measurements. The results indicate that the proposed sensors are a potential solution for further implementation in human–robot interfaces.

Human motion intention detection is an essential part of the control of upper-body exoskeletons. While surface electromyography (sEMG)-based systems may be able to provide anticipatory control, they typically require exact placement of the electrodes on the muscle bodies which limits the practical use and donning of the technology. In this study, we propose a novel physical interface for exoskeletons with integrated sEMG- and pressure sensors. The sensors are 3D-printed with flexible, conductive materials and allow multi-modal information to be obtained during operation. A K-Nearest Neighbours classifier is implemented in an off-line manner to detect reaching movements and lifting tasks that represent daily activities of industrial workers. The performance of the classifier is validated through repeated experiments and compared to a unimodal EMG-based classifier. The results indicate that excellent prediction performance can be obtained, even with a minimal amount of sEMG electrodes and without specific placement of the electrode.

Squeeze film dampers (SFDs) are widely used to dissipate mechanical energy caused by rotor vibrations as well as to improve overall stability of the rotor system. Especially turbomachine rotors, supported on little damped rolling element bearings (REBs), are primarily sensitive to unbalance excitation and thus high amplitude vibrations. To ensure safe operation, potential failure modes, such as an oil starved damper state, need to be well examined prior to the introduction in the ultimate industrial application. Hence, the aim of this research project is to evaluate the performance of the rotor support for a complete oil starvation of the SFD. An academic rotor dynamic test bench has been developed and briefly presented. Experimental testing has been conducted for two static radial load cases resembling the full load and idle condition of a certain turbomachine. Evidently, the measurement results exposed severe vibration problems. Even a split first whirl mode arises due to a pronounced anisotropic bearing stiffness. Moreover, for the least radially loaded bearing, highly nonlinear behavior emerged at elevated unbalance excitation. Consequently, the rollers start to rattle which will have a negative effect on the overall bearing lifetime. To explain the nature of the nonlinear behavior, advanced quasi-static bearing simulations are exploited. A number of possible solutions are proposed in order to help mitigate the vibration issues.

Turbomachine rotors, supported by little damped rolling element bearings, are generally sensitive to unbalance excitation. Accordingly, most machines incorporate squeeze film damper technology to dissipate mechanical energy caused by rotor vibrations and to ensure stable operation. When developing a novel geared turbomachine able to cover a large power range, a uniform mechanical drivetrain needs to perform well over the large operational loading range. Especially, the rotor support, containing a squeeze film damper and cylindrical roller bearing in series, is of vital importance in this respect. Thus, the direct objective of this research project was to map the performance of the envisioned rotor support by estimating the damping ratio based on the simulated and measured vibration response during run-up. An academic test rig was developed to provide an in-depth analysis on the key components in a more controlled setting. Both the numerical simulation and measurement results exposed severe vibration problems for an insufficiently radial loaded bearing due to a pronounced anisotropic bearing stiffness. As a result, a split first whirl mode arose with its backward component heavily triggered by the synchronous unbalance excitation. Hence, the proposed SFD does not function properly in the lower radial loading range. Increasing the static load on the bearing or providing a modified rotor support for the lower power variants will help mitigating the vibration issues.

Automatic ball balancing is a technique adopted in rotordynamics to reduce unknown rotor unbalance automatically. This technique sounds appealing as it can ease a panoply of balancing issues considerably. The presence of stiction, however, scatters consistent qualitative balancing and led to a limited implementation in the industry. Temporary speed reduction, a recent technique, could be used as a countermeasure for the stiction-induced scattering. Presented in this paper is an in-depth study detailing how the technique should be implemented to guarantee effective balancing. By analysing a rotordynamic model of the Jeffcott kind, the influence of a multitude of parameters is studied such as the initial mass positions, the initial unbalance, the adopted speed profile, shaft damping, stiction and the speed reduction plateau of the adopted speed reduction strategy. The main findings of the study are that the adverse effects of stiction can be contained considerably using the speed reduction technique, especially in the under-excited range where a ball balancer behaves poorly when adopting a standard run-up profile. Finally, the speed plateau of the speed reduction technique should be selected carefully, preferably accounting for stiction, shaft damping and even more so the initial unbalance.