In order to transport materials flexibly and smoothly in a tight plant environment, an omni-directional mobile robot based on four Mecanum wheels was designed. The mechanical system of the mobile robot is made up of three separable layers so as to simplify its combination and reorganization. Each modularized wheel was installed on a vertical suspension mechanism, which ensures the moving stability and keeps the distances of four wheels invariable. The control system consists of two-level controllers that implement motion control and multi-sensor data processing, respectively. In order to make the mobile robot navigate in an unknown semi-structured indoor environment, the data from a Kinect visual sensor and four wheel encoders were fused to localize the mobile robot using an extended Kalman filter with specific processing. Finally, the mobile robot was integrated in an intelligent manufacturing system for material conveying. Experimental results show that the omni-directional mobile robot can move stably and autonomously in an indoor environment and in industrial fields.

A novel magnetorheological (MR) clutch for high-power applications is designed, simulated and tested. The clutch is implemented in a two-layer multiplate transmission form and adopts a two-way liquid cooling method to improve the heat dissipation capability. In this paper, a brief introduction to the transmission form of the proposed MR clutch is given first. Then, theoretical analyses of the output torque, magnetic circuit and temperature characteristic are conducted and further design details are presented and discussed, followed by a magnetostatic simulation of the designed circuit. A prototype of the clutch was fabricated and several tests were carried out to evaluate the torque transmission, time response and steady slip power of the prototype. The results show that the proposed MR clutch can produce a maximum output torque of 1545 N m and possesses a high steady slip power of up to 35 kW. Therefore, the developed two-layer multiplate MR clutch is promising for applications in many high-power situations.

Compared with traditional speed regulation (SR) approaches like variable frequency and hydraulic coupling, magnetorheological clutch (MRC) provides a more superior solution for high-efficiency energy saving SR. However, recent developments have demonstrated that severe heating is an outstanding challenge for MRC, especially in high-power applications. Among commonly used cooling methods, liquid cooling offers a viable alternative for the problem. Aiming at pre-evaluating the cooling efficiency of a liquid-cooled MRC in high-power situations, this study introduces a heat-flow coupling simulation method. In this paper, theoretical basis for the simulation is presented first, which is followed by an illustration of the heat-flow coupling simulation. This paper details the simulation model establishment, finite element meshing (FEM), boundary conditions, and simulation parameters. After the simulations, the results concerning the steady flow field of the internal coolant, along with the steady-state temperature fields of MRC, magnetorheological (MR) fluids and the coolant are presented and discussed. Finally, several heating tests of an MRC prototype under various operation conditions are performed and the results verify the correctness and rationality of the simulation.

Mechanical properties are critical to the working performance of magnetorheological fluids (MRFs), especially in high temperature situations. This paper presents an experimental investigation to analyze the effects of temperature on mechanical properties of MRFs. First, a parallel disk method was implemented for the shear stress measurement of MRFs and the measurement principle was theoretically illustrated. Then, a detailed introduction to the MRF sample preparation and the testing device development was performed as well. In the study, five kinds of MRF samples with different material parameters were prepared and a shear stress testing device which possesses the temperature control function was developed and evaluated. After these, a series of measurements were conducted on the viscosity–temperature characteristic, shear stress–temperature characteristic and thermal stability of MRF samples. Measuring results indicated that the mechanical properties of MRFs were obviously dependent on temperature. The phenomenon mainly embodied in the reduction of off-field viscosity and shear stress with increasing temperature, as well as the performance degradation after undergoing a low–high–low temperature cycle or a high temperature treatment of more than 150 ℃.

The ability to sense external force is an important technique for force feedback, haptics and safe interaction control in minimally-invasive surgical robots (MISRs). Moreover, this ability plays a significant role in the restricting refined surgical operations. The wrist joints of surgical robot end-effectors are usually actuated by several long-distance wire cables. Its two forceps are each actuated by two cables. The scope of force sensing includes multidimensional external force and one-dimensional clamping force. This paper focuses on one-dimensional clamping force sensing method that do not require any internal force sensor integrated in the end-effector’s forceps. A new clamping force estimation method is proposed based on a joint torque disturbance observer (JTDO) for a cable-driven surgical robot end-effector. The JTDO essentially considers the variations in cable tension between the actual cable tension and the estimated cable tension using a Particle Swarm Optimization Back Propagation Neural Network (PSO-BPNN) under free motion. Furthermore, a clamping force estimator is proposed based on the forceps’ JTDO and their mechanical relations. According to comparative analyses in experimental studies, the detection resolutions of collision force and clamping force were 0.11 N. The experimental results verify the feasibility and effectiveness of the proposed clamping force sensing method.