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The development of new processes and materials for additive manufacturing is currently progressing rapidly. In order to use the advantages of additive manufacturing, however, product development and design must also be adapted to these new processes. Therefore it is suitable to use structural optimization. To achieve the best results in lightweight design, it is important to have an approach that reduces the volume in the unloaded regions and considers the restrictions and characteristics of the additive manufacturing process. In this contribution, a case study using a humanoid robot is presented. Thus, the pelvis module of a humanoid robot is optimized regarding its weight and stiffness. Furthermore, an integrated design is implemented in order to reduce the number of parts and the screw connections. The manufacturing uses a new aluminum-based material that has been specially developed for use in additive manufacturing and lightweight construction. For the additive manufacturing by means of the Selective Laser Melting (SLM) process, different restrictions and the assembly concepts of the humanoid robot have to be taken into account. These restrictions have to be considered in the setting of the individual parameters and target functions of the structural optimization. As a result, a framework is presented that shows the steps of the redesign and the optimization of the pelvis module. In order to achieve high accuracy with the product, the redesign of the pelvis module is demonstrated with regard to mechanical and thermal postprocessing. Finally, the redesigned part and the different assembly concepts are compared to analyze the economic and technical effects of the optimization.
Das Ingenieurbüro Evomotiv GmbH und die University of Applied Sciences Offenburg entwickeln seit Ende 2008 ein Antriebskonzept für leichte Stadtfahrzeuge. Ziel des Elektroantriebs ist die Serientauglichkeit der hochintegrierten, getriebelosen und eisenfreien Radnabenmotoren. Das Bundesministerium für Wirtschaft und Technologie (BMWi) unterstützt das Projekt. Das Konzept des Radnabenmotors erhielt 2006 den Bosch—Innovationspreis und gewann 2008 den Shell-Eco-Marathon. Im Jahr 2011 wird Evomotiv mit seinen Partnern erste Prototypen auf der Straße testen.
The engineering company Evomotiv GmbH and the University of Applied Sciences Offenburg have developed a drive concept for light city scooters since 2008. The electrical drive train's goal is the series production of the highly-integrated, non-transmission and non-ferrous wheel-hub motor. The German Federal Ministry of Economy and Technology (BMWi) supports this project. The concept of this wheel-hub motor was awarded with the Bosch-Innovation prize in 2006. In 2011 Evomotiv will test the first prototypes with its cooperation partners on the track.
For the RoboCup Soccer AdultSize League the humanoid robot Sweaty uses a single fully convolutional neural network to detect and localize the ball, opponents and other features on the field of play. This neural network can be trained from scratch in a few hours and is able to perform in real-time within the constraints of computational resources available on the robot. The time it takes to precess an image is approximately 11 ms. Balls and goal posts are recalled in 99 % of all cases (94.5 % for all objects) accompanied by a false detection rate of 1.2 % (5.2 % for all). The object detection and localization helped Sweaty to become finalist for the RoboCup 2017 in Nagoya.
One of the challenges in humanoid robotics is motion control. Interacting with humans requires impedance control algorithms, as well as tackling the problem of the closed kinematic chains which occur when both feet touch the ground. However, pure impedance control for totally autonomous robots is difficult to realize, as this algorithm needs very precise sensors for force and speed of the actuated parts, as well as very high sampling rates for the controller input signals. Both requirements lead to a complex and heavy weight design, which makes up for heavy machines unusable in RoboCup Soccer competitions.
A lightweight motor controller was developed that can be used for admittance and impedance control as well as for model predictive control algorithms to further improve the gait of the robot.
The humanoid Sweaty was the finalist in this year’s robocup soccer championship(adult size). For the optimization of the gait and the stability, data concerning forces and torques in the ankle joints would be helpful. In the following paper the development of a six-axis force and torque sensor for the humanoid robot Sweaty is described. Since commercial sensors do not meet the demands for the sensors in Sweatys ankle joints, a new sensor was developed. As a measuring devices we used strain gauges and custom electronics based on an acam PS09. The geometry was analyzed with the FEM program ANSYS to get optimal dimensions for the measuring beams. In addition ANSYS was used to optimize the position for the strain gauges on the beam.
Biological in situ methanation: Gassing concept and feeding strategy for enhanced performance
(2017)
The expansion of fluctuating renewable electricity production from wind and solar energy requires huge storage capacities. Power-to-gas (PtG) can contribute to tackle that issue via a two-step process, the electrolytic production of hydrogen and a subsequent methanation step (with additional CO2). The resulting fully grid compatible methane, also known as synthetic natural gas (SNG), can be both stored and transported in the vast existing natural gas infrastructure.
To overcome current major drawbacks of PtG, the relatively low efficiency and the high costs, we developed an improved method for the methanation step. In our approach we use a further development of the biological in situ methanation of hydrogen in biogas plants. Because this strategy uses directly internal residual CO2 from the biogas process in the biogas plant, you neither need additional external CO2 nor special reactors. Thus, PtG is combined with the production of an upgraded highly methane rich raw biogas.
However, the low solubility of hydrogen in aqueous solutions and the exploitation of the maximum biological production rates are still an engineering challenge for high performance biological in situ methanation.
In our experiments a setup with membrane gassing turned out to be most promising to ensure a sufficient gas liquid mass transfer of the hydrogen. The monitoring of hydrogenotrophic and aceticlastic archaea showed some adaption of these microbial subgroups to the hydrogen feed.
In order to achieve high methane concentrations of more than 90 % in the raw biogas a CO2-controlled hydrogen feed flow rate is suggested. For methane concentrations lower than 90 % simple current controlled hydrogen supply can be applied.