CAD, 3D Modeling, Engineering Analysis, and Prototype Experimentation PDF

Jeremy Zheng Li
CAD, 3D Modeling,
Engineering
Analysis, and
Prototype
Experimentation
Industrial and Research Applications
CAD, 3D Modeling, Engineering Analysis,
and Prototype Experimentation
Jeremy Zheng Li
CAD, 3D Modeling,
Engineering Analysis,
and Prototype
Experimentation
Industrial and Research Applications
Jeremy Zheng Li
University of Bridgeport
Bridgeport, CT, USA
ISBN 978-3-319-05920-4 ISBN 978-3-319-05921-1 (eBook)

DOI 10.1007/978-3-319-05921-1
Springer Cham Heidelberg New York Dordrecht London
Library of Congress Control Number: 2014944530
# Springer International Publishing Switzerland 2015

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Preface
Computer-aided design (CAD), 3D modeling, and engineering analysis can be

efficiently applied in many research and industrial fields including aerospace,
defense, automobile, consumer product, and many other product development.
These efficient research and engineering tools apply computer-assisted technology
to perform 3D modeling on different products, support geometrical design, make
structural analysis, assist optimal product design, create graphic and engineering
drawings, and generate production documents. This technology helps scientists and
technical professionals efficiently import basic geometrical inputs and design
information to accelerate the engineering design process, with well-controlled
design documents, to support production and manufacturing processes. Currently
these research and engineering tools have been playing more and more important
roles in different businesses and enterprises due to their financial and technical
importance in business, industrial, engineering, and manufacturing applications.
The computer-aided modeling and analysis allow more sophisticated, flexible,
reliable, and cost-effective manufacturing control. Automation and automated
production system are to use control system to reduce human labor intervention
during manufacturing processes and put strong impact on industries. Automation
and automated system design not only raise the production rate but also control the
product quality. It can effectively keep consistent product quality, reduce produc-
tion lead time, ease material handling, maintain optimal work flow, and meet the
product requirement by controlling the flexible and convertible manufacturing/
production processes. Computer-aided modeling and engineering design can
quickly simulate and model the automated production systems and reduce product
development life cycles. Computer-aided engineering solution can improve and
optimize the industrial integral processes in design, development, engineering
analysis, and product manufacturing. Also the present and future economic globali-
zation requires cost-effective manufacturing via highly industrial automation, effi-
cient design tooling, and better production control. This book describes the
technology, types, and general applications of these research and engineering
tools through conceptual analysis and real case study in computer-aided design,
3D modeling, and engineering analysis. Some new product systems, developed by
author, are introduced to help readers understand how to design and develop new
product systems by using computer-aided design, engineering analysis, and
v
vi Preface
prototype experiment. The case studies include design and development of

green/sustainable energy systems (solar still, solar panel, and wind power energy),
biomedical and surgical instruments, energy-saving cooling system, automated and
high-speed assembly system (highly viscous liquid filling and chemical gas charg-
ing), robotic system for industrial/automated manufacturing, magnetic sealing
system, and high-speed packaging machinery system. Multiple engineering case
studies in this book aim at the introduction, study, and analysis by using computer-
aided modeling and engineering analysis for industrial and engineering
applications. All these newly developed product systems have also been verified
by prototyping and testing to validate the functionality of these new systems. Both
computer-aided analysis and experimental methodologies introduced in this book
show close results that positively show the feasibility and credibility of analytic and
experimental methodologies introduced in this book.
Bridgeport, CT, USA Jeremy Zheng Li

Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Solar Energy System for Water Distillation . . . . . . . . . . . . . . . 3
1.2 Wind Power Turbine System . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Solar Panel Tracking System . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4 Energy-Saving Cooling System . . . . . . . . . . . . . . . . . . . . . . . . 7
1.5 Automated and High-Speed Manufacturing Systems . . . . . . . . . 8
1.6 Robotic System for Industrial Applications . . . . . . . . . . . . . . . 9
1.7 Magnetic Sealing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.8 Automated and High-Speed Packaging
Machinery System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.9 Biomedical and Surgical Systems . . . . . . . . . . . . . . . . . . . . . . 13
Part I Energy Systems
2 Solar Energy System for Water Distillation . . . . . . . . . . . . . . . . . . 17

2.1 Design of Solar Energy System for Water Distillation . . . . . . . . 17
2.2 Computer-Aided Simulation of Solar Energy System
for Water Distillation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.3 Experiment on Solar Energy System
for Water Distillation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.4 Discussion and Future Improvement of Solar Energy
System for Water Distillation . . . . . . . . . . . . . . . . . . . . . . . . . 25
3 Wind Power Turbine System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.1 Design of New Wind Power Turbine System . . . . . . . . . . . . . . 27
3.2 Computer-Aided Simulation of Wind Power
Turbine System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.3 Experiment on Wind Power Turbine System . . . . . . . . . . . . . . 34
3.4 Discussion and Future Improvement on Wind Power
Turbine System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
vii
viii Contents
4 Solar Panel Tracking System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

4.1 Design of Solar Panel Tracking System . . . . . . . . . . . . . . . . . . 39
4.2 Computer-Aided Simulation of Solar Panel
Tracking System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.3 Experiment on Solar Panel Tracking System . . . . . . . . . . . . . . 56
4.4 Discussion and Future Improvement on Solar Panel
Tracking System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5 Energy-Saving Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.1 Design of Energy-Saving Cooling System . . . . . . . . . . . . . . . . 65
5.2 Computer-Aided Simulation on Energy-Saving
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.3 Experiment on Energy-Saving Cooling System . . . . . . . . . . . . 77
5.4 Discussion and Future Improvement on Energy-Saving
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Part II Automated Systems
6 Automated and High-Speed Manufacturing System . . . . . . . . . . . . 85

6.1 Design of Automated and High-Speed
Manufacturing Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
6.2 Computer-Aided Simulation of Automated
and High-Speed Manufacturing Systems . . . . . . . . . . . . . . . . . 92
6.2.1 Computer-Aided Simulation on Automated
High-Viscous Liquid Filling System . . . . . . . . . . . . . . 92
Chemical Gas Charging System . . . . . . . . . . . . . . . . . 94
6.3 Experiment on Automated and High-Speed
Manufacturing Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
6.3.1 Experiment on Automated and High-Speed
Heavy Viscous Liquid Filling System . . . . . . . . . . . . . 102
Chemical Gas Charging System . . . . . . . . . . . . . . . . . 104
6.4 Discussion and Future Improvement on Automated
and High-Speed Manufacturing Systems . . . . . . . . . . . . . . . . . 107
7 Robotic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
7.1 Design of Robotic System for Industrial Applications . . . . . . . . 109
7.2 Computer-Aided Simulation on Robotic System
for Industrial Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
7.3 Experiment on Robotic System for Industrial Applications . . . . 120
7.4 Discussion and Future Improvement on Robotic System . . . . . . 128
Contents ix
8 Magnetic Sealing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

8.1 Design of Magnetic Sealing System . . . . . . . . . . . . . . . . . . . . . 129
8.2 Computer-Aided Simulation on Magnetic
Sealing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
8.3 Experiment on Magnetic Sealing System . . . . . . . . . . . . . . . . . 142
8.4 Discussion and Future Improvement on Magnetic
Sealing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
9 Automated and High-Speed Packaging System . . . . . . . . . . . . . . . . 147
9.1 Design of Automated and High-Speed Packaging
9.2 Computer-Aided Simulation on Automated
and High-Speed Packaging Machinery System . . . . . . . . . . . . . 148
9.3 Experiment on Automated and High-Speed Packaging
and High-Speed Packaging Machinery Systems . . . . . . . . . . . . 169
Part III Biomedical Systems
10 Biomedical and Surgical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . 173

10.1 Design of Biomedical and Surgical Systems . . . . . . . . . . . . . . . 173
10.2 Computer-Aided Simulation on Biomedical
and Surgical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
10.2.1 Biomedical Open Surgiclip Instrument . . . . . . . . . . . . 177
10.2.2 Biomedical Endoscopic Surgiclip Instrument . . . . . . . . 192
10.3 Experiment on Biomedical and Surgical Systems . . . . . . . . . . . 217
10.3.1 Experiment on Biomedical Open
Surgiclip Instrument . . . . . . . . . . . . . . . . . . . . . . . . . . 218
10.3.2 Experiment on Biomedical Endoscopic
Surgiclip System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
10.4 Discussion and Future Improvement on Biomedical
and Surgical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Biography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
Introduction
1
3D modeling can perform mathematic and geometric analysis on 3D object surfaces

via CAD software (Gupta et al. 2010). 3D models can be expressed as 2D images
via process of 3D rendering and used in computer-aided simulation to study
physical phenomena (Kim and Kim 2011). 3D models can also be geometrically
created by 3D printing process. 3D modeling technology allows efficient modeling
processes including curve-controlled modeling that can simulate the motion of 3D
objects instead of only static geometry (Senthil et al. 2013). 3D computer graphics
software can assist 3D modeling processes to create 3D geometrical models. 3D
models can represent 3D objects by collecting points connected by different
geometric entities including lines, triangles, squares, rectangles, curved surfaces,
and irregular geometries in three-dimensional space (Lee et al. 2010). 3D modeling
is widely utilized in many different areas, such as 3D graphics design, product
development, and computer games (Sun et al. 2005). 3D modeling processes
include solid modeling that defines object by volume and shell/boundary modeling
that determines object by defining surfaces and boundary (Sipiran and Bustos
2010). 3D modeling can transform all object points, such as internal points and
points on circumference surfaces, into polygon elements representing the sphere
and volume for model rendering (Ouertani et al. 2011). Triangular modeling
meshing is widely used since the meshes can be easily rendered. Polygon meshing
element is another modeling method but it is not very popular since the tessellation
processing is not provided in the transition to achieve rendering surfaces
(Li et al. 2012). 3D polygonal modeling is one of the most popular modeling
methods due to its accurate, flexible, and quick meshing process. In 3D polygonal
modeling, 3D points are linked via many tiny line elements to generate polygonal
meshes (Harik et al. 2008). 3D curved modeling is another common method, in
which all the object surfaces are specified by curves that are manipulated by the
weight-controlled points in 3D space. The curves will move close to the points
when weight of these 3D points is increased for more accurate modeling process
(Reich and Paz 2008). Compared to 2D modeling methodology, 3D modeling can
change and animate parts with (1) quick object rendering, (2) easier object
# Springer International Publishing Switzerland 2015 1

J. Zheng Li, CAD, 3D Modeling, Engineering Analysis, and Prototype
Experimentation, DOI 10.1007/978-3-319-05921-1_1
2 1 Introduction
rendering, and (3) more accurate rendering (Tian et al. 2009). 3D modeling has
been applied in different businesses and industries including movie filming, con-
sumer product design, industrial design, cartoon animation, video gaming, archi-
tecture design, and engineering research (Walthall et al. 2011). CAD software can
be used to assist 3D modeling for product design and development.
Computer-aided design (CAD) is to apply computer systems to assist the
engineering process for creating, modifying, analyzing, and optimizing the product
design (Stefano et al. 2013). CAD software is used to accelerate design process,
improve design quality, ease technical communication via engineering documenta-
tion, and build database for production (Veltkamp et al. 2011). CAD results can be
output in electronic files for printing, manufacturing process, production operation,
etc. The CAD systems can be applied in different product designs including
electronic, civil, mechanical, and automated systems (Pessoa et al. 2012). CAD is
an efficient engineering design tool that has been widely used in different
applications including designs of car, ship, aircraft, industrial products, and archi-
tecture. (Starly et al. 2005). CAD can also be extensively applied to generate
computer-aided animation for filming, commercial advertising, and product
manuals (Kosmadoudia et al. 2013). Current CAD software packages provide 2D
drafting and 3D solid modeling. CAD can allow three-dimensional object rotation,
view designed object from different angles, and check full geometrical features
from inside and outside of desired objects (Piatt et al. 2006). CAD can be applied
for building conceptual design and product layout, defining production methods via
structural analysis of product assembly, and detailing engineering 3D models/2D
manufacturing drawings (Sung et al. 2011). CAD systems were originally devel-
oped with computer languages including Algol and Fortran but CAD technology
has been significantly changed due to development of object-oriented programming
(Vincent et al. 2013). Modern CAD systems have been developed using interaction
of graphical user interface with object geometry and boundary envelop to control
relationships among different object geometries in complex sketches, part models,
and product assemblies (López-Sastre et al. 2013). Currently CAD systems can
work with most platforms such as Windows, UNIX, Mac OS X, and Linux. Today
there are many different CAD systems applied in business, research, engineering,
and industry including Pro/Engineer, SolidWorks, CATIA, Solid Edge, Inventor,
Unigraphics, CADDS, and AutoCAD (Rocca 2012). Computer-aided design and
engineering analysis have been applied to create 3D product features, specify the
material information in mechanical and thermal properties, define geometrical
shape, determine part dimension, perform manufacturing tolerance control, and
analyze the system functionality and structure of product systems (Adán et al. 2012;
Chae et al. 2011). CAD technology significantly reduces drafting time and effi-
ciently helps professionals in product design and development (Chaouch and
Verroust-Blondet 2009). Current CAD software packages provide efficient ways
to control product design in 3D space, make engineering drawings quickly, and
allow users easily review product design in different views to accelerate the design
process (Claes et al. 2011). Compared to the manual drafting design, CAD technol-
ogy can significantly shorten the design time, improve design quality, and optimize
1.1 Solar Energy System for Water Distillation 3
complex geometric design (Adams and Yang 2004). CAD technology can be
applied to assist geometric dimensioning and tolerancing (GD&T) control, create
conceptual design, make assembly layout, and perform kinematic and dynamic
analysis (Goel et al. 2012). 3D geometrical parameters and boundary conditions can
be used to specify the product dimensions, shape, and solid elements (Bertoni and
Chirumalla 2011). The computer-aided engineering analysis (CAE) can be used
with CAD to determine the structural strength of products including tensile, yield,
principal, and shear strength (Ding, et al. 2009). CAD system can also be used to
perform graphic simulations for preparing different enterprise documents, such as
project of environmental protection in which the CAD-assisted constructions can be
superimposed into existing environmental graphic piles to determine what effects
will be caused to the environment if targeted constructions are being built (Catalano
et al. 2011). Computer-aided design of automated system brings cost-effective
processes to control complex manufacturing systems and production in industry
(Fuge et al. 2012).
In this book, the CAD software of Pro/Engineer is utilized for 3D solid
modeling/product design and Autodesk simulation software is used for engineering
simulation/structural analysis.
1.1 Solar Energy System for Water Distillation
People can have daily clean and pure drinking water easily since getting clean water
is simply opening the faucet. However, in many underdeveloped countries or in
some extreme disaster-related situations, it is difficult to get clean and pure water
(Anjaneyulu et al. 2012). Solar distilling process is a way of changing impure water
into clean water. Based on report from the World Health Organization, about 1.1
billion people over the world are not able to find safe drinking water. Among them,
about 2.1 million people die each year due to drinking of contaminated water
(Badran et al. 2005). The solar distilling process is a method of distilling water
by using the heat from the sun to generate moisture evaporation from humid
environment and applying air to cool the condenser to produce filtrated water.
Distillation process is one of the methods to control water purification (Jabbar
et al. 2009). Sunlight is one of multiple heat energies that can be applied to perform
water distillation process. In solar water distillation process, there is no fuel cost but
requires associated costly distilling equipment (Manikandan et al. 2013). Although
the solar distilling drinking water costs several times that of water supplied from
city utilities, it is still less expensive than the bottle water in outside store due to its
energy-wise distilling process (Lattemann and Höpner 2008). In case the local
residents are worried about purification quality or concerned about the purified
addictives added to the local city water, solar distilling of tap water will be a safe
and energy-saving process (Chakraborty et al. 2004). Since the energy cost is
continuously increased and the pressure of more human population is constantly
exerted on current available freshwater, the solar desalination of seawater has its
energy-efficient and cost-economic advantages (Jabbar et al. 2009; Li 2011c). In
4 1 Introduction
solar still unit, the impure water is gathered around the outside surface of collector
and evaporated by sunlight that is absorbed through clear plastic panel. When pure
water vapor passes the condenser, it will get cooled and condensed on the cold
surface. The filtrated water droplet will drip down by its gravity to the pure water
collector at lower chamber in solar still unit. This distilling process takes away the
impurities including heavy metals and microbiological organisms from environ-
mental water (Tiwari and Tiwari 2007). The solar still system can also be applied in
the places where rainwater, well water, or city water is not available. In case of
power outage during severe weather conditions, such as hurricane season, the solar
distillation system can supply an alternative clean water resource. The basic basin-
type solar still unit mainly consists of some stones, transparent plastic or glass
panel, condenser, and collector to store condensed pre-water (Yang et al. 2011). As
the sun heats and evaporates the moisture, water vapor moves to condenser where
the vapor gets cold and condensed to form water droplet which will drop down to
pure water collector at the bottom of solar still unit. Other solar distill systems, such
as wick solar still, can distil the salt water. In wick solar still system, salted water
input in from the top gets evaporated after heated by the sunlight through transpar-
ent plastic or glass panel (Alloway 2000). The vapor starts condensation at the
underside of plastic panel and drips to the bottom collector. The purity of distilled
water stored in the bottom collector relies on how much salt can be separated from
the salt water in solar distillation unit. If more wicks are constructed in the solar
still, more heat can be transmitted to the salt water which makes more distilled
water product. A plastic fine grid thin plate can be installed in order to capture more
brine from salt water before it goes down to the container. This will provide longer
time to heat up impure water and separate the brine from salt water. The wick-type
solar still should be equipped with good seal in order to prevent vapor from
escaping to the outside environment. Some wicks should be darkened in order to
absorb more heat to increase distilled water productivity (Jabbar et al. 2009). There
are several other different types of solar sill designs including the single-basin
distillation unit that consists of a basin equipped with a tilted thin glass or plastic
plate to hold impure water. The dark basins can function better to capture the
sunlight energy. The solar distillation units equipped with glass usually show
durable function and longer life but the units equipped with plastic sheet are of
lower cost and have easy installations. The tilted thin glass or plastic plate permits
the water to easily drain out of the solar distillation units into the collector through a
tube (Anjaneyulu et al. 2012).
1.2 Wind Power Turbine System
The wind power is a process in which the wind turbine converts wind energy into
mechanical (kinetic) energy (Ogbonnaya 2011; Passon et al. 2007). The mechani-
cal energy can be applied to generate the electricity in wind power plant system,
or employed to operate machinery or pumping water in windmill or wind pump
system (Agarwal and Manuel 2007; Simhauser 2010; Saravanamuttoo et al. 2009).
1.3 Solar Panel Tracking System 5
Wind power density which is related to the wind velocity and air density can be
used to calculate the mean annual power generated in each square meter of turbine
sweeping sectional area and the density changes with different heights (Bir and
Jonkman 2007; Kim et al. 2011; Li 2013; Vallee et al. 2009). In the real wind
power turbine, it is not possible to capture total wind power since some acquired
air will exit the turbine system. The ratio of inlet and outlet wind velocity should
be considered in the wind turbine system design and the maximum efficiency of
gained wind power by current turbine is around 60 % (Carey 2010; Li 2012f;
Singh and Nestmann 2011). The power delivered by wind turbine system will be
reduced due to the losses in gear train, converter, rotor blade, and generator
(Fulton et al. 2006). The turbines are normally placed at upwind location of
structural tower and turbine rotor blades are constructed in strong stiffness to
keep the blades from being bended into structural tower due to strong gusty wind
(Christodoulou et al. 2011; Li 2012f; Ogbonnaya et al. 2010). Wind turbine
systems have been designed to capture the wind energy in a specific place and
aerodynamic analysis can be employed to verify the proper height of structural
tower, to decide the feasible control systems, and to determine the rotor blade
geometry and numbers (Komandur and Sunder 2008; MacLeod and Jastremski
2010; Silva et al. 2011).
1.3 Solar Panel Tracking System
The global warming demands and requests the alternate energy resources from
green and renewable energy sources including solar power energy. The solar panel
tracking systems are the device that orients solar panel following movement of the
sun (Bhandari and Stadler 2009; Munilla 2013). Solar panel can be photovoltaic
and reflective panels or some optical related devices. In photovoltaic flat panel
system, tracking mechanism is applied to reduce the incidental angle between
input sunlight and solar panel to increase the incoming energy received from the
sun. In concentrated solar photovoltaic system, the tracking mechanism is
employed to orient optical device towards the sun to receive maximum direct
sunlight energy (Brinkworth and Sandberg 2006; Li 2013b). The effective
sunlight-receiving area in solar panel system changes with the cosine of angular
deviation between panel direction and the sun (Hoke and Komor 2012). Since
sunlight has two components in which around 90 % of solar energy is contained in
direct sunlight and rest energy is contained in diffusive sunlight, the sun requires to
be visible as much as possible; otherwise more direct sunlight energy will be
proportionately reduced in cloudy sky (Darling et al. 2011). The tracking system
with accuracies of 4.5 can catch more than 98.8 % of the energy from direct
sunlight and also 100 % of the diffusive sunlight (Laird 2011; Mendonça and
Jacobs 2009). Although the sun moves 360 from east to west each day, the
approximate visible portion of the sun is around 180 (average half day time). If
a solar panel in horizontal location does not rotate from east (dawn) to west
(sunset), only sunlight that travels about 80 could be caught and rest of the
6 1 Introduction
sunlight energy in the early morning and late afternoon will be lost (Timilsina
et al. 2012). The solar panel orientation from east to west can help to maximize the
capture of daily sunlight energy. Single-axial tracking system that has one degree
of freedom with angular rotation around one axis can be applied to this solar
system (Wang et al. 2011). There are several types of single-axial tracking systems
including horizontal, vertical, inclined, and polar aimed single-axial tracking
systems. In horizontal single-axial tracking system, the orientating axis is installed
horizontally related to the ground and setup of multiple solar panel groups is
simple since all rotating axes of all groups can be maintained parallel to each
other. In vertical single-axial tracking system, the orientating axis is mounted
vertically related to the ground. This tracking system rotates solar panel from
east to west during the day and it works more efficiently than horizontal axial solar
tracking system at higher elevation (Myers et al. 2010). The setup of multiple
groups in vertical axial tracking systems should consider reducing the shade to
minimize unexpected sunlight energy losses. In tilted single-axial tracking system,
it has two rotating axes with which the solar panel can rotate around horizontal axis
and vertical axis individually. The tilted angle system can be adjusted to decrease
the wind load pressure (Simhauser 2010). The multiple group setups are needed to
reduce the shade to minimize the sunlight energy losses. Although the panels in
group setups can be adjusted without shade when perpendicular to the rotating
axis, the setups that parallel to their rotating axes are complicated and will be
limited by the panel tilted angles and its elevations. The polar aimed single-axial
tracking system equips a telescope-guided unit and tilted single axis is adjusted to
aim at the polar star. In this tracking system, the solar system’s tilted axial angle
equals to its site latitude that keeps good alignment between rotating axis of
tracking system and orientating axis of the earth. The sun travels 48 between
the north and south as well in a full year and only sunlight that travels about 24
could be caught (Branker et al. 2011). The tracking system with orientation from
the east to the west (daily movement) and from the north to the south (seasonal
movement) called double-axial solar tracking system should be used to minimize
the lost sunlight energy. The double-axial tracking system that has two degrees of
freedom with angular rotation around two axes can also be employed to the solar
system. In this system, two axes are normally perpendicular to each other
(Ramadhan and Naseeb 2011). The primary axis is the rotating axis related to
the ground and secondary axis is normal to the primary axis. Several major types of
double-axial tracking systems include tip-tilted double-axial tracker and azimuth-
altitudinal double-axial tracker (Falconett and Nagasaka 2010). The rotation of
solar panel related to the tracking system is important to the solar function and
double-axial tracker permits better receiving of solar energy due to its capability of
tracking the sun in vertical and horizontal directions. Some factors should be
considered while selecting the types of tracking systems, such as environment
condition, local latitude, on-site weather, electrical price, and installation
dimensions. The tracking systems using motor drivers and gearing unit to orientate
the solar panels are directed by controller to track the sun traveling directions
(Ferrey 2006; Ramadhan and Naseeb 2011).
1.4 Energy-Saving Cooling System 7
1.4 Energy-Saving Cooling System
The cooling process is to move heat from one place to another place and heat
transfers are driven not only by mechanical energy but also by the energies from
electricity, heat, and magnetism (Bagarella et al. 2013; Christian and Hermes 2013;
Lucas and Koehler 2012). There are many applications using cooling systems
including cryogenics, commercial freezers, residential refrigerators, and air
conditioners (Agrawal and Karimi 2012; Barbosa and Sigwalt 2012; Li 2009d).
The current widely used applications of cooling systems are for industrial cooling
processes in manufacturing and production, air conditioning for residential and
commercial buildings, medical treatments, surgical operations, climate-controlled
food conservation, and many others (Derking et al. 2012; Engelbrecht et al. 2012;
Oró et al. 2012a, b). In industrial and production processes, the cooling systems can
be applied for gas liquefaction, air purification, oil refinery, and metallic material
temper treatment (Khan et al. 2012; Li 2012; Mumanachit et al. 2012). There are
several cooling processes including cyclic cooling (i.e., vapor cycle and gas cycle),
magnetic cooling, and thermoelectric cooling (Ally et al. 2012; Sanaye and Asgari
2013). In cyclic cooling process, heat is taken away from lower temperature source
and released to higher temperature source that is driven by external energy work.
The refrigerant absorbs and releases the heat as it circulates in a cooling system
(Bhanja and Kundu 2011; Shamsoddini and Khorasani 2012). The cyclic cooling
processes include vapor cooling cycle and gas cooling cycle (Egolf et al. 2012; Zhu
et al. 2013). In vapor cooling cycle, vapor is compressed with no change of entropy
and leaves compressor at higher temperature but pressure is still below the vapor
pressure at that associated temperature. The vapor starts condensing into the liquid
phase after passing the condenser and the evaporation will be generated when
liquidized refrigerant flows across the expansive valve to absorb the heat through
evaporator unit to cool external environment (Colombo et al. 2012; Cuevas
et al. 2012). In gas cooling cycle, the gas phase does not change during compression
and expansion. The cooling capacity equals the product of gaseous specific heat and
temperature rise in lower temperature source (Abed et al. 2013; Thomas
et al. 2012). The gas cooling cycle is widely applied as cooling system in gas
turbine-driven fight jet or airplane. In thermoelectric cooling system, the heat flow
between two different media contacts is driven by Peltier effect that is widely
applied in mobile cooling unit for temperature control of instruments and electronic
devices (Coşkun et al. 2012; Šarevski and Šarevski 2012). In magnetic cooling
system, the refrigerating media is usually a paramagnetic salt and active magnetic
dipoles are from the electron shells of paramagnetic atoms (Ayou et al. 2012;
Faúndez et al. 2013). The multiple magnetic dipoles in cooling media are driven
to be aligned under higher magnetic field and degrees of freedom in cooling media
are being put into lower entropy environment (Aprea et al. 2013; Qureshi and
Zubair 2013). The thermal sink then receives heat removed from cooling media due
to its entropic loss. The contacts between cooling media and thermal sink is then
disconnected and the unit is insulated causing switch-off in magnetic field that
8 1 Introduction
raises thermal capacity of cooling media and reducing its temperature below
thermal sink temperature (Gheisari et al. 2012; Kagawa et al. 2013).
The coefficient of performance (COP) of a cooling system is a critical parameter
in judging the systematic efficiency of a cooling system (Kitanovski et al. 2012;
Piacentino and Talamo 2013). COP is designated as the ratio of cooling capacity to
external energy input (Kumlutaş et al. 2012). The performance factor (PF) of a
cooling system is another important parameter in examining the systematic effi-
ciency of a cooling system. PF is determined by the ratio of energy input to cooling
capacity (Ekren et al. 2011; Góral and Kluza 2012). The newly developed cooling
system introduced in this book focused on energy saving and manufacturing cost
reduction due to its simplified design.
1.5 Automated and High-Speed Manufacturing Systems
Automated machinery system is to apply various control systems to control and

operate the machinery with minimized or decreased human intervention (Bao
et al. 2013; Janchiv et al. 2013). The major advantages of automated machinery
system include reducing labor, saving energy, optimizing material usage, improv-
ing quality, keeping accuracy, and maintaining precision (Andrikopoulos
et al. 2013; Bay et al. 2008; Jeon et al. 2013). Automated machinery systems can
be supported by many different ways including computers, pneumatics, hydraulics,
mechanics, and electronics (Baniardalani and Askari 2013; Kim et al. 2013). Two
popular controls applied to automated machinery system are feedback control and
sequential control (Koo et al. 2013; Li 2011b; Liu et al. 2013). The feedback control
includes continuous measurement by applying optical or proximity sensors and
computes adjustments to maintain the allowable range for measured variables
(Bang et al. 2013; Beebe 2009; Liaquat and Malik 2013). For example, when
using feedback control for air-heating system, the sensor detects the heated air
temperature and the signal is being continuously fed back to the systematic con-
troller to compare with targeted variable setting (Berretti et al. 2012; Che
et al. 2013; Lini et al. 2013). The temperature difference is calculated in the
controller and the signal will be sent to the heater after temperature adjustment
has been determined (Nikolakopoulos and Alexis 2013; Pai 2013; Tombari
et al. 2010a, b). The sequential control involves executing programmed logic
sequence in discrete operations. The relay logic is one of the forms in sequential
control and electrical relays control electric contacts that can make either connec-
tion or disconnection between the electronic devices (Berretti et al. 2012; Cho
et al. 2013; Park et al. 2013). For example, when applying sequential control for
elevator, relay logic has been created while engaging or disengaging the electrical
contacts to start or stop electric motor to operate the elevator (Bouazza and Ouali
2013; Li 2012; Lini et al. 2013). Machine tools can be automatically operated by
numerical control (NC). Automated machinery systems can be applied in
manufacturing and assembly processes, such as petroleum refining, power genera-
tion, chemical production, plastic molding and injection, steel making, automobile
1.6 Robotic System for Industrial Applications 9
assembly, food processing, automated welding, and many other industrial

applications (Choi et al. 2013; Sami and Patton 2013; Tuan et al. 2013). The
major advantages using automated machinery systems include higher productivity,
better quality, more consistency, less human involvement, and reduced labor cost
(Faltemier et al. 2008; Ullah et al. 2013). The automated system is preferably used,
where the cyclic time has to be reduced, higher accuracy must be maintained,
working environment is hazardous or dangerous to the human, and job task is far
beyond the operator’s capability, to keep strong economic competitiveness of
enterprises in the challenging market (Lee et al. 2013; Seifabadi et al. 2013).
Automated machinery system can meet the growing demand for flexibility and
convertibility in production processes. The manufacturing industries are continu-
ously demanding the capability to flexibly change from making one product to
another new product with no need to completely set up a new production line (Han
et al. 2013; Li 2011b; Seok et al. 2013). The numerical control (NC) has been
currently applied to control automated production systems in many companies
quickly expanding the automated applications and widely benefiting the human
activities (Christophe et al. 2010; Hu et al. 2013; Van et al. 2013). Computer-aided
control technology can be employed as the basis to create complicated industrial
systems through implementing mathematical and business’s functioning models,
such as computer-aided design (CAD), computer-aided engineering analysis
(CAE), and computer-aided manufacturing (CAM) (Ding et al. 2013; Han
et al. 2013; Wang and Yang 2013). The integration of information technology
(IT) with industrial machines and manufacturing processes can significantly sup-
port the control system design and development, such as programmable logic
control (PLC) system (Jeon et al. 2013; Ji et al. 2013; Lamooki 2013). The PLC
system can be normally used to control the operation sequence between input
sensors and output actuators. The automated control systems can be widely applied
in different industries including producing aerospace, food, mining, automotive,
environmental waste process, medicines, agricultural products, chemicals, metal
working, product inspection, and machine cutting (Huang et al. 2010; Kong and
Tomizuka 2013; Lee et al. 2013). The importance to increase manufacturing rate is
to integrate the automated software with machinery drives, production services,
and business solutions to make company more competitive (Li et al. 2013;
Yang et al. 2013).
1.6 Robotic System for Industrial Applications
Robotic technology is a technical field dealing with engineering design,

manufacturing operation, automatic applications, computational control, sensing
feedback, and data processing (Howard et al. 2006). The robotic system design usually
integrates the technologies of computer science, mechanical engineering, electronic
engineering, and manufacturing engineering (Kazerooni 2005; Li et al. 2011). The
mathematical expression of a robotic system is used to control algorithms
in observing how a functioning process has been handled (Harja et al. 2007).
10 1 Introduction
In history, the robotic systems were sometime being used to simulate human
behavior and perform certain tasks. Today, the robotic systems are rapidly develop-
ing with continuous advances of automation technology, scientific research, and
engineering design (Lerman et al. 2006). The robotic systems can perform different
special jobs that are heavy duty, too dirty, very dull, and environmentally hazardous
to the humans. Robotic systems are more accurate and reliable than humans so they
have been widely applied in production processes including product packaging,
manufacturing assembly, material transport, space exploration, surgical procedure,
and many others (Pounds et al. 2004; Ratti and Vachtsevanos 2010). The actuators in
robotic systems, such as motors and drivers, transfer the stored energy to the
different kinds of motions including linear and angular movement (Mian
et al. 2010). The mechanism of robotic systems is controlled to perform different
functions. The sensors allow robotic systems to obtain data information from
measurement and decide the related response to perform different tasks (Kennedy
and Desai 2003; Salti et al. 2013). In the robotic operation, sensors receive and
provide information of external conditions (i.e., location, temperature, pressure) and
situations of robotic system itself (i.e., location of its arm, gripper, joint pin points)
(Klopcar et al. 2007; Tapus et al. 2008). All these received data information can be
collected, calculated, and executed in systematic controller to instruct the movement
of robotic system. The robotic systems can be used for manipulating the products
including picking and placing parts in the manufacturing processes (Leibe
et al. 2008). The robotic arms, equipped with mechanical or vacuum grippers, can
move around in a range of 3D motion by more advanced ways using balanced
dynamic algorithm (Mellinger et al. 2010). The robotic motion study focuses on two
areas: kinematic motion and dynamic motion. Direct kinematic motion study
performs the calculation of gripper location, rotation, speed, and accelerated rate
while the associated connecting joint values are given (Rachidi et al. 2013;
Shakernia et al. 2002). Inverse kinematics motion study considers the situation in
which the connecting joint values are computed while the gripper position values are
given (Mian et al. 2008). The kinematics can deal with the collision prevention,
singularity elimination, and system redundancy. After getting associated locations,
speeds, and accelerations by applying kinematics, the effect of forces on its motion
can be determined by employing the dynamics (Shen et al. 2008; Tsagarakis and
Caldwell 2003). The direct dynamics focuses on the computation of acceleration in
robotic systems if exerted forces are given and inverse dynamics studies the robotic
driving forces required to generate the robotic system acceleration (Tapus
et al. 2007). All the above information can be applied to adjust and control the
algorithms of the robotic systems (Torbjorn et al. 2009).
1.7 Magnetic Sealing System
There are several types of magnetic sealing systems. The magnetic liquid seals are
applied in rotating machinery to allow rotation while keeping a tight seal by using
ferrofluid, that is contained in place by applying the permanent magnet, as the
1.8 Automated and High-Speed Packaging Machinery System 11
physical barrier to prevent leaking (González-Jorge et al. 2005; Mitamura

et al. 2008). Magnetic liquid rotating seals have almost no requirement of mainte-
nance and very low leakage in the different applications (Shlyk et al. 2004). This
type of seal is normally installed in mechanical assemblies with a centralized shaft,
support bearings, external housing, and other components. The support bearings
offer two critical functions: keeping shaft centralized with even seal gap and
holding outside loads. Since the magnetic liquid rotating seal is actually an
oil-distributive fluid contained magnetically between rotary shaft and stationary
wall inside of housing, the life cycle for this type of seal is increased and frictional
torque load is reduced (Cong et al. 2005; González-Jorge et al. 2007). There is no
requirement for electrical power since magnet has been permanently charged.
Magnetic rotary liquid seal system is designed for many applications for gaseous
and vapor sealing but not for pressured fluid sealing due to weakness caused by
sharp varied temperature, alternative pressure, high speed, differential loads, and
severe environmental changes (Hirsch 2003; Li 2010). Another magnetic seal, also
called vacuum seal, relies on the technology of using electromagnetic field to hold
metal components together. This magnetic sealing unit is usually applied to seal the
nonenvironment-friendly products and keep hazardous materials from leakage
(Topal et al. 2003; Zydlo et al. 2005). It has been designed to block any impurities
or tiny particles that intended to permeate the seal mechanism and build up an
airtight seal between rotary shaft and stationary wall inside the housing (Ochonski
2005; Tušek et al. 2011).
A new type of magnetic sealing system introduced in this book focuses on more
reliable functioning sealing system with less manufacturing cost and enlarged life
cycles. Currently many rotary machineries use the conventional seals in lip or
labyrinth geometrical shapes (Li et al. 2005). However, these conventional seals
show significant wear and leakages of gas and liquid through these types of seals
were detected (Takashi 2002). The life cycle of these traditional seals is much
shorter than that of magnetic seals (Morton and Fruh 2002). The magnetic sealing
mechanism can be applied to improve sealing function in different engineering
applications (Zhao et al. 2006).
1.8 Automated and High-Speed Packaging Machinery System
The packaging engineering and technology is a technical field ranging from

packing system design to final product placement. All the sequential layouts in
the production line should be taken into account while designing the package
system for any developed end products (Fuge et al. 2012; Han and Lee 2013;
Jeon et al. 2013). Packaging production systems are used to reliably package the
products to prevent products from damage during delivery and in the storage (Cho
et al. 2013; Fusco and Russo 2013). Many innovations in the packaging systems
were initially developed for military practices since certain military packaged
products must be transported in the most severe environment, harsh distribution,
terrible storage, and dangerous conditions (Chu and Chang 2005; Jeong et al. 2013;
12 1 Introduction
Lee et al. 2010). When designing the package engineering systems, it should focus
on the industrial and technical aspects in production, marketing, industrial logis-
tics, materials being handled, and final product-related design (Devanathan and
Ramani 2010; Harja et al. 2007; Hu et al. 2013). The package being processed must
prevent the products from breakdown while keeping the cost-effective and efficient
packaging production cycles. The objectives of packaging technique target that the
products wrapped in the package should be kept from ruin caused by external
compression, physical shock, harsh drop-off, varied temperature, mechanical
vibration, and electrostatic discharge (Gerkey and Matarić 2004; Goel
et al. 2012; Jiang et al. 2013). The transport packaging needs to follow the standard
logistics system in order to meet the protective strength and holding capability of
transporting packages. The package design and testing might be performed within
the company or from outside packaging engineering firms (Andrikopoulos
et al. 2013; Baniardalani and Askari 2013). To pack products by machinery system,
the packaging machine selections should consider its packaging capabilities, tech-
nical requirements, systematic maintainability, labor involvement, packing reli-
ability, operation safety, machine serviceability, flexibility to be integrated into the
production line, layout space, front and running cost, energy efficiency, and
ergonomic design for future transport handling (Agarwal and Manuel 2007; Gao
et al. 2013; Seifabadi et al. 2013). Automated packaging systems can improve
packing quality and increase productivity. There are many types of packaging
machineries including systems for cartooning, bottling, accumulation, collection,
slitting, sealing, converting, filling, and wrapping (Kim et al. 2013; Salti
et al. 2013; Song and Li 2013). Packages are designed from many different types
of hard or flexible materials that have folding lines to permit further folding into
the package shapes. Some major processes that packaging manufacturing is mainly
involved in are extrusion-assisted forming, thermo-assisted forming, molding-
assisted forming, and other technology-assisted forming processes (Koo
et al. 2013; Regli et al. 2011; Seifabadi et al. 2013). Packaging productions can
be designed for high-speed processes including filling, packing, and shipping (Fang
et al. 2013; Rezgui et al. 2011). The structural and thermal analysis of packing
tools and materials requires to be performed to evaluate the packaging quality and
its further improvement (Ratti and Vachtsevanos 2010; Wang et al. 2013). Good
packaging system design makes products more tangible to the users, sets a tight
customer connection, and efficiently influences marketing decision to engage
(Passalis et al. 2011; Yoon 2013). It is very important to understand how to
combine global marketing information with customer needs and cultural prefer-
ence to effectively join current and future compelling global discipline (Stefano
et al. 2013; Zhu 2013).
1.9 Biomedical and Surgical Systems 13
1.9 Biomedical and Surgical Systems
New biomedical and surgical instruments have been designed and developed to
perform complex surgery and biomedical treatment by applying the minimally
body-invasive approaches and reliable medical instruments (Brown et al. 2007;
Cheng et al. 2004; Kavitha and Ramakrishnan 2011). Many different medical
treatments and surgical procedures can be facilitated efficiently for gynecology,
urology, prostatectomy, general medical treatment, cardiac valve restore, plastic
surgery, orthopedics, and neurology by applying good medical instruments (Ballihi
et al. 2012; Chambers et al. 2013; Kosta et al. 2012). Doctors and surgeons are
required to know the knowledge and learn the skills to correctly use different
surgical instruments in sterile and aseptic surgical environment (Fadzil
et al. 2011; Kayalvizhi et al. 2013). The goal of newly developed biomedical and
surgical instruments is for doctors and surgeons to be able to perform the medical
treatments more smoothly and efficiently to ensure that the medical operative
procedures are safe and instrument functions are reliable (Gill and Munroe 2012;
Goy et al. 2012; Kumar et al. 2012). To carry through a surgical procedure, doctors
and surgeons must well control and accurately manipulate the medical instruments
to keep full safety and functioning features that are designed for minimum human
errors (Hemalatha and Manivannan 2011; Janghel et al. 2012; Li 2012). New
biomedical and surgical instruments are designed and developed to improve upon
conventional surgical procedures to ease and benefit doctors and surgeons in
medical treatments and surgical operations by providing clear visualization, precise
control, ergonomic satisfaction, consistent function, safe interaction, and flexible
adjustment (Haddad-Mashadrizeh et al. 2013; Kalantzaki et al. 2013; Li 2011). The
newly designed and developed biomedical and surgical instruments introduced in
this book also aim at eliminating surgiclip drop-off incident, less operational force,
more stable driving mechanism, and more robust structural design while
manipulating the thick body tissues in medical treatments and surgical operations.
Part I
Energy Systems
Solar Energy System for Water Distillation
2
Some newly designed and developed product systems are introduced in this chap-
ter. It includes the green (sustainable) energy system for water distillation, wind
power system, automated and high-speed machinery system, solar panel tracking
system, robotic system, biomedical and surgical system, energy-saving cooling
system, magnetic sealing system, and high-speed product packaging system. All
these new product systems have been designed and developed through computer-
aided modeling and simulation. The design methodology has been described for
these new product systems to detail the design procedure and assist readers in their
future academic endeavor.
2.1 Design of Solar Energy System for Water Distillation
Solar water distillation systems have the potential to make the clean water for
safer drink, cooking, and many other commercial usages. The solar still is to apply
solar energy to generate the water evaporation and catch the vapor by condensing
it at cold surface. The evaporating rate can be controlled through increasing water
temperature and enlarging the contact area between water and air. The small
individual solar water distillation devices are for residential purpose and larger
distilled water system for industrial applications. Since many areas do not have
enough water distillation or purification systems, people are sometimes concerned
about environmental pollutants in the water supply. The application of solar water
distillation system is one of the effective possible solutions. The solar water
distillation system has the advantage over regular water filtration systems that
still show some potential threats to the people due to the difficulty of removing
some inorganic materials. In solar water distillation process, water gets heated and
finally becomes steam. The steam is then cooled and condensed into liquid water
through heat exchanger and any inorganic materials contained in the water can be

18 2 Solar Energy System for Water Distillation
Fig. 2.1 Newly developed green (solar) energy distillation system
filtered out. Meanwhile, this solar distillation process does not affect good organic
minerals existed in the water. This new green (solar) energy distillation system
can also separate the dissolved salts from sea water to make fresh drinking water.
This cost-effective solar system is simple and it can be easily installed with less
maintenance. It keeps higher water temperature at unit entrance, maintains proper
temperature difference between input water and condensing surface, and
minimizes the vapor leakage. This new systematic design helps entering water
to absorb as much radiation as possible with less heat losses from the floor
and walls.
This new green (solar) energy distillation system is displayed in Fig. 2.1.
Water flows in from inlet tube and moves the little ball up to open up the internal
channel for entering water which will be collected in the basin thereafter. When
target water level is arrived, the large ball travels up and little ball travels down to
barricade the inlet tube to keep more water from entering the basin. This solar
distillation system will get hot due to the sunrays emitted from the reflector to warm
up the absorber. The absorber takes in the sunrays and provides the heat to the
impure water entering from inlet tube. Then water begins evaporating and the vapor
will be condensed when it arrives at the upper chamber of basin, adhered to the
internal wall, and changed to the water droplet because the temperature in upper
chamber is lower than that in bottom chamber. The condensed water droplets can
travel to the U-type channel in solar energy distillation system to make pure water
from any type of impure water including sea water. The purified water from output
pipe can be accumulated in the output container.
2.2 Computer-Aided Simulation of Solar Energy System for Water Distillation 19
2.2 Computer-Aided Simulation of Solar Energy System

for Water Distillation
Since the sun is extremely far away from the earth, its radiated light can be
considered to be almost parallel to the earth surface. The solar energy recorded at
the earth surface is around 1,368 W/m2 (Alloway 2000). Since the earth rotates
itself and moves around the sun eccentrically because of its elliptically traveling
path, the distance between the sun and earth changes as the earth moves. If ψ is the
angle between perpendicular direction to the earth surface and the solar radiated
flux flow of N, solar energy caught by panel surface in solar distillation system can
be calculated by the equation of N cos(ψ). Angle ψ also changes based on latitude
(ζ), declination (λ), hour angle, and zenith angle (Alloway 2000):

360
λ ¼ 23:5 sin ð284 þ SÞ ð2:1Þ
365
In diffusion radiation, tilt factor, the ratio of radiated diffusion flux flow arrived
on the tilted surface to the horizontal surface, is represented by the ωF as follows
(Gevorkian 2007):
1 þ cos ðηÞ
ωF ¼ ¼ 0:93 ð2:2Þ
2
The computer-aided modeling and numerical simulation are applied to design
and develop this new solar distillation system.
Figure 2.2 shows the computer-aided FEA meshing in this new solar energy
distillation system.
Figures 2.3 and 2.4 display the computer-aided simulation of solar radiation
intensity in this new solar energy distillation system. The computational simulation
from Fig. 2.3 demonstrates that the maximum solar radiation intensity is
2,388.50 W/m2.
Figure 2.4 exhibits the distilled water output vs. duration time in this new solar
Figure 2.4 presents that the distilled water output is proportion to the basin
temperature in this solar energy distillation system. If solar basin temperature is
raised, the water evaporation will be accelerated to keep more pure water produced
from this solar distillation system.
In order to verify if the structural support of solar distillation system is properly
designed, the wind load and snow load are being presented in the following
mathematical equations (2.3) and (2.4), respectively.
Velocity pressure (qz) at solar distillation system height z can be calculated by
the equation (ASCE 7-05 2005)
qz ¼ 0:00256 K Z K ZT K D V 2 I ð2:3Þ
Fig. 2.2 Computer-aided FEA meshing in new solar distillation system
Fig. 2.3 Solar radiation intensity in this solar distillation system vs. duration time
where qz—effective velocity pressure, KD—wind directionality factor, KZ—

exposure velocity pressure coefficient, KZT—topographic factor, V—wind velocity,
and I—importance factor.
Snow load (PF) on solar distillation can be determined by the equation
(ASCE 7-05 2005)
2.3 Experiment on Solar Energy System for Water Distillation 21
Fig. 2.4 Distilled water output vs. duration time in new solar distillation system
PF ¼ 0:7 CE CT I S PS CS ð2:4Þ
where PF—snow load, CE—exposure factor, CT—thermal factor, IS—importance

factor, PS—50-year ground snow load, and CS—slope factor.
The wind load and snow load, calculated from above mathematical models, can
be applied in the computer-aided modeling and numerical simulation to determine
if this new solar distillation system can properly function during severe weather
environment. The FEA simulation and structural analysis are demonstrated in
Figs. 2.5 and 2.6.
The computer-aided simulation and analysis in Figs. 2.5 and 2.6 indicate the
profiles of stress and deflection in this newly designed solar distillation system.
The analytic results show that the maximum stress of 13,358.53 psi on structural
components in this solar system is less than the material yield strength of 36,300 psi
and maximum deflection of 0.0106 in. is within material allowable deformation
limit. So this solar distillation system can properly work in different severe weather
environments including strong wind and heavy snow conditions.
2.3 Experiment on Solar Energy System for Water Distillation
The prototype of this new solar energy distillation system has been built and
experiments have been conducted with all tested results being demonstrated as
follows.
Table 2.1 displays the prototype testing result of solar radiation intensity
vs. experimental duration time.
Fig. 2.5 Computer-aided simulation of stress profile in new solar distillation system
Table 2.2 presents the prototype testing result of solar distilled water output
vs. experimental duration time.
The above prototype testing verifies the proper function of this system since the
experimental results of solar radiation intensity vs. experimental duration time in
Table 2.1 and solar distilled water output vs. experimental duration time in Table 2.2
are very close to the results stated, respectively, in Figs. 2.3 and 2.4 by computer-
aided modeling and numerical simulation.
Table 2.3 shows the experiment results of maximum stress and maximum
deflection in this new solar distillation energy system.
The prototype experimental results in Table 2.3 confirm the appropriate function
of this system since the average maximum stress 13,358.51 psi and average
maximum deflection 0.0111 in. are very similar to the results of maximum stress
13,358.53 psi and maximum deflection 0.0106 in. that are expressed, respectively,
in Figs. 2.5 and 2.6 by computer-aided modeling and simulation.
2.3 Experiment on Solar Energy System for Water Distillation 23
Fig. 2.6 Computer-aided simulation of deflection profile in new solar distillation system
Table 2.1 Prototype Time (h) Solar radiation intensity (W/m2)

testing of solar radiation
2 920
intensity vs. experimental
duration time 4 1,150
6 1,380
8 1,750
10 2,260
12 2,320
14 1,880
16 1,340
18 660
20 480
22 290
24 160
Table 2.2 Prototype Time (h) Distilled water output (ml)

testing of solar distilled
2 950
water output
vs. experimental 4 1,480
duration time 6 1,940
8 2,480
10 3,550
12 4,780
14 5,450
16 5,680
18 5,880
20 6,210
22 6,370
24 6,460
Table 2.3 Prototype Number Maximum Maximum

testing of maximum stress of experiment stress (psi) deflection (in.)
and maximum deflection in
1 13,358.48 0.0111
this new solar distillation
energy system 2 13,358.55 0.0104
3 13,358.52 0.0115
4 13,358.49 0.0112
5 13,358.55 0.0108
6 13,358.46 0.0114
7 13,358.54 0.0115
8 13,358.51 0.0105
9 13,358.48 0.0111
10 13,358.44 0.0115
11 13,358.56 0.0108
12 13,358.51 0.0104
13 13,358.47 0.0114
14 13,358.44 0.0112
15 13,358.56 0.0115
16 13,358.61 0.0103
17 13,358.44 0.0114
18 13,358.48 0.0112
19 13,358.52 0.0115
20 13,358.49 0.0104
Average 13,358.51 0.0111
2.4 Discussion and Future Improvement of Solar Energy System for Water Distillation 25
2.4 Discussion and Future Improvement of Solar

Energy System for Water Distillation
The filtration process can take away many environmental pollutants caused by
manufacturing process and improper disposal of industrial wastes that have been
detected in the drinking water supply. Solar water distillation is one of the most
effective technologies for removing all such pollutants. There are a few disfavors in
solar water distillation systems including the capital expense of solar unit in the
front. To reduce the front cost of this new solar water distillation unit, some
modifications are planned, i.e., simplify the geometrical design layout, modify the
heat exchanger cell for better thermal efficiency, and analyze to select appropriate
materials to bring down the unit cost to further improve this new solar water
Wind Power Turbine System
3
3.1 Design of New Wind Power Turbine System
The wind power turbines, with horizontal or vertical axis types, are technical
equipment that convert wind kinetic energy to mechanical energy used to generate
electricity. The applications range from residential appliance battery charge using
small wind power turbines to commercial electricity production using large wind
power turbine system. Wind power turbines are developed not only to utilize the
green wind energy for different energy enterprises but also to protect environment
from air pollution. Computer-aided aerodynamic modeling and analysis can be
applied to define the height of wind power turbine system, determine turbine blade
geometry, specify turbine control system, and choose the number of turbine blades.
The major turbine components include rotor with blades installed to change wind
kinetic energy to slowly rotated mechanical energy, electrical generator with drive
gearbox and electronics controller to change from slow-inlet shaft rotation to high-
outlet shaft rotation for electricity generation, and all structural components to
support wind power turbine system.
Two new wind power turbine systems, based on author’s new research, were
designed through computer-aided modeling, numerical simulation, and prototype
testing. Figures 3.1, 3.2, 3.3, and 3.4 display the 3D models of these two new wind
power turbines and some turbine components including driver gear and blade.
In design and development of wind power turbine system, the segmental element
theory is applied in computer-aided design and engineering analysis to determine
3D complex geometry of turbine components, analyze the dynamic forces on a full
turbine blade by dividing a blade into multiple small segments to find the load
profile in different blade elements, and verify the turbine performance. The full load
exerted to the rotor can be determined by integrating the segmental loads for all
turbine blade elements. The maximum rising force can be found when turbine blade
moves in opposite direction to the wind direction. The critical parameters in turbine

28 3 Wind Power Turbine System
Fig. 3.1 Wind power turbine

system (new design 1)
Fig. 3.2 Wind power turbine

system (new design 2)
3.2 Computer-Aided Simulation of Wind Power Turbine System 29
Fig. 3.3 Driver gear design

in new wind power turbine
system
Fig. 3.4 Turbine blade

design in new wind turbine
system
design and development are oriented angle β between arriving air and blade
orientation, forces acted at the quarter of chord from blade head edge, pitching
torque caused by dynamic forces of coming air, tangential force of coming air to
draw the blade, and normal force of coming air to rise the blade. The computer-
aided simulation and prototype testing of these two new wind power turbine
systems are described in the following chapters.
3.2 Computer-Aided Simulation of Wind Power

Turbine System
The computer-aided simulation and analysis of lifting and dragging forces in wind
power turbine energy system can be applied to determine these targeted output
forces by analyzing the aerodynamic performance around the wind turbine blade.
All the analytic results can be used to guide wind turbine system design, improve
turbine functionality, and optimize turbine system for best performance. Equation
(3.1) can be applied to specify the lifting force on each turbine blade (Kundu and
Cohen 2008):
ρAIR ANET DLIFT S2RESULTANT

N LIFT ¼ ð3:1Þ
2
Here, ρAIR—density of incoming air, ANET—net surface area of turbine blade,

DLIFT—lifting coefficient, and SRESULTANT—resultant speed.
Fig. 3.5 Computer-aided simulation of airflow over wind power turbine blade
The full wind power can be determined by the following equation (Kundu and
Cohen 2008):
DPOWER ρAIR ASWEPT S3WIND

PFULL ¼ ð3:2Þ
2
Here, DPOWER—power coefficient, ASWEPT—swept area in wind power turbine,
and SWIND—wind speed.
The turbine blade material is made of fiber glass composite with high strength
and low density. The complex geometrical contour design in wind power system is
assisted by computer-aided 3D modeling and aerodynamic analysis in determining
turbine lifting force and turbine full power has been performed through computa-
tional simulation and finite element analysis. Figure 3.5 demonstrates the computer-
aided simulation of airflow over wind power turbine blade.
Computer-aided design and analysis is the computational methodology to model
the system design and simulate the product function, system structure, and pro-
duced stress and deflection profiles in designed system. All the simply defined
individual elements can be calculated through computational simulation and ana-
lytic results for full system can be finally determined. Figures 3.6, 3.7, 3.8, 3.9, 3.10,
and 3.11 represent the stress and deflection profiles for some critical components
in this new wind power turbine system through computer-aided modeling and
simulation.
The computer-aided simulation and analysis in Figs. 3.6 and 3.7 exhibit the
stress and deflection profiles of turbine blade in this newly designed system.
Fig. 3.6 Computational modeling of stress profile in turbine blade
Fig. 3.7 Computational modeling of deflection profile in turbine blade

Fig. 3.8 Computational modeling of stress profile in wind power turbine system 1
Fig. 3.9 Computational modeling of deflection profile in wind power turbine system 1
Fig. 3.10 Computational modeling of stress profile in wind power turbine system 2
Fig. 3.11 Computational modeling of deflection profile in wind power turbine system 2
The analytic results show that the maximum stress of 22,520.82 psi in turbine
blade is less than the material yield strength of 36,300 psi and maximum deflection
of 0.01154 in. is within material allowable deformation limit.
stress and deflection profiles of newly designed turbine system_1. The analytic
results present that the maximum stress of 22,828.34 psi in turbine system_1 is less
than the material yield strength of 36,300 psi and maximum deflection of
0.01198 in. is within material allowable deformation limit.
The computer-aided simulation and analysis in Figs. 3.10 and 3.11 demonstrate
the stress and deflection profiles of newly designed turbine system_2. The analytic
results present that the maximum stress of 25,005.59 psi in turbine system_2 is less
The above computer-aided 3D modeling and numerical simulation display that
the maximum stresses on these important parts are all lower than the material
strength and all related maximum component deformations meet material deflec-
tion spec. Based on above analytic results, this newly developed wind power energy
system shows its proper systematic design, feasible function, and reliable structure
in the green and sustainable energy applications.
3.3 Experiment on Wind Power Turbine System
New wind power energy system has been prototyped and tested to examine and
assert the computer-aided analysis and numerical simulation results. Table 3.1
shows the prototype experimental results of maximum stress and maximum deflec-
tion on turbine blade in this new wind power turbine system.
The prototype testing results of turbine blade in Table 3.1 prove the normal
function of the turbine blade since the average maximum stress 22,520.85 psi and
average maximum deflection 0.0112 in. are closely equal to the results of maximum
stress 22,520.82 psi and maximum deflection 0.0115 in. that are exhibited, respec-
tively, in Figs. 3.6 and 3.7 by computer-aided modeling and numerical simulation.
Table 3.2 presents the testing results of maximum stress and maximum deflec-
tion of wind power turbine energy system 1.
The prototype testing results of new wind power turbine energy system 1 in
Table 3.2 verify the proper function of system 1 because the average maximum
stress 22,828.29 psi and average maximum deflection 0.0116 in. are approximately
equal to the results of maximum stress 22,828.34 psi and maximum deflection
0.0120 in. that are depicted, respectively, in Figs. 3.8 and 3.9 by computer-aided
modeling and numerical simulation.
Table 3.3 expresses the experimental results of maximum stress and maximum
deflection of wind power turbine energy system 2.
The prototype experimental results of new wind power turbine energy system
2 in Table 3.3 confirm the appropriate function of system 2 since the average
3.3 Experiment on Wind Power Turbine System 35

experiment of maximum of experiment stress (psi) deflection (in.)
stress and maximum
1 22,520.88 0.0118
deflection on turbine blade
in this new wind power 2 22,520.84 0.0114
energy system 3 22,520.78 0.016
4 22,520.80 0.0109
5 22,520.89 0.0108
6 22,520.89 0.0106
7 22,520.88 0.0118
8 22,520.86 0.0111
9 22,520.79 0.0105
10 22,520.78 0.0108
11 22,520.87 0.0108
12 22,520.89 0.0108
13 22,520.92 0.0112
14 22,520.81 0.0106
15 22,520.80 0.0108
16 22,520.86 0.0111
17 22,520.93 0.0108
18 22,520.88 0.0107
19 22,520.78 0.0108
20 22,520.83 0.0116
Average 22,520.85 0.0112

testing results of maximum of experiment stress (psi) deflection (in.)
stress and maximum
1 22,828.26 0.0118
deflection of wind power
turbine energy system 1 2 22,828.35 0.0122
3 22,828.25 0.0112
4 22,828.38 0.0124
5 22,828.26 0.0112
6 22,828.24 0.0111
7 22,828.31 0.0113
8 22,828.38 0.0123
9 22,828.25 0.0111
10 22,828.24 0.0112
11 22,828.27 0.0117
12 22,828.36 0.0123
13 22,828.29 0.0114
14 22,828.25 0.0112
15 22,828.35 0.0115
16 22,828.25 0.0122
17 22,828.26 0.0112
18 22,828.37 0.0112
19 22,828.24 0.0121
20 22,828.31 0.0122
Average 22,828.29 0.0116

stress and maximum
1 25,005.65 0.0129
deflection of wind power
turbine energy system 2 2 25,005.61 0.0122
3 25,005.55 0.0132
4 25,005.57 0.0129
5 25,005.68 0.0121
6 25,005.67 0.0133
7 25,005.54 0.0130
8 25,005.66 0.0133
9 25,005.68 0.0121
10 25,005.57 0.0132
11 25,005.66 0.0122
12 25,005.68 0.0131
13 25,005.65 0.0133
14 25,005.54 0.0130
15 25,005.57 0.0122
16 25,005.68 0.0121
17 25,005.67 0.0132
18 25,005.65 0.0133
19 25,005.57 0.0123
20 25,005.55 0.0122
Average 25,005.62 0.0128
maximum stress 25,005.62 psi and average maximum deflection 0.0128 in. are
almost equal to the results of maximum stress 25,005.59 psi and maximum
deflection 0.0124 in. that are depicted, respectively, in Figs. 3.10 and 3.11 by
computer-aided modeling and numerical simulation.
3.4 Discussion and Future Improvement on Wind

Power Turbine System
In the near future, wind energy will become one of the most cost-effective and
environment-friendly sources of electrical power. In wind power energy system, a
turbine is connected to a mechanical electrical generator so that the electricity can
be generated by natural wind energy. The piezoelectric materials can be mechani-
cally formed into different geometrical blades and connected to the piezoelectric
actuators to make electrical power by wind power energy (wind pressure). Because
the wind power energy system is a passive system (not a mechanically driven
system), it will be less likely broken down and, therefore, no frequent and costly
repair is usually required. In order to further improve this new wind power energy
system, the following modifications will be planned: (1) modify the turbine blade
structure to keep wind flow passing turbine blade more consistent, (2) simplify the
3.4 Discussion and Future Improvement on Wind Power Turbine System 37
turbine structure to have less materials required to build wind turbine to lower the
cost, (3) rectify this new turbine system so that it will cost less energy for unit
operation, (4) amend this new design for easier system installation, (5) and improve
the airflow pathway near diameter of the turbine blades to maintain a low-pressure
region that increases wind flow to the turbine for high system efficiency.
Solar Panel Tracking System
4
4.1 Design of Solar Panel Tracking System
A newly developed solar tracking system is introduced with its adjustable orienta-
tion angle to track daily sunlight in 3D directions in order to receive the maximum
solar energy via systematic photovoltaic arrays. The driving mechanisms designed
with gear train unit in this solar tracking system can orientate solar system between
east and west and a rotating table can orientate solar unit between north and south.
The prototype of this new solar tracking system is depicted in Figs. 4.1 and 4.2.
Figure 4.1 shows the prototype of this new solar tracking system that has an
orientation rack and orientation base (with stepper motor and gear reducer inside)
installed to rotate solar panel frame in the eastern-western direction and has motor
driving system, base plate, and orientation plate mounted to keep solar panel frame
gradually rotating to follow sun’s yearly travel in north-south orbit. Several
detecting sensors are installed to trace the sunlight through receiving varied current
signals from photodiodes in order to automatically manipulate the solar panel
rotation in eastern-western and northern-southern 3D directions.
4.2 Computer-Aided Simulation of Solar Panel

Tracking System
This new solar tracking system is designed based on analysis of computer-aided

modeling and numerical simulation. The 3D modeling of the solar tracking system
is performed by 3D CAD software and structure analysis is carried out by FEA
technique. The structure analysis includes validating the functionality and strength
of driving system in east-west and north-south solar panel orientation.

40 4 Solar Panel Tracking System
Fig. 4.1 Solar panel system front view
Fig. 4.2 Solar panel system rear view

4.2 Computer-Aided Simulation of Solar Panel Tracking System 41
1. Calculation of wind force:
The wind load required should be considered in the solar tracking system design
to make sure that all the functioning parts, such as panel frame, lateral channel
beam, longitudinal channel beam, orientation adaptor, orientation rack, orientation
base, orientation driver support, and orientation link, will still work under the
maximum wind load in worst conditions. The wind load equation can be expressed
as follows (Mehta and Coulburne 2010):
Fwind ¼ Aproject Pwind Ddrag ð4:1Þ
The wind pressure Pwind can be defined by the following equation:
Pwind ¼ 0:00256 V 2wind ð4:2Þ
Here, Fwind—load caused by wind (lbf), Aproject—projected surface area of solar

panel at different orientation (ft2), Pwind—pressure caused by wind (psf), Ddrag—
coefficient of drag, and Vwind—speed of wind (mph).
2. Calculation of gear-train force in solar panel orientation:
To keep the gears from damage during solar panel tracking system operation, the
gear train must be able to handle the resultant force from force of wind, weight of
solar panel and hardware, and other related frictional forces. The resultant force can
be determined as follows (Mehta and Coulburne 2010):
T panel ðtorque to orientate the solar panelÞ ¼ N d 0:5 dp

¼ FR 0:5 Dgear ð4:3Þ
FR ¼ W total weight Cf
Here, Nd—force to drive gear (N), d—gear pitch diameter, FR—orientation

force (N), DO—outside gear diameter, WTW—total weight of solar panel system
(kg), and Cf—friction coefficient of different contact materials. The force to drive
gears changes when solar panel orientates to the different angles which can be
determined through computer-aided modeling and simulation.
Figures 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 4.10, 4.11, 4.12, 4.13, 4.14, 4.15, 4.16,
4.17, 4.18, 4.19, 4.20, 4.21, 4.22, 4.23, 4.24, 4.25, 4.26, 4.27, 4.28, and 4.29 show
the 3D part models, stress profile, and deflection profile of critical components in
this new solar tracking system.
The computer-aided simulation and analysis in Figs. 4.4 and 4.5 demonstrate the
stress and deflection profiles of newly designed solar panel system. The analytic
results present that the maximum stress of 2,267.076 psi in this solar panel system is
less than the material yield strength of 36,300 psi and maximum deflection of
Fig. 4.3 Solar panel
Fig. 4.4 Stress profile in solar panel

Fig. 4.5 Deflection profile in solar panel
Fig. 4.6 Solar panel frame

Fig. 4.7 Stress profile in panel frame
Fig. 4.8 Deflection profile in panel frame

Fig. 4.9 Lateral

channel beam
Fig. 4.10 Stress profile in lateral channel beam

Fig. 4.11 Deflection profile in lateral channel beam
Fig. 4.12 Longitudinal

channel beam
Fig. 4.13 Stress profile in longitudinal channel beam
Fig. 4.14 Deflection profile in longitudinal channel beam

Fig. 4.15 Orientation

adaptor
Fig. 4.16 Stress profile in orientation adaptor

Fig. 4.17 Deflection profile in orientation adaptor
Fig. 4.18 Orientation rack

Fig. 4.19 Stress profile in orientation rack
Fig. 4.20 Deflection profile in orientation rack

Fig. 4.21 Orientation base
Fig. 4.22 Stress profile in orientation base

Fig. 4.23 Deflection profile in orientation base
Fig. 4.24 Orientation driver

support
Fig. 4.25 Stress profile in orientation driver support
Fig. 4.26 Deflection profile in orientation driver support

Fig. 4.27 Orientation link
Fig. 4.28 Stress profile in orientation link

Fig. 4.29 Deflection profile in orientation link
stress and deflection profiles of lateral channel beam in newly designed solar panel
system. The analytic results state that the maximum stress of 15,877.88 psi in this
lateral channel beam is less than the material yield strength of 36,300 psi and
maximum deflection of 0.00828 in. is within material allowable deformation limit.
The computer-aided simulation and analysis in Figs. 4.13 and 4.14 display the
stress and deflection profiles of longitudinal channel beam in newly designed solar
panel system. The analytic results exhibit that the maximum stress of 17,589.58 psi
in this longitudinal channel beam is less than the material yield strength of
36,300 psi and maximum deflection of 0.02748 in. is within material allowable
deformation limit.
The computer-aided simulation and analysis in Figs. 4.16 and 4.17 present the
stress and deflection profiles of orientation adaptor in newly designed solar panel
system. The analytic results demonstrate that the maximum stress of 14,196.50 psi
in this orientation adaptor is less than the material yield strength of 36,300 psi and
stress and deflection profiles of orientation rack in newly designed solar panel
orientation rack is less than the material yield strength of 36,300 psi and maximum
deflection of 0.0511 in. is within material allowable deformation limit.
stress and deflection profiles of orientation base in newly designed solar panel
system. The analytic results exhibit that the maximum stress of 17,384.07 psi in this
orientation base is less than the material yield strength of 36,300 psi and maximum
stress and deflection profiles of orientation driver support in newly designed solar
panel system. The analytic results exhibit that the maximum stress of 17,788.09 psi
in this orientation base is less than the material yield strength of 36,300 psi and
the stress and deflection profiles of orientation link in newly designed solar panel
system. The analytic results indicate that the maximum stress of 18,023.74 psi in
this orientation link is less than the material yield strength of 36,300 psi and
Based on computer-aided analysis, shown in Figs. 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9,
4.10, 4.11, 4.12, 4.13, 4.14, 4.15, 4.16, 4.17, 4.18, 4.19, 4.20, 4.21, 4.22, 4.23, 4.24,
4.25, 4.26, 4.27, 4.28, and 4.29, the maximum stresses generated in all important
components including panel frame, lateral channel beam, longitudinal channel
beam, orientation adaptor, orientation rack, orientation base, orientation driver
support, and orientation link are all less than the material yield stress and the
relevant maximum deflections of these components are all within allowable defor-
mation limits of the materials. The above computational simulations have shown
good performance of this newly developed solar tracking system.
4.3 Experiment on Solar Panel Tracking System
New solar panel tracking system has been prototyped and tested to compare and
verify the computer-aided simulation results. Table 4.1 demonstrates the experi-
mental results of maximum stress and maximum deflection of solar panel in this
new solar panel tracking system.
The prototype experimental results of solar panel in Table 4.1 verify the proper
function of this new solar panel system because the average maximum stress
2,267.160 psi and average maximum deflection 0.00519 in. are approximately
0.00507 in. that are represented, respectively, in Figs. 4.4 and 4.5 by computer-
aided simulation.
deflection of solar panel frame in this new solar panel tracking system.
4.3 Experiment on Solar Panel Tracking System 57
Table 4.1 Experimental Number Maximum Maximum

results of maximum stress of experiment stress (psi) deflection (in.)
and maximum deflection of
1 2,267.12 0.00505
solar panel in this new solar
panel tracking system 2 2,267.09 0.00509
3 2,267.15 0.00508
4 2,267.06 0.00511
5 2,267.11 0.00515
6 2,267.15 0.00516
7 2,267.18 0.00524
8 2,267.19 0.00518
9 2,267.17 0.00519
10 2,267.15 0.00527
11 2,267.18 0.00525
12 2,267.21 0.00524
13 2,267.24 0.00522
14 2,267.22 0.00529
15 2,267.18 0.00527
16 2,267.14 0.00526
17 2,267.19 0.00529
18 2,267.18 0.00518
19 2,267.14 0.00519
20 2,267.17 0.00517
Average 2,267.16 0.00519

and maximum deflection
1 14,343.12 0.03124
of solar panel frame
in this new solar panel 2 14,343.11 0.03118
tracking system 3 14,343.08 0.03119
4 14,343.09 0.03129
5 14,343.02 0.03124
6 14,343.15 0.03115
7 14,343.16 0.03148
8 14,343.18 0.03138
9 14,343.19 0.03131
10 14,343.14 0.03124
11 14,343.12 0.03122
12 14,343.01 0.03121
13 14,343.08 0.03118
14 14,343.17 0.03119
15 14,343.24 0.03117
16 14,343.29 0.03124
17 14,343.22 0.03148
18 14,343.24 0.03129
19 14,343.18 0.03125
20 14,343.16 0.03124
Average 14,343.15 0.03126

1 15,877.78 0.00835
lateral channel beam in this
new solar panel tracking 2 15,877.84 0.00838
system 3 15,877.69 0.00837
4 15,877.71 0.00836
5 15,877.68 0.00848
6 15,877.55 0.00846
7 15,877.68 0.00844
8 15,877.65 0.00849
9 15,877.59 0.00845
10 15,877.57 0.00842
11 15,877.66 0.00838
12 15,877.69 0.00847
13 15,877.68 0.00848
14 15,877.78 0.00837
15 15,877.77 0.00844
16 15,877.72 0.00845
17 15,877.67 0.00842
18 15,877.65 0.00848
19 15,877.68 0.00838
20 15,877.71 0.00841
Average 15,877.69 0.00842
The prototype experimental results of solar panel frame in Table 4.2 prove the
normal function of solar panel frame as the average maximum stress 14,343.15 psi
and average maximum deflection 0.03126 in. are almost same as the results of
maximum stress 14,343.03 psi and maximum deflection 0.03143 in. that are
indicated, respectively, in Figs. 4.7 and 4.8 by computer-aided simulation.
Table 4.3 records the experimental results of maximum stress and maximum
deflection of lateral channel beam in this new solar panel tracking system.
The prototype experimental results of lateral channel beam in Table 4.3 confirm
the appropriate function of lateral channel beam since the average maximum stress
15,877.69 psi and average maximum deflection 0.00842 in. are approximately same
as the results of maximum stress 15,877.88 psi and maximum deflection 0.00827 in.
that are laid out, respectively, in Figs. 4.10 and 4.11 by computer-aided simulation.
Table 4.4 states the experimental results of maximum stress and maximum
deflection of longitudinal channel beam in this new solar panel tracking system.
The prototype experimental results of longitudinal channel beam in Table 4.4
verify proper function of this longitudinal channel beam because the average
maximum stress 17,589.44 psi and average maximum deflection 0.02761 in. are
very close to the results of maximum stress 17,589.58 psi and maximum deflection
0.02748 in. that are shown, respectively, in Figs. 4.13 and 4.14 by computer-aided
simulation.

1 17,589.48 0.02759
longitudinal channel beam
4 17,589.44 0.02759
5 17,589.47 0.02768
6 17,589.54 0.02766
7 17,589.49 0.02767
8 17,589.45 0.02765
9 17,589.42 0.02757
10 17,589.38 0.02759
11 17,589.47 0.02768
12 17,589.42 0.02769
13 17,589.48 0.02767
14 17,589.44 0.02768
15 17,589.45 0.02755
16 17,589.38 0.02763
17 17,589.39 0.02765
18 17,589.41 0.02761
19 17,589.42 0.02755
20 17,589.45 0.02759
Average 17,589.44 0.02761

1 14,196.45 0.00019
of orientation adaptor
4 14,196.41 0.00014
5 14,196.48 0.00011
6 14,196.35 0.00012
7 14,196.38 0.00011
8 14,196.37 0.00013
9 14,196.31 0.00012
10 14,196.33 0.00011
11 14,196.38 0.00010
12 14,196.41 0.00008
13 14,196.42 0.00009
14 14,196.36 0.00011
15 14,196.35 0.00008
16 14,196.32 0.00007
17 14,196.31 0.00011
18 14,196.33 0.00010
19 14,196.35 0.00012
20 14,196.36 0.00010
Average 14,196.38 0.00011

1 16,842.25 0.05109
orientation rack in this new
solar panel tracking system 2 16,842.24 0.05115
3 16,842.31 0.05114
4 16,842.21 0.05118
5 16,842.23 0.05117
6 16,842.22 0.05119
7 16,842.21 0.05117
8 16,842.24 0.05115
9 16,842.18 0.05124
10 16,842.19 0.05118
11 16,842.20 0.05115
12 16,842.24 0.05117
13 16,842.21 0.05118
14 16,842.19 0.05119
15 16,842.21 0.05124
16 16,842.18 0.05121
17 16,842.22 0.05122
18 16,842.24 0.05117
19 16,842.18 0.05118
20 16,842.24 0.05116
Average 16,842.22 0.05118
Table 4.5 presents the experimental results of maximum stress and maximum
deflection of orientation adaptor in this new solar panel tracking system.
The prototype experimental results of orientation adaptor in Table 4.5
prove the normal function of orientation adaptor as the average maximum stress
14,196.38 psi and average maximum deflection 0.00011 in. are similar to the results
of maximum stress 14,196.50 psi and maximum deflection 0.00017 in. that are
presented, respectively, in Figs. 4.16 and 4.17 by computer-aided simulation.
deflection of orientation rack in this new solar panel tracking system.
The prototype experimental results of orientation rack in Table 4.6 confirm the
appropriate function of orientation rack since the average maximum stress
16,842.22 psi and average maximum deflection 0.05118 in. are almost equal
to the results of maximum stress 16,842.35 psi and maximum deflection
0.05107 in. that are indicated, respectively, in Figs. 4.19 and 4.20 by computer-
aided simulation.
Table 4.7 conveys the experimental results of maximum stress and maximum
deflection of orientation base in this new solar panel tracking system.
The prototype experimental results of orientation base in Table 4.7 prove the
normal function of orientation base as the average maximum stress 17,384.20 psi
and average maximum deflection 0.00331 in. are closely equal to the results of

1 17,384.15 0.00338
orientation base in this new
3 17,384.06 0.00348
4 17,384.18 0.00341
5 17,384.24 0.00337
6 17,384.22 0.00324
7 17,384.25 0.00329
8 17,384.21 0.00327
9 17,384.17 0.00325
10 17,384.18 0.00332
11 17,384.19 0.00327
12 17,384.18 0.00325
13 17,384.22 0.00327
14 17,384.24 0.00330
15 17,384.25 0.00327
16 17,384.26 0.00329
17 17,384.24 0.00324
18 17,384.19 0.00326
19 17,384.18 0.00331
20 17,384.17 0.00330
Average 17,384.20 0.00331

1 17,788.15 0.00017
orientation driver support
4 17,788.18 0.00024
5 17,788.19 0.00025
6 17,788.16 0.00026
7 17,788.08 0.00023
8 17,788.12 0.00025
9 17,788.19 0.00029
10 17,788.18 0.00027
11 17,788.24 0.00029
12 17,788.24 0.00027
13 17,788.21 0.00024
14 17,788.27 0.00026
15 17,788.26 0.00025
16 17,788.27 0.00024
17 17,788.24 0.00029
18 17,788.22 0.00027
19 17,788.24 0.00026
20 17,788.21 0.00024
Average 17,788.20 0.00025

1 18,023.68 0.01915
orientation link in this new
3 18,023.62 0.01918
4 18,023.54 0.01911
5 18,023.59 0.01912
6 18,023.78 0.01911
7 18,023.67 0.01915
8 18,023.62 0.01910
9 18,023.60 0.01911
10 18,023.61 0.01912
11 18,023.54 0.01908
12 18,023.55 0.01910
13 18,023.57 0.01911
14 18,023.56 0.01912
15 18,023.57 0.01914
16 18,023.55 0.01915
17 18,023.59 0.01911
18 18,023.61 0.01912
19 18,023.62 0.01910
20 18,023.63 0.01914
Average 18,023.61 0.01912
recorded, respectively, in Figs. 4.22 and 4.23 by computer-aided simulation.
Table 4.8 lays out the experimental results of maximum stress and maximum
deflection of orientation driver support in this new solar panel tracking system.
The prototype experimental results of orientation driver support in Table 4.8
verify the proper function of orientation driver support because the average maxi-
mum stress 17,788.20 psi and average maximum deflection 0.00025 in. are almost
same as the results of maximum stress 17,788.09 psi and maximum deflection
0.00016 in. that are displayed, respectively, in Figs. 4.25 and 4.26 by computer-
aided simulation.
Table 4.9 shows the experimental results of maximum stress and maximum
deflection of orientation link in this new solar panel tracking system.
The prototype experimental results of orientation link in Table 4.9 confirm the
appropriate function of orientation link since the average maximum stress
0.01921 in. that are exhibited, respectively, in Figs. 4.28 and 4.29 by computer-
aided simulation.
4.4 Discussion and Future Improvement on Solar Panel Tracking System 63
4.4 Discussion and Future Improvement on Solar

Panel Tracking System
Solar power system can transfer the natural sunlight energy to the electrical
mechanical energies. It has the major advantages including safe and clean features
compared to the traditional energy resources. This chapter introduces the
methodologies using computational simulation and prototype testing to determine
the important factors affecting the performance of this new solar panel tracking
system. Both computational simulation and prototype experiment show its reliable
function. Future improvement has been planned to optimize this solar tracking
system by computer-aided modeling and analysis to determine the optimal working
condition, further reduce system weight to save system cost, and revise the gear
train for more quiet operation.
Energy-Saving Cooling System
5
5.1 Design of Energy-Saving Cooling System
The energy-saving cooling systems have been investigated in recent years and more
R&D efforts have been put to improve its performance with higher energy-saving
features. This new automatically controlled energy-saving cooling system has been
developed, analyzed, and prototyped to verify its function and reliability ability.
The major advantages of this new system include simpler structure, compact setup,
and easy parameter adjustment to improve its performance, increased efficiency,
quiet operation, and less frictional losses in this free piston cooling system. The
gaseous pressure inside system can be manipulated by two automatic valves
controlled through PLC program in the controller and the motion of free piston is
monitored by proximity sensors to improve the performance by automatically
adjusting the functioning parameters. The prototype and internal view are shown
in Figs. 5.1 and 5.2.
In this new design, partial compressive work in the middle fluctuating chamber
can be transferred into the useful motive work if compared with some cooling
systems such as Solvay system in which no energy can be retrieved from middle
chamber and full compressive work is transformed into the heat discharged to the
air. Furthermore, the functioning efficiency in this system is improved because the
cooling capacity can be output at the two ends of systematic cylinder. This new
system operates quietly since the vibration and shock are decreased due to its
symmetrical setup design. The systematic phase angle of various thermal and
mechanical function curves can be easily manipulated and adjusted through
automatically controlled valves to improve its function and efficiency. Figures 5.1
and 5.2 display the external and internal view of this newly developed cooling
system. Two proximity sensors, two compressive cylinders Vc (V0 c), and two
expansive cylinders Ve (V0 e) are symmetrically installed in the cooling system.
Two free pistons F (F0 ), one thin plate G mounted in the middle of cylinder with a

66 5 Energy-Saving Cooling System
Fig. 5.1 New energy-saving

cooling system
Fig. 5.2 Internal view of new energy-saving cooling system
small hole on it, and two middle chambers Vmc (V0 mc) are set up in this system.
Due to its symmetrical design, only chambers of Vc, Ve, and Vmc, compressor
piston H, and free piston F in this system are required to be analyzed. With the
installation of two automatically controlled valves, the air pressure in Vmc and V0 mc
can be changed to adjust the phase angles of all functional curves to improve the
machine function through PLC-controlled automatic valves. Two electric sensors at
the two ends of the cylinder can monitor the piston’s moving distance that can be
fed back to the PLC unit to readjust the thermal parameters to improve the system
function.
5.2 Computer-Aided Simulation on Energy-Saving Cooling System 67
Fig. 5.3 P–V cyclic diagram

in expansive chamber
5.2 Computer-Aided Simulation on Energy-Saving

Cooling System
The initial cyclic condition of this new energy-saving cooling system is previously
displayed in Fig. 5.2. In this stable working condition, piston H locates at the
lower position in the compressive chamber and free piston F is at the right end of
the expansive chamber. The P–V cyclic diagram of expansive chamber is shown
in Fig. 5.3.
Because the gaseous media with high pressure (P ¼ PH) enters chamber Vmc via
a tiny hole at the end time period of last functioning cycle, gaseous media with low
pressure (P ¼ PL) in chamber Vmc will be mixed with high-pressure gaseous media.
The mixed gaseous pressure in chamber Vmc is Pmix. When piston H starts moving
upward in compressive chamber Vc, gaseous media in chamber Vmc is assumed not
entering chamber V0 mc since the traveling speed of free piston is fast and the
diameter of hole is very small. Because the left-side gaseous pressure of free piston
F is higher than the right-side gaseous pressure of F (Pmc ¼ Pave > Pe), free piston F
does not move and the gaseous pressure Pe in expansive chamber reaches high
pressure PH and gaseous volume Ve in expansive chamber increases from zero to
V2 as piston H continues moving up. This process can be represented by curve 1–2
in Fig. 5.3. Then the gaseous media in chamber Vmc flows into chamber V0 mc.
Since the gaseous pressure at the left and right sides of free piston F is same, F
travels to the left with constant speed. When crankshaft rotates to the angle (θ) near
180 , the gaseous volume Ve in expansive chamber increases from V2 to V3 which
can be represented by the line 2–3. During initial period that piston H moves
downwards in chamber Vc, free piston F does not move since the gaseous media in
chamber V0 mc is assumed not to flow into chamber Vmc, and pressure Pe in
expansive chamber reduces from P3 to P4 which is represented by line 3–1.
When piston H continues traveling downwards in compressive chamber Vc,
gaseous media in chamber V0 mc enters chamber Vmc via tiny hole and free piston
F moves to the right end in the expansive chamber with constant speed which
can be represented by line 4–1. This concludes the full functioning cycle of this
cooling system.
The computer-aided simulations can be applied to verify the function of this new
cooling system. The piston H in compressive chamber moves in sine law (Kundu
and Cohen 2008):
M V co ½1 þ cos ðθÞ
V c ðθ Þ ¼ ð5:1Þ
2
V ¼ Vk þ Vc þ Ve ð5:2Þ
Here, Vk is the clearance volume:
X Mi Ve Vc
P¼R Vk
þ þ ð5:3Þ
Tk
Te Tc
As piston H in compressive chamber travels upwards with crankshaft rotating to

angle ω,
ðPe Pme Þ A ¼ FF ð5:4Þ
X Mi V c ð ωÞ
Pð ω Þ ¼ R Vk þ0þ ð5:5Þ
Tk
Tc
Assuming W ¼ TTkc , L ¼ VVeok , and Q ¼ TT ce

h i
PðωÞ L W þ VVc ðeoωÞ V c ðω Þ
P¼ h i Qþ ð5:6Þ
L W þ V eo
Ve V eo
The differential equation of free piston motion can be derived based on the
second Newton law:
" #
d2 V e ð θ Þ
m 2
¼ Pe Pmc S FF ð5:7Þ
dt
Combine the above equations:

h i h i
V e ðθÞ
d2 V eo PðωÞ L W þ VVc ðeoωÞ
2
¼ mw2 Y o
dθ A
1
ð5:8Þ
QV e ðθÞ V c ðθÞ A PL þPH
LWþ V eo þ V eo 2mw2 Y o
Fig. 5.4 Piston and link

assembly in compressive
chamber
Here, pressure P(ω) can be determined by the following equation:
d2 V c ð θ Þ
¼0 ð5:9Þ
dθ2
The computer-aided simulation determines the stress and deflection profiles
shown in Figs. 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 5.10, 5.11, 5.12, 5.13, 5.14, 5.15, 5.16,
5.17, and 5.18.
The computer-aided simulation and analysis in Figs. 5.5 and 5.6 show the stress
and deflection profiles of compressive piston link assembly in newly designed
energy-saving cooling system. The analytic results exhibit that the maximum stress
of 25,698.25 psi in this piston link assembly is less than the material yield strength
of 36,300 psi and maximum deflection of 0.00169 in. is within material allowable
deformation limit.
stress and deflection profiles of compressive chamber in newly designed energy-
saving cooling system. The analytic results demonstrate that the maximum stress of
26,088.02 psi in this compressive chamber is less than the material yield strength of
deformation limit.
stress and deflection profiles of piston link in newly designed energy-saving cooling
piston link is less than the material yield strength of 36,300 psi and maximum
Fig. 5.5 Stress profile of compressive piston link assembly
Fig. 5.6 Deflection profile of compressive piston link assembly

Fig. 5.7 Piston head in

compressive chamber
Fig. 5.8 Stress profile of piston head in compressive chamber
stress and deflection profiles of crankshaft in newly designed energy-saving cooling
system. The analytic results show that the maximum stress of 20,667.27 psi in this
crankshaft is less than the material yield strength of 36,300 psi and maximum
Fig. 5.9 Deflection profile of piston head in compressive chamber
Fig. 5.10 Piston link in

compressive chamber
Fig. 5.11 Stress profile of piston link in compressive chamber
Fig. 5.12 Deflection profile of piston link in compressive chamber

Fig. 5.13 Crankshaft in compressive chamber
Fig. 5.14 Stress profile of crankshaft in compressive chamber

Fig. 5.15 Deflection profile of crankshaft in compressive chamber
Fig. 5.16 Piston in

expansive chamber
Fig. 5.17 Stress profile of piston in expansive chamber
Fig. 5.18 Deflection profile of piston in expansive chamber

5.3 Experiment on Energy-Saving Cooling System 77
stress and deflection profiles of piston in newly designed energy-saving cooling
system. The analytic results present that the maximum stress of 7,884.44 psi in this
piston is less than the material yield strength of 36,300 psi and maximum deflection
of 0.00006 in. is within material allowable deformation limit.
The above computational simulation results demonstrate that the maximum
stresses on these critical components are all less than the material yield stress and
maximum material deflections are all within material allowable deformation limits.
The computational solutions confirm the good and reliable function of this newly
developed energy-saving cooling system.
5.3 Experiment on Energy-Saving Cooling System
The newly designed energy-saving cooling system has been prototyped and tested
to compare and verify the results from computer-aided simulation. Table 5.1
demonstrates the prototype testing results of compressive piston link assembly in
this new energy-saving cooling system.
The prototype experimental results of compressive piston link assembly in
Table 5.1 verify the proper function of this compressive piston link assembly

testing of compressive of experiment stress (psi) deflection (in.)
piston link assembly in this
1 25,698.33 0.00159
new energy-saving cooling
system 2 25,698.29 0.00161
3 25,698.38 0.00155
4 25,698.45 0.00148
5 25,698.49 0.00139
6 25,698.48 0.00138
7 25,698.55 0.00144
8 25,698.49 0.00138
9 25,698.57 0.00147
10 25,698.54 0.00139
11 25,698.56 0.00138
12 25,698.53 0.00154
13 25,698.54 0.00149
14 25,698.56 0.00142
15 25,698.59 0.00136
16 25,698.57 0.00138
17 25,698.56 0.00135
18 25,698.55 0.00145
19 25,698.48 0.00144
20 25,698.42 0.00148
Average 25,698.50 0.00145

testing of piston head of of experiment stress (psi) deflection (in.)
compressor chamber in this
1 26,088.12 0.00018
system 2 26,088.17 0.00019
3 26,088.11 0.00023
4 26,088.24 0.00019
5 26,088.29 0.00024
6 26,088.33 0.00026
7 26,088.38 0.00029
8 26,088.39 0.00032
9 26,088.35 0.00031
10 26,088.21 0.00036
11 26,088.18 0.00035
12 26,088.24 0.00033
13 26,088.35 0.00029
14 26,088.38 0.00027
15 26,088.39 0.00025
16 26,088.37 0.00022
17 26,088.33 0.00019
18 26,088.29 0.00021
19 26,088.27 0.00023
20 26,088.26 0.00022
Average 26,088.28 0.00026
because the average maximum stress 25,698.50 psi and average maximum deflec-
tion 0.00145 in. are approximately equal to the results of maximum stress
25,698.25 psi and maximum deflection 0.00169 in. that are represented, respec-
Table 5.2 expresses the prototype testing results of piston head of compressor
chamber in this new energy-saving cooling system.
The prototype experimental results for piston head of compressor chamber in
Table 5.2 confirm the appropriate function of piston head since the average maxi-
mum stress 26,088.28 psi and average maximum deflection 0.00026 in. are approx-
imately same as the results of maximum stress 26,088.02 psi and maximum
deflection 0.00017 in. that are indicated, respectively, in Figs. 5.8 and 5.9 by
computer-aided modeling and numerical simulation.
Table 5.3 records the prototype testing results of piston link of compressor
chamber in this new energy-saving cooling system.
The prototype experimental results for piston link of compressor chamber in
Table 5.3 prove the normal function as the average maximum stress 23,242.65 psi
and average maximum deflection 0.00175 in. are close to the results of maximum
stress 23,242.99 psi and maximum deflection 0.00147 in. that are laid out, respec-
tively, in Figs. 5.11 and 5.12 by computer-aided modeling and numerical
simulation.
5.3 Experiment on Energy-Saving Cooling System 79
Table 5.3 Prototype Number of Maximum Maximum

testing of piston link of experiment stress (psi) deflection (in.)
1 23,242.78 0.00148
system 2 23,242.92 0.00155
3 23,242.88 0.00167
4 23,242.56 0.00178
5 23,242.48 0.00167
6 23,242.68 0.00179
7 23,242.85 0.00188
8 23,242.84 0.00187
9 23,242.68 0.00178
10 23,242.55 0.00184
11 23,242.68 0.00186
12 23,242.54 0.00179
13 23,242.69 0.00178
14 23,242.48 0.00168
15 23,242.49 0.00172
16 23,242.51 0.00184
17 23,242.38 0.00178
18 23,242.47 0.00177
19 23,242.84 0.00175
20 23,242.68 0.00176
Average 23,242.65 0.00175
Table 5.4 states the prototype testing results of crankshaft of compressor cham-
ber in this new energy-saving cooling system.
The prototype experimental results for crankshaft of compressor chamber in
Table 5.4 verify the proper function of crankshaft because the average maximum
stress 20,667.43 psi and average maximum deflection 0.00013 in. are similar to the
results of maximum stress 20,667.27 psi and maximum deflection 0.00019 in. that
are shown, respectively, in Figs. 5.14 and 5.15 by computer-aided modeling and
numerical simulation.
Table 5.5 demonstrates the prototype testing results of piston in compressor
chamber of this new energy-saving cooling system.
The prototype experimental results of piston in compressor chamber in Table 5.5
confirm the appropriate function of this piston since the average maximum stress
7,884.67 psi and average maximum deflection 0.00010 in. are almost equal to the
are presented, respectively, in Figs. 5.17 and 5.18 by computer-aided modeling and

testing of crankshaft of of experiment stress (psi) deflection (in.)
1 20,667.35 0.00017
system 2 20,667.29 0.00015
3 20,667.38 0.00022
4 20,667.24 0.00015
5 20,667.39 0.00012
6 20,667.45 0.00014
7 20,667.48 0.00011
8 20,667.55 0.00012
9 20,667.59 0.00018
10 20,667.56 0.00011
11 20,667.52 0.00012
12 20,667.54 0.00014
13 20,667.52 0.00011
14 20,667.48 0.00009
15 20,667.45 0.00008
16 20,667.38 0.00009
17 20,667.35 0.00012
18 20,667.24 0.00008
19 20,667.37 0.00011
20 20,667.44 0.00012
Average 20,667.43 0.00013

testing of piston in of experiment stress (psi) deflection (in.)
compressor chamber of this
1 7,884.54 0.00008
system 2 7,884.41 0.00011
3 7,884.55 0.00012
4 7,884.84 0.00009
5 7,884.88 0.00011
6 7,884.78 0.00005
7 7,884.75 0.00012
8 7,884.69 0.00009
9 7,884.68 0.00008
10 7,884.54 0.00009
11 7,884.55 0.00011
12 7,884.42 0.00012
13 7,884.41 0.00013
14 7,884.59 0.00012
15 7,884.75 0.00011
16 7,884.84 0.00012
17 7,884.89 0.00013
18 7,884.72 0.00011
19 7,884.88 0.00008
20 7,884.62 0.00009
Average 7,884.67 0.00010
5.4 Discussion and Future Improvement on Energy-Saving Cooling System 81
5.4 Discussion and Future Improvement on Energy-Saving

Cooling System
The environment protection is one of the most important ways against global
warming. The demand for saving energy and improving performance in cooling
system helps environmental conservation and customer satisfaction. The systematic
efficiency improvement is indispensable for saving energy in cooling system. This
new cooling system shows its reliable function with good energy-saving and
efficiency-increased features. The future improvement will include symmetrically
balancing the piston setup featuring reduced shock, lower vibration, quiet opera-
tion, and higher efficiency in cooling system. Some design simplification, such as
free piston glove cutoff, heat exchanger, and compressive crankshaft, will be
planned for further cost reduction.
Part II
Automated Systems
Automated and High-Speed Manufacturing
System 6
6.1 Design of Automated and High-Speed

Manufacturing Systems
Automated production and manufacturing are the engineering fields dealing with
various product manufacturing, production processes, machining equipment
developments, and integration of production systems and manufacturing equip-
ment. Computer-aided engineering (CAE) technology can provide engineering
design teams with quick and cost-effective professional tools to efficiently iterate
the design process for better quality and reliable function. The CAE technique can
allow multiple design concepts being reviewed and evaluated without real product
manufactured until the design process has been completed. Computer-aided
manufacturing (CAM) helps to ensure qualified production process by computer-
integrated technology that permits the production processes interchanging technical
data information to each other. Figures 6.1, 6.2, and 6.3 show the newly developed
automated/high-speed system to fill the high-viscous liquids, based on author’s
current research.
This automated and high-speed liquid filling system is designed to fill different
high-viscous liquids. It can be flexibly applied to many industries including chemi-
cal, pharmaceutical, dairy, cosmetic, and food production. Some very thick liquids
including medical cream, cosmetic products, and food sauces can be filled into the
bottles and containers using this new automated filling system with positive dis-
placement pump applied in the heavy viscous liquids under high-temperature
environment and rotary gear pump in the heavy duty work for filling oil products,
construction tar, roofing bitumen, thick ink, and special wax. Specially designed
jacket inside rotary gear pump can keep pump working at raised temperature up to
125 C and double-drive rotors in the pump make this system efficiently delivering
high-viscosity liquids. To accelerate the liquid filling speed, multiple pumping
nozzles with various sizes can be integrated in the filling system. The internally
swaged nozzles are applied in this new automated liquid filling system for the
bottles with narrow bottlenecks and complex geometrical shapes. The well-

86 6 Automated and High-Speed Manufacturing System
Fig. 6.1 Automated high-viscous liquid filling and sealing manufacturing system
Fig. 6.2 Automated high-

viscous liquid filling
mechanism
designed indexing conveyor controls the product movement within targeted toler-
ance range and empty bottles or containers are picked up and placed to the fixture
holders secured in the indexing conveyer by specially designed robotic system. The
fixture holder in liquid filling system is designed to maintain precise dimensional
6.1 Design of Automated and High-Speed Manufacturing Systems 87
Fig. 6.3 Automated

ultrasonic sealing (welding)
mechanism to fill high-
viscous liquid
and location tolerances between fixture holders and containers to keep reliable
systematic function in automated and high-speed liquid filling process. When
empty container is driven to the filling position, the indexing conveyor stops via
programmable logic control (PLC) by detecting the fixture holder location signaled
from installed opposed mode sensor. Horizontal air slider installed in fixture holder
system moves gripper pair forward to secure container for filling process. The liquid
filling nozzle moves down by vertical air slider into container entrance to begin
filling process. As soon as filling process is completed, the opposed mode sensor
sends the signal to PLC system and vertical air slide moves filling nozzle up. Then
the gripper pairs release the container and move away from fixture holder location
for next liquid filling cycle. The PLC system with opposed mode sensors in this
prototype can control filling pump and nozzle to precisely determine the liquid
amount being filled. When targeted liquid volume is reached, the pump and nozzle
will turn off instantly resulting in precise filling process for high-viscous liquid
products. The PLC system storing all operation parameters can be used for cost-
effective and fast tooling changeovers. The automated and high-speed plastic
welding is a fast production process to join the plastic parts together. It is one of
the common processes to weld the plastic materials. Some plastic welding
methodologies applied in industry include ultrasonic welding, extrusion welding,
hot gas welding, high-frequency welding, injection welding, friction welding,
solvent welding, speed tip welding, laser welding, contact welding, and hot plate
welding. Among these plastic welding methodologies, the regular plastic welding
methodology is to use external hot resource to heat joining parts together for sealing
effect including extrusion welding, hot gas welding, speeding tip welding, hot plate
welding, and contact welding (Song and Li 2013). The high-frequency welding
technology is to join plastic components together through high-frequency electro-
magnetic process including ultrasonic welding; the laser welding method is to weld
work pieces together by applying pressure while the laser beam travels along
welding curves; the solvent welding process applies a melt or a liquefied method to
weld components together; and the friction welding method utilizes the vibration
among connecting surfaces by adjusting defined vibration frequencies and
amplitudes (Wang et al. 2013). The ultrasonic welding, with vibration produced
from high-frequency sound energy to dissolve the plastic parts, is applied to the
sealing mechanism in this new automated and high-speed production system since
it is the quickest welding method suitable for high-speed production. As the
ultrasonic vibration stops, molten plastics become solidified and plastic
components are welded. Also the ultrasonic welding in this sealing system not
only maintains high welding rate but also prevents the containers from usual
damages by traditional sealing methods that relies on mechanical tolerance to
control clearance between two mating parts. The sequential operation of this
automated and high-speed welding system using ultrasonic welding is described
as follows. As container stops at the accurate location below horn of welding
mechanism, the fixture gripper travels forward to grab and secure the container
for welding process. The tooling gripper picks up a container cap from vibration
bowl rail and vertically moves up by pneumatic air slider. The pneumatic slider in
horizontal setup drives cap gripper toward the center of container and pneumatic
slider in vertical setup moves welding mechanism downward with pneumatic air
rotary rotating cap gripper in 180 . As container cap is brought to the center of
container top entrance by horizontal slider, vertical slider moves top tooling gripper
downward to finally insert the cap into container. After cap being pressed down to
the target position inside container, the top tooling gripper frees cap and travels
back to pick up next cap in vibration bowl rail. The newly developed mechanism
drives the ultrasonic welding horn downward and quickly welds cap and container
together to seal the product.
Figures 6.4, 6.5, and 6.6 display newly developed automated and high-speed
production system for chemical gas charging process based on author’s new
research.
The challenge of design and development in this automated and high-speed
manufacturing system is to quickly and reliably seal high-pressure chamber during
chemical gas charging process. The regular sealing methodologies include injecting
gel for sealing purpose but show the poor sealing capability in high-speed gas
charging process. In this newly developed automated gas charging and plug sealing
mechanism, the plug needs to be quickly inserted to seal the container entrance
while chemical gas is being charged into the container through air chamber since
the pressured chemical gas will escape if container is not being sealed simulta-
neously. Because of this, the chemical gas charging process in this newly designed
system is done inside the confined gas chamber area, shown in Fig. 6.7, and sealing
plug is automatically assembled at the container inlet precisely with proper
manufacturing tolerance control for best gas charging and sealing functions.
The unit chamber of sealing plug insert and gas charge in this automated and
high-speed chemical gas charging system includes plug delivery inlet, central hole
for plug insert and assembly, and pneumatic valves and fittings. When empty
container is automatically driven to the assembly station, the linear air actuator
Fig. 6.4 Automated and high-speed chemical gas charging and sealing system
Fig. 6.5 Automated and

high-speed sealing plug
delivery mechanism
moves full plug assembly system down until it touches the inlet of container.
Meanwhile, the plugs are fed to the plug assembly station by automated delivery
mechanism. The sealing plug is pressed through the central hole of air chamber by
top pusher with 0.125 in. below the top surface of container and pressured chemical
gas is then charged into chamber. When expected gas volume is filled in the
container, the top pusher continues moving plug down to fully seal the container,
as shown in Fig. 6.8.
Fig. 6.6 Automated and

high-speed chemical gas
charging and mechanical
sealing mechanism
Pusher Inlet
Sealing Plug Inlet
Mounting Hole
Pneumatic Air
Tubing & Fitting
Gas Chamber
Fig. 6.7 Confined air chamber with plug feeding and pusher mechanism
Plug Pusher
(Moves Up
and Down)
Sealing Plug
is being fed in
Chemical Gas
is being filled in Electric Linear
Actuator (Moves
Up and Down)
Container Adaptor &

Gasket for Sealing
Fig. 6.8 Gas chamber and sealing plug mechanism in this new automated gas charging system
Fig. 6.9 Bronze metal

ring seal
To reduce the gas leakage between entrance of container and plug insert
assembly mechanism during automated and high-speed production process, a
bronze metal ring, shown in Fig. 6.9, is installed to seal the leaking gap. This
metal ring is tightly pressed and accurately fit to the bottom center hole in plug
insert assembly mechanism.
Since the friction force between plug and center hole in plug assembly mecha-
nism is larger than gas pressure force, there is no gas leakage from top area of plug
assembly unit.
6.2 Computer-Aided Simulation of Automated

and High-Speed Manufacturing Systems
The computer-aided modeling and numerical simulation of automated and high-

speed high-viscous liquid filling system and automated and high-speed chemical
gas charging system are described in Sects. 3.2.1 and 3.2.2, respectively.

High-Viscous Liquid Filling System
The computational analysis and numerical simulation of high-viscous liquid

leaking rate RL in this automated and high-speed liquid filling system can be defined
in the following mathematical equation (Kundu and Cohen 2008):
0:5
TP PEntrance 2 PExit 2
RL ¼ V E DC 2:5 EC ð6:1Þ
PP LC LSG T E CF DW
Here, V—liquid flow rate, E—constant, TE—average temperature, TP—basic

temperature, DC—container inside diameter, EC—container filling efficiency,
PEntrance—pressure at the entrance, PExit—pressure at the exit, DW—Darcy-
Weisbach frictional coefficient, LSG—specific gravity of liquids, LC—length of
container, PP—pressure base, and CF—coefficient of compressibility.
The mathematic equation (6.1) can be modeled in the computer-aided design and
numerical simulation. It indicates that the leakage of high-viscous fluid in
automated and high-speed filling process is related to different factors including
liquid flow rate V and pressure difference of (PEntrance PExit). The computational
simulation in Fig. 6.10 states that the leakage of heavy viscous liquid in this new
automated and high-speed filling system is so small that the leakage can be
neglected.
0.0004
Liquid Leakage (ml)
0.0003
0.0002
0.0001
0.0000
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100105110115120125126127
Filling Plug Linear Speed (ft/ min)
Fig. 6.10 Heavy viscous liquid leakage vs. piston linear speed
6.2 Computer-Aided Simulation of Automated and High-Speed. . . 93
Fig. 6.11 Computational modeling of stress profile in liquid filling mechanism
The computer-aided structural and stress analysis has been performed to help
this new system design and development. The analytic results on some important
components, such as liquid filling mechanism and ultrasonic welding (sealing)
mechanism in this new automated and high-speed viscous liquid filling system,
are depicted in Figs. 6.11, 6.12, 6.13, and 6.14.
The computer-aided simulation and analysis in Figs. 6.11 and 6.12 show the
stress and deflection of liquid filling mechanism in this newly designed automated
and high-speed viscous liquid filling system. The analytic results present that the
maximum stress of 21,937.83 psi in this liquid filling mechanism is less than the
material yield strength of 36,300 psi and maximum deflection of 0.01324 in. is
within material allowable deflection limit.
stress and deflection of ultrasonic welding mechanism in this new automated and
high-speed viscous liquid filling system. The analytic results present that the
maximum stress of 24,973.92 psi in this ultrasonic welding mechanism is less
0.01089 in. is within material allowable deflection limit.
Based on the above computer-aided modeling and numerical simulation, this
new automated and high-speed high-viscous liquid filling system can function
Fig. 6.12 Computational modeling of deflection profile in liquid filling mechanism
properly with good sealing capability and high production rates. Also the
manufacturing cost for this new liquid filling system is relatively low since
the less tolerance control is required in this new liquid filling system design.

Chemical Gas Charging System
The mathematical modeling of gas leakage in chemical gas charging process can be
expressed as follows (White 2003):

P 1 VC
V GL ¼ B Δ ð6:2Þ
N Δt T
h i
Here, VGL—leakage rate of gas, B—unit conversion constant, Δ NP ¼ PF
NF NPII —
final pressure PF divided by final gas deviation constant NF minus initial pressure PI
1
divided by initial gas deviation constant NI, Δt —time duration in minutes to build a
Fig. 6.13 Computational modeling of stress profile in ultrasonic welding mechanism
stabilized pressure, VC—tubing string volume above container, and T—temperature

in container.
This mathematical equation can be modeled and analyzed by computer-aided 3D
modeling and numerical simulation, with analytic result expressed in Fig. 6.15.
The computational simulation result indicates that this newly designed chemical
gas charging system has strong sealing capability and even very small gas leakage
under high pressure can be reasonably ignored.
To perform computer-aided structural analysis, the following mathematic equa-
tion is applied to define the load or the force increment in the computational
simulation (White 2003):
FLoad ¼ PGas SArea ð6:3Þ
Here, FLoad—load or force applied to the component, PGas—maximum gas

pressure, and SArea—gas charging area.
The computer-aided structural analysis can assist this new system design with
analytic results on some critical parts including container fixture mechanism, plug
delivery mechanism, plug insertion mechanism, and sealing plug feeding unit
represented in Figs. 6.16, 6.17, 6.18, 6.19, 6.20, 6.21, 6.22, and 6.23.
Fig. 6.14 Computational modeling of deflection profile in ultrasonic welding mechanism
0.00016
0.00014
Gas Leakage (cc/min)
0.00012
0.00010
0.00008
0.00006
0.00004
0.00002
0.00000
0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400 420 440
Gas Pressure (psia)
Fig. 6.15 Gas leakage vs. gas pressure

Fig. 6.16 Computational simulation of stress profile in container fixture mechanism
stress and deflection of container fixture mechanism in this new automated and
high-speed viscous liquid filling system. The analytic results state that the maxi-
mum stress of 24,692.52 psi in this container fixture mechanism is less than the
stress and deflection of plug delivery mechanism in this new automated and high-
speed viscous liquid filling system. The analytic results demonstrate that the
maximum stress of 21,072.31 psi in this plug delivery mechanism is less than the
stress and deflection of plug insertion mechanism in this new automated and high-
speed viscous liquid filling system. The analytic results state that the maximum
stress of 13,766.81 psi in this plug insertion mechanism is less than the material
yield strength of 36,300 psi and maximum deflection of 0.07182 in. is within
material allowable deflection limit.
stress and deflection of plug feeding unit in this new automated and high-speed
Fig. 6.17 Computational simulation of deflection profile in container fixture mechanism
Fig. 6.18 Computational simulation of stress profile in plug delivery mechanism

Fig. 6.19 Computational simulation of deflection profile in plug delivery mechanism
Fig. 6.20 Computational simulation of stress profile in plug insertion mechanism

Fig. 6.21 Computational simulation of deflection profile in plug insertion mechanism
Fig. 6.22 Computational simulation of stress profile in plug feeding unit at bowl exit
Fig. 6.23 Computational simulation of deflection profile in plug feeding unit at bowl exit
viscous liquid filling system. The analytic results state that the maximum stress of
7,216.14 psi in this plug feeding unit is less than the material yield strength of
deflection limit.
Based on computer-aided simulation in Figs. 6.16, 6.17, 6.18, 6.19, 6.20, 6.21,
6.22, and 6.23, the maximum stresses produced in all critical parts including
container fixture mechanism, plug delivery mechanism, plug insertion mechanism,
and sealing plug feeding unit are all less than the material yield stress and also
relevant maximum deflections of these parts are within allowable limits of the
materials. The above computational simulation shows the good performance of this
new automated and high-speed chemical gas charging system with superior sealing
capability in normal pressure and neglected gas leakage in high gas pressure. This
new gas charging system can be potentially applied in high speed and fully
automated manufacturing process with the cost-effective features due to simplified
and less tolerance-controlled system design.

Manufacturing Systems
New automated and high-speed heavy viscous liquid filling system and automated
and high-speed chemical gas charging system are being prototyped and tested to
compare and verify the computer-aided simulation results.
6.3.1 Experiment on Automated and High-Speed Heavy

Viscous Liquid Filling System
Table 6.1 records the prototype testing results of heavy viscous media leakage
vs. filling plug linear speed in this new automated and high-speed viscous liquid
filling system.
The prototype experiment of viscous media leakage vs. plug linear speed in
Table 6.1 verifies the proper function of this liquid filling system because the close
result is laid out in Fig. 6.10 by computer-aided modeling and numerical simulation.
Table 6.2 states the experiment results of maximum stress and maximum
deflection of liquid filling mechanism in this new automated and high-speed liquid
filling system.
The prototype testing results in Table 6.2 confirm the appropriate function of this
liquid filling mechanism since the average maximum stress 21,937.78 psi and
average maximum deflection 0.0128 in. are closely equal to the results of maximum
stress 21,937.83 psi and maximum deflection 0.0132 in. that are recorded, respec-
tively, in Figs. 6.11 and 6.12 by computational simulation.
Table 6.3 demonstrates the prototype experimental results of maximum stress
and maximum deflection of ultrasonic welding mechanism in this new automated
and high-speed liquid filling system.
Table 6.1 Prototype Filling plug linear Heavy viscous media

testing of viscous media speed (ft/min) leakage (ml)
leakage vs. filling plug
10 0.000022
linear speed
20 0.000032
30 0.000038
40 0.000042
50 0.000045
60 0.000051
70 0.000068
80 0.000075
90 0.000088
100 0.000095
110 0.000102
120 0.000108
6.3 Experiment on Automated and High-Speed Manufacturing Systems 103

1 21,937.73 0.0129
of liquid filling mechanism
in this new heavy viscous 2 21,937.77 0.0135
liquid filling system 3 21,937.95 0.0122
4 21,937.91 0.0125
5 21,937.88 0.0127
6 21,937.68 0.0133
7 21,937.75 0.0131
8 21,937.78 0.0125
9 21,937.69 0.0129
10 21,937.66 0.0122
11 21,937.71 0.0133
12 21,937.81 0.0126
13 21,937.64 0.0124
14 21,937.78 0.0135
15 21,937.68 0.0127
16 21,937.88 0.0123
17 21,937.85 0.0135
18 21,937.86 0.0122
19 21,937.79 0.0129
20 21,937.88 0.0135
Average 21,937.78 0.0128

stress and maximum
1 24,973.88 0.0112
deflection of ultrasonic
welding mechanism in this 2 24,973.96 0.0105
new heavy viscous liquid 3 24,973.98 0.0118
filling system 4 24,973.94 0.0115
5 24,973.89 0.0108
6 24,973.99 0.0115
7 24,973.95 0.0113
8 24,973.88 0.0118
9 24,973.99 0.0105
10 24,973.98 0.0112
11 24,973.97 0.0116
12 24,973.96 0.0117
13 24,973.98 0.0107
14 24,973.99 0.0118
15 24,973.88 0.0115
16 24,973.98 0.0107
17 24,973.99 0.0115
18 24,973.96 0.0117
19 24,973.97 0.0108
20 24,973.98 0.0107
Average 24,973.96 0.0112
Table 6.4 Prototype Filling gas pressure (psia) Gas media leakage (cc/min)
experimental results of gas
0 0.00000
media leakage vs. filling
gas pressure 20 0.00000
40 0.00000
60 0.00000
80 0.00000
100 0.00000
120 0.00000
140 0.00000
180 0.00000
200 0.00000
220 0.00000
240 0.00000
260 0.00000
280 0.00000
300 0.00000
320 0.00000
340 0.00000
360 0.00000
380 0.00000
400 0.00000
420 0.00001
440 0.00002
The experimental results of ultrasonic welding mechanism in Table 6.3 prove

the normal function of this ultrasonic welding mechanism as the average maximum
stress 24,973.96 psi and average maximum deflection 0.0112 in. are similar to the
are presented, respectively, in Figs. 6.13 and 6.14 by computer-aided simulation.

Chemical Gas Charging System
Table 6.4 demonstrates the prototype experimental results of gas media leakage
vs. filling gas pressure in this new automated and high-speed chemical gas charging
system.
The prototype testing of gas media leakage vs. gas pressure in Table 6.4 verifies
the proper function of this gas filling system because the equally profiled result is
represented in Fig. 6.15 by computer-aided modeling and numerical simulation.
Table 6.5 represents the prototype testing results of maximum stress and maxi-
mum deflection of container fixture mechanism in this new automated and high-
speed chemical gas charging system.
The prototype testing results of container fixture mechanism in Table 6.5 con-
firm the appropriate function of this container fixture mechanism since the average
6.3 Experiment on Automated and High-Speed Manufacturing Systems 105

1 24,692.56 0.1178
container fixture
mechanism in this new 2 24,692.48 0.1181
automated chemical gas 3 24,692.45 0.1188
charging system 4 24,692.56 0.1177
5 24,692.59 0.1179
6 24,692.46 0.1180
7 24,692.49 0.1189
8 24,692.62 0.1185
9 24,692.68 0.1178
10 24,692.57 0.1181
11 24,692.56 0.1176
12 24,692.66 0.1179
13 24,692.68 0.1182
14 24,692.62 0.1188
15 24,692.51 0.1178
16 24,692.55 0.1182
17 24,692.62 0.1185
18 24,692.64 0.1188
19 24,692.56 0.1190
20 24,692.55 0.1181
Average 24,692.57 0.1182
maximum stress 24,692.57 psi and average maximum deflection 0.1182 in. are very
similar to the results of maximum stress 24,692.52 psi and maximum deflection
0.1186 in. that are indicated, respectively, in Figs. 6.16 and 6.17 by computational
simulation.
Table 6.6 records the prototype experimental results of maximum stress and
maximum deflection of plug delivery mechanism in this new automated and high-
speed chemical gas charging system.
The prototype experimental results in Table 6.6 prove the normal function of this
plug delivery mechanism as the average maximum stress 21,072.36 psi and average
maximum deflection 0.0880 in. are almost equal to the results of maximum stress
21,072.31 psi and maximum deflection 0.0875 in. that are laid out, respectively, in
Figs. 6.18 and 6.19 by computer-aided simulation.
Table 6.7 states the testing results of maximum stress and maximum deflection
of plug insertion mechanism in this new automated and high-speed chemical gas
charging system.
The prototype testing results of plug insertion mechanism in Table 6.7 verify the
proper function of this plug insertion mechanism because the average maximum
stress 13766.88 psi and average maximum deflection 0.0722 in. are very close to the
results of maximum stress 13766.81 psi and maximum deflection 0.0718 in. that are
shown, respectively, in Figs. 6.20 and 6.21 by computer-aided simulation.

stress and maximum
1 21,072.38 0.0882
deflection of plug delivery
5 21,072.36 0.0882
6 21,072.39 0.0885
7 21,072.42 0.0874
8 21,072.29 0.0878
9 21,072.36 0.0888
10 21,072.38 0.0882
11 21,072.42 0.0879
12 21,072.41 0.0878
13 21,072.29 0.0888
14 21,072.39 0.0889
15 21,072.37 0.0885
16 21,072.38 0.0879
17 21,072.43 0.0873
18 21,072.27 0.0887
19 21,072.38 0.0878
20 21,072.35 0.0872
Average 21,072.36 0.0880

stress and maximum
1 13,766.86 0.0725
deflection of plug insertion
5 13,766.95 0.0727
6 13,766.87 0.0716
7 13,766.77 0.0715
8 13,766.88 0.0727
9 13,766.95 0.0726
10 13,766.89 0.0724
11 13,766.92 0.0715
12 13,766.86 0.0727
13 13,766.78 0.0716
14 13,766.89 0.0725
15 13,766.86 0.0727
16 13,766.93 0.0715
17 13,766.78 0.0726
18 13,766.83 0.0713
19 13,766.88 0.0727
20 13,766.87 0.0717
Average 13,766.88 0.0722
6.4 Discussion and Future Improvement on Automated and High-Speed. . . 107

1 7,216.25 0.0185
plug feeding unit in this
new automated chemical 2 7,216.22 0.0175
gas charging system 3 7,216.18 0.0178
4 7,216.09 0.0183
5 7,216.11 0.0173
6 7,216.24 0.0175
7 7,216.27 0.0181
8 7,216.08 0.0173
9 7,216.11 0.0175
10 7,216.22 0.0173
11 7,216.24 0.0178
12 7,216.18 0.0181
13 7,216.27 0.0183
14 7,216.25 0.0172
15 7,216.22 0.0172
16 7,216.18 0.0173
17 7,216.26 0.0183
18 7,216.16 0.0173
19 7,216.18 0.0172
20 7,216.08 0.0185
Average 7,216.19 0.0177
Table 6.8 demonstrates the experimental results of maximum stress and maxi-
mum deflection of plug feeding unit in this new automated and high-speed chemical
gas charging system.
The prototype experimental results of plug feeding unit in Table 6.8 confirm the
appropriate function of this plug feeding unit since the average maximum stress
7,216.19 psi and average maximum deflection 0.0177 in. are closely equal to the
are presented, respectively, in Figs. 6.22 and 6.23 by computer-aided simulation.

and High-Speed Manufacturing Systems
Automation can bring explosive growth of business. The real-time systems will
effectively control the complex adaptive and multiprocessing systems. The applied
control software permits elemental nodes to communicate with each other in the
larger and complicated adaptive system. Since the automated and high-speed
production systems are too expensive to be rebuilt for each design change and
system modification, the designed automated systems should be potentially flexible
or easily reconfigurable to produce a variety of products on customized demand.
Automated and high-speed production technologies in modern workplace require

skilled individuals to smoothly and correctly handle the technical problems that
vary depending on the product being manufactured, process being employed, and
machineries being utilized. The automated production systems needs task forces
having basic production knowledge and hands-on experience to perform
troubleshooting of high-tech and high-speed automated machinery systems or
reinstallation of it if required to maintain continuous production flow. Because of
these above technical reasons, the automated and high-speed systems are highly
recommended to be designed for reliable function, quicker maintenance, simple
installation, cheaper reconfiguration, and easier technical training. Two new
automated and high-speed production systems of high-viscous liquid filling and
chemical gas charging introduced in this book have aimed at these professional
design targets. Upon a few small changes, viscous liquid filling system can be easily
reconfigured for chemical gas charging process. This new cost-effective system
design allows efficient quality diagnostic software and adaptable interfaces working
in high-level reliability with permeate access up to bottom diagnosis and error-
rectification database through centralized control. To further improve these new
automated and high-speed production systems, the modifications will include
making moving mechanisms (such as ultrasonic welder support, liquid filling
nozzle connector, and sealing plug plunger) lighter to reduce the vibration,
modifying design layout for easier maintenance, searching cheaper high-viscous
liquid pump to reduce the cost, and readjusting the system tolerance control for
cost-effective manufacturing.
Robotic System
7
7.1 Design of Robotic System for Industrial Applications
Robotics research integrates multiple academic and technical fields including

mathematics, mechatronics, physics, automation, and mechanical engineering.
Robotic systems can be applied to the industry to perform many special, dangerous,
heavy labor involved, accurate, and repetitive tasks. Figure 7.1 shows the prototype
of this newly designed robotic system. It can be used for automated manufacturing
and assembly processes including picking up and placing the work pieces and
products in automated industrial production.
Actuators in robotic system operate as human muscles to change the energy into
body motion. Electric motor is a very common type of actuator, linear actuator is
used when strong force is needed in linear motion, piezo motor relies on piezo
element vibration to operate the motor, air wire is a hollow cylindrical element and
its length varies as different internal air pressure is applied, and electroactive
polymer is a plastic material and its length can be altered by electricity. The sensor
has a firm central element surrounded by conductive liquids that is boxed by the
elastic substance. Electrode, mounted at the hard central element surface, is linked
to a resistance-inspecting unit inside the central element. As elastic substance
touches an object, the liquid volume boxed electrode will vary causing the resis-
tance change that traces the external forces from target object. Computer-aided
vision technology can be applied in robotic system and automation to obtain
numerical information from digital images via video and camera systems. Robotic
systems can flexibly manipulate objects by robotic arms to perform different
complex tasks. Mechanical grippers are commonly used in robotic system to pick
up and place small objects and vacuum grippers are widely applied to pick and
place large objects. Kinematics can be applied to determine effectors’ moving
velocity, travel acceleration, reaching location, and oriented rotation while design-
ing and analyzing the robotic system. Dynamics can be used to determine the
external force or load effect on robotic arm movement and dynamic methodology

110 7 Robotic System
Fig. 7.1 Prototype of new

robotic system
is an effective tool used in computational simulation to adjust and optimize the

control algorithms of robotic systems.
The prototype shown in Fig. 7.1 has been analyzed and validated through
computer-aided 3D modeling, numerical simulation, and prototype experiment in
the following chapters. The analytic and experimental results show that the maxi-
mum 3D moving distances of this new robotic system are 8 ft (x direction), 12 ft
(y direction), and 10 ft (z direction), respectively.
7.2 Computer-Aided Simulation on Robotic System

for Industrial Applications
One new robotic system from author’s current researches has been introduced and
analyzed in this chapter for picking and placing products in biomedical/surgical
procedures and automated production processes. The robotic systems is 3D
modeled, designed, and validated through computer-aided modeling, numerical
simulation, and engineering analysis. The designed robotic system is programmed
with specific mathematical model that accurately controls the robot arm movement.
The simplest double-link robot arm with less complex mathematical model is
shown in Fig. 7.2.
In simplified double-lever arm system, the first lever A_B moves around the
origin point O in the M_N Cartesian coordinate system and the second lever B_C
goes around the hinge point B that joins levers A_B and B_C. The angle ζ is
selected between lever A_B and horizontal axis O_M and angle λ is set between
7.2 Computer-Aided Simulation on Robotic System for Industrial Applications 111
Fig. 7.2 Double-lever model

for robot arm
levers A_B and B_C. The robot arm is at the end places (MB, NB) of lever A_B and
(MC, NC) of lever B_C.
Three analytic methodologies can be applied to analyze the robotic system:
kinematics—specify robot arm position (MB, NB) while angles ζ and λ are
known; inverse kinematics—solve angles ζ and λ while robot arm position (MB,
NB) is given; and trajectory generation—ascertain robot arm new position (MC, NC)
by modifying angles ζ and λ while present position (MB, NB) is provided.
• Kinematical method:
From Fig. 7.2, the end point of lever B_C can be defined as follows (Gevorkian
2007):
MC ¼ ðA BÞ cos ðζ Þ þ ðB CÞ cos ðζ þ λÞ ð7:1Þ
N C ¼ ðA BÞ sin ðζ Þ þ ðB CÞ sin ðζ þ λÞ ð7:2Þ
Here,
MB ¼ ðA BÞ cos ðζ Þ
N B ¼ ðA BÞ sin ðζ Þ
MC ¼ MB þ ðB CÞ cos ðζ þ λÞ
N C ¼ N B þ ðB CÞ sin ðζ þ λÞ
• Inverse kinematical method:
Based on kinematical equations (7.1) and (7.2), it needs a nonlinear solution to

specify angles ζ and λ while end position (MC, NC) is provided.
Considering the following mathematical equations (Gevorkian 2007):
cos ðα þ βÞ ¼ cos ðαÞ cos ðβÞ sin ðαÞ sin ðβÞ ð7:3Þ
sin ðα þ βÞ ¼ cos ðαÞ sin ðβÞ þ sin ðαÞ cos ðβÞ ð7:4Þ
the algebraic model can be used to resolve this nonlinear problem by combining
mathematical equations (7.1) and (7.2). Solving the above nonlinear mathemati-
cal equations can obtain new mathematical equation to determine angle λ
(Gevorkian 2007):
" #
MC 2 þ N C 2 ðA BÞ2 ðB CÞ2
λ ¼ arccos ð7:5Þ
2 ðA BÞ ðB CÞ
Since cos(λ) ¼ cos(λ), the inverse kinematical problem can have two solutions
with lever B_C clockwise and counterclockwise rotation as displayed in Fig. 7.3.
Angles ζ can be specified upon solution of angle λ in inverse kinematical model
(Gevorkian 2007):
MC ¼ ½ðA BÞ þ ðB CÞ cos ðλÞ cos ðζ Þ ðB CÞ sin ðλÞ sin ðζ Þ ð7:6Þ
N C ¼ ðB CÞ sin ðλÞ cos ðζ Þ þ ½ðA BÞ þ ðB CÞ cos ðλÞ sin ðζ Þ ð7:7Þ
The angle λ can be specified by resolving the above nonlinear mathematical

equations (7.6) and (7.7).
• Trajectory-generated method:
In double-levered robot arm application, the arm position (MB, NB) is correlated
to the lever angles ζ B and λB. As robot arm revolves to a new position (MC, NC), the
angles ζ C and λC can be specified upon inverse kinematical analysis. Several
methods to manipulate robotic arm rotating from one place to another place are
alter angle ζ prior to setting λ, modify angle λ before settling ζ, change angles ζ and
λ together at the same time, move robot arm around in clockwise direction, and turn
robot arm around in counterclockwise direction. An efficient and well-functioned
robot system design can cut down the energy necessitated to move robot arm and
minimize the time required to switch the systematic mechanism. Figure 7.4 lays out
a robot arm orientating in a trajectory-generated curve with angle ζ altering in
clockwise direction.
Two traveling trajectories of robot arm in Fig. 7.4 convey the desirable moving
situation. In linear trajectory-generated method, the straight or non-straight line can
be separated into multiple tiny elements and associated (Mi, Ni) coordinates at the
Fig. 7.3 Inverse kinematical

model for robotic arm
Fig. 7.4 Robot arm in

trajectory-generated move
with clockwise change in
angle ζ
end of each element are determined via computer-aided simulation. The targeted
angle pairs ζ i and λi are calculated for each (Mi, Ni) coordinate pair and robot arm
mechanisms can be manipulated as each new pair of ζ i and λi is computed. The
computational simulation of angle pair’s ζ i and λi is continuously performed along
straight or non-straight line until anticipated arm position is achieved.
The more complex robotic arm movement can also be simulated and analyzed
through computational modeling and numerical simulation. Figure 7.5 indicates the
simulated trajectory moving curve of robot arm upon many important data points
along traveling path. The robot arm moving path becomes smoother when angle
pairs ζ i and λi are being adjusted at the same time.
Fig. 7.5 Computational 10

simulation of robotic arm
Following
traveling path upon multiple 8
Position
data points
6
0
Present
-2
Position
-4
-6
-8
-10
-10 -8 -6 -4 -2 0 2 4 6 8 10
Figure 7.6 records the robot arm traveling in an alternative trajectory path with
smoother curve as angle pair’s ζ i and λi are manipulated simultaneously.
The robotic system is a nonlinear functioning system that demands the integra-
tion of complicated mathematical modeling, computer-aided analysis, and numeri-
cal simulation to study and resolve the robotic motion problems. The different lever
lengths can be applied to specify possible 3D traveling ranges that robotic arms can
cover. The inverse kinematical method can be revised to follow through the
trajectory-generated solution and apply computational modeling and numerical
simulation to analyze the complex motion of robotic arm system. Figures 7.7,
7.8, 7.9, 7.10, 7.11, and 7.12 show computer-aided simulation and solution of
pulse-width modulation (PWM) values that are used to drive the motors to move
robotic system in different directions, to determine the kinematic motion of the
robotic system.
The traveling trajectories of robotic system, converted from computer-aided
analytic solutions of PWM values exhibited in Figs. 7.7, 7.8, 7.9, 7.10, 7.11, and
7.12, can be used to optimize the robotic system design to achieve desired moving
ranges through computer-aided modeling and numerical simulation. For each (Mi,
Ni) coordinate pair, the required angles ζ i and λi are calculated via computational
modeling and numerical simulation for optimal systematic function. The robotic
arm mechanisms are being updated as soon as each new angle pair of ζ i and λi is
verified and computational solutions of angles ζ i and λi continue until the desired
robotic arm location is reached. The computational simulation shows that the
maximum 3D traveling ranges of this new robotic system shown in Fig. 7.13 are
8 ft (front to back), 12 ft (left to right), and 10 ft (top to bottom).
To verify if this newly developed robotic system has necessary strong
structure to handle automated and high-speed manufacturing and production, the
Fig. 7.6 Computational 10

simulation of robotic arm Following
traveling with an alternative 8
Position
moving path
6
2
Present
0
Position
-2
-4
-6
-8
-10
-10 -8 -6 -4 -2 0 2 4 6 8 10
Fig. 7.7 Simulated PWM

values—drive motor to move
robot arm toward the front
computer-aided structural analysis has been performed on some critical

components, with stress and deflection profiles presented in Figs. 7.14, 7.15, 7.16,
7.17, 7.18, and 7.19.
stress and deflection of arm in this new robotic system. The analytic results tell that

robot arm toward the back

robot arm toward the left

robot arm toward the right

robot arm toward the upper
direction

robot arm toward the lower
direction
Fig. 7.13 Simulated maximum 3D moving range of newly developed robotic system
the maximum stress of 22,421.51 psi in this arm is less than the material yield
strength of 36,300 psi and maximum deflection of 0.01045 in. is within material
allowable deflection limit.
Fig. 7.14 Computer-aided simulation of stress profile in the arm of new robotic system
stress and deflection of arm link in this new robotic system. The analytic results
demonstrate that the maximum stress of 22,634.97 psi in this arm link is less than
the material yield strength of 36,300 psi and maximum deflection of 0.04469 in. is
stress and deflection of arm base in this new robotic system. The analytic results
state that the maximum stress of 19,097.23 psi in this arm base is less than the
The above computer-aided simulation results indicated that the maximum
stresses on these critical components are all below the material yield stress and
The above analytic solutions have shown the proper systematic function and
reliable quality of this newly designed and developed robotic system.
Fig. 7.15 Computer-aided simulation of deflection profile in the arm of new robotic system
7.3 Experiment on Robotic System for Industrial Applications
The kinematic motion of robot arm in this robotic system is measured by pulse-
width modulation (PWM) methodology to the prototype. The PWM register’s
values are utilized to operate the motors of robotic system in different orientations.
The following tables present the movement of the robot arm in this new robotic
system toward the front, back, left, right, higher, and lower directions.
Table 7.1 demonstrates the prototype testing results of PWM register as robot
arm of this new robotic system moves to the front.
Based on Table 7.1, while the robot arm of this new robotic system moves to the
front, the prototype testing results of PWM register verify the proper function
because the testing values are close to the profiled PWM register results by
computer-aided modeling and simulation as shown in Fig. 7.7.
Table 7.2 depicts the prototype experimental results of PWM register as robot
arm of this new robotic system moves to the back.
7.3 Experiment on Robotic System for Industrial Applications 121
Fig. 7.16 Computer-aided simulation of stress profile in the link of new robotic system
Table 7.2 represents that while the robot arm of this new robotic system moves to
the back, the prototype experimental results of PWM register confirm the appropri-
ate function since the testing values are similar to the simulated PWM register
results by computer-aided modeling and simulation as depicted in Fig. 7.8.
Table 7.3 expresses the prototype testing results of PWM register as robot arm of
this new robotic system moves to the left.
Table 7.3 conveys that while the robot arm of this new robotic system moves to
the left, the prototype testing results of PWM register prove the normal function as
the testing values are almost equal to the simulated PWM register results by
computer-aided modeling and simulation conveyed as shown in Fig. 7.9.
Table 7.4 indicates the prototype experimental results of PWM register as robot
arm of this new robotic system moves to the right.
Fig. 7.17 Computer-aided simulation of deflection profile in the link of new robotic system
Table 7.4 records that while the robot arm of this new robotic system moves to
the right, the prototype experimental results of PWM register verify the proper
function because the testing values are very similar to the simulated PWM register
results by computer-aided modeling and simulation as shown in Fig. 7.10.
Table 7.5 lays out the prototype testing results of PWM register as robot arm of
this new robotic system moves to the upper direction.
Table 7.5 states that while the robot arm of this new robotic system moves to the
upper direction, the prototype experimental results of PWM register confirm the
appropriate function since the testing values are closely equal to the simulated
PWM register results by computer-aided modeling and simulation as shown in
Fig. 7.11.
Table 7.6 displays the prototype experimental results of PWM register as robot
arm of this new robotic system moves to the lower direction.
Fig. 7.18 Computer-aided simulation of stress profile in the base of new robotic system
Table 7.6 shows that while the robot arm of this new robotic system moves to the
lower direction, the prototype testing results of PWM register prove the normal
function as the testing values are almost same as the simulated PWM register results
by computer-aided modeling and simulation as shown in Fig. 7.12.
The kinematic motion of prototyped robotic system traced and detected by PWM
registers shows 3D movement of robot arm in this new robotic system. The
prototype experiment indicates that the robot arm moves in 3D directions with
8.02 ft in the direction of front to back, 12.05 ft in the direction of left to right, and
10.04 ft in the direction of top to bottom. Comparing to computer-aided simulation
of 8 ft in front-to-back direction, 12 ft in left-to-right direction, and 10 ft in top-to-
bottom direction previously shown in Fig. 7.13, the experimental results are very
close to the simulated results.
Fig. 7.19 Computer-aided simulation of deflection profile in the base of new robotic system
Table 7.1 Prototype Time (ms) PWM register 1 PWM register 2

experimental results of
0.5 0 0
PWM register as robot arm
moving to the front 1.0 178 178
1.5 305 305
2.0 410 410
2.5 425 425
3.0 468 468
3.5 585 585
4.0 648 648
4.5 725 725

0.5 0 0
moving to the back 1.0 188 188
1.5 378 378
2.0 405 405
2.5 415 415
3.0 448 448
3.5 605 605
4.0 708 708
4.5 745 745

0.5 0 0
moving to the left 1.0 248 450
1.5 380 375
2.0 625 980
2.5 780 1,218
3.0 578 915
3.5 775 1,420
4.0 978 1,550
4.5 1065 1,725

0.5 0 0
moving to the right 1.0 455 245
1.5 480 475
2.0 878 705
2.5 685 490
3.0 675 380
3.5 948 725
4.0 1,230 875
4.5 1,378 1,025
The experiment has also been performed to assert if this newly developed robotic
system has required well-set structure to handle different industrial applications
including automated and high-speed manufacturing and production. The structure
and strength testing have been carried out on some critical robotic components
with stress and deflection measurement displayed in the following tables.
mum deflection of robot arm in this new robotic system.
The prototype testing results of robot arm in Table 7.7 prove the normal function
as the average maximum stress 22,421.56 psi and average maximum deflection
0.0110 in. are very close to the results of maximum stress 22,421.51 psi and
Table 7.5 Prototype Time (ms) PWM register

testing results of PWM
0.5 0
register as robot arm
moving to the upper 1.0 248
direction 1.5 495
2.0 625
2.5 755
3.0 945
3.5 1,188
4.0 1,375
4.5 1,695
Table 7.6 Prototype Time (ms) PWM register

testing results of PWM
0.5 0
register as robot arm
moving to the lower 1.0 255
direction 1.5 635
2.0 818
2.5 1,050
3.0 1,245
3.5 1,375
4.0 1,620
4.5 1,705

stress and maximum
1 22,421.57 0.0108
deflection of robot arm in
this new robotic system 2 22,421.54 0.0104
3 22,421.48 0.0102
4 22,421.49 0.0115
5 22,421.62 0.0115
6 22,421.61 0.0104
7 22,421.56 0.0113
8 22,421.59 0.0103
9 22,421.49 0.0113
10 22,421.62 0.0109
11 22,421.61 0.0111
12 22,421.55 0.0112
13 22,421.57 0.0103
14 22,421.48 0.0115
15 22,421.63 0.0113
16 22,421.61 0.0112
17 22,421.57 0.0101
18 22,421.59 0.0115
19 22,421.57 0.0114
20 22,421.48 0.0108
Average 22,421.56 0.0110

experimental results of of experiment stress (psi) deflection (in.)
maximum stress and
1 22,634.91 0.0455
maximum deflection of
robot arm link in this new 2 22,634.93 0.0445
robotic system 3 22,634.88 0.0448
4 22,634.98 0.0456
5 22,634.95 0.0457
6 22,634.89 0.0454
7 22,634.86 0.0446
8 22,634.92 0.0454
9 22,634.91 0.0456
10 22,634.90 0.0449
11 22,634.88 0.0445
12 22,634.98 0.0457
13 22,634.91 0.0455
14 22,634.93 0.0446
15 22,634.99 0.0457
16 22,634.92 0.0455
17 22,634.98 0.0443
18 22,634.93 0.0455
19 22,634.90 0.0453
20 22,634.98 0.0445
Average 22,634.93 0.0452
maximum deflection 0.0105 in. that are presented, respectively, in Figs. 7.14 and
7.15 by computer-aided modeling and numerical simulation.
mum deflection of robot arm link in this new robotic system.
The prototype experimental results of robot arm link in Table 7.8 verify the
proper function because the average maximum stress 22,634.93 psi and average
maximum deflection 0.0452 in. are closely equal to the results of maximum stress
22,634.97 psi and maximum deflection 0.0447 in. that are represented, respectively,
in Figs. 7.16 and 7.17 by computer-aided modeling and numerical simulation.
Table 7.9 represents the experimental results of maximum stress and maximum
deflection of robot arm base in this new robotic system.
The prototype experimental results of robot arm base in Table 7.9 confirm the
appropriate function since the average maximum stress 19,097.27 psi and average
maximum deflection 0.2316 in. are approximately same as the results of maximum
stress 19,097.23 psi and maximum deflection 0.2320 in. that are laid out, respec-
simulation.

experimental results of of experiment stress (psi) deflection (in.)
maximum stress and
1 19,097.27 0.2318
maximum deflection of
robot arm base in this new 2 19,097.29 0.2322
robotic system 3 19,097.32 0.2311
4 19,097.35 0.2310
5 19,097.36 0.2312
6 19,097.21 0.2318
7 19,097.22 0.2315
8 19,097.38 0.2312
9 19,097.27 0.2323
10 19,097.25 0.2311
11 19,097.29 0.2314
12 19,097.18 0.2313
13 19,097.20 0.2322
14 19,097.27 0.2312
15 19,097.35 0.2315
16 19,097.27 0.2313
17 19,097.29 0.2320
18 19,097.20 0.2318
19 19,097.21 0.2312
20 19,097.25 0.2320
Average 19,097.27 0.2316
7.4 Discussion and Future Improvement on Robotic System
To date, there is considerable evidence that more and more product companies are
applying robotic systems to their scope of production practice due to significant
benefits for the business but some firms are little concerned about the cost. The
robotic technology is exceptional with 3D manipulated visual images and systems
can be oriented intuitively with degrees of freedom in multiple directions. In
addition, the robotic stability that the technicians fully control can significantly
reduce the unexpected defects caused by human errors and robotic technology
largely justifies the technical limitation to avoid the deficiencies of normal produc-
tion technique. However, there is still something required to be improved for this
new robotic system. For example, it remains difficult-to-operate system in multi-
quadrants required for some complicated production processes. Also, the robotic
system cost needs to be decreased. To make these improvements, the current
robotic system modification should include modifying robotic system design for
cost-effective and easy maintenance, improving system design for more reliable
function, and studying optimal robotic mechanism through computer-aided simu-
lation for high energy and mechanical efficiency. More prototype experiments have
been planned to implement this new robotic system and the prototype will be also
sent to fields for further evaluations.
Magnetic Sealing System
8
8.1 Design of Magnetic Sealing System
The gas and lubrication oil leakages in reciprocating machinery systems including
compressors and cooling units are usual problems that have not been well solved
yet which normally influences the machine performance. This new magnetic
sealing mechanism design is to solve these gaseous or fluid media leaking
problems. In this new sealing mechanism, the rare-earth magnet steel can perform
as a permanent magnet. Both computer-aided simulation and prototype testing
verify that this sealing mechanism can effectively decrease the leaking problem
in machinery systems including compressors and cooling systems. This new mech-
anism has better sealing performance than traditional rubber seal, diaphragm seal,
corrugated pipe seal, and magnetic fluid seal. Figures 8.1, 8.2, and 8.3 display full
view of new high-pressure gas compressive and filtration system, 3D cross-section
view of new high-pressure gas compressive system, and 2D cross-section view of
new high-pressure gas compressive system.
As shown in Figs. 8.2 and 8.3, the rare-earth magnet steel can perform as a
permanent magnet steel with very higher density of magnetic flux Br, strong
magnetic field Hg, and larger product of magnetism and energy (BH)large that
keeps magnetic particles to be strongly bonded to the inner wall of permanent
magnet steel. The main advanced features of this magnetic sealing system include
raised Br in the working gap of magnetic circuit, more durable function in sealing
performance, longer lifetime in sealing capability, more compact in system config-
uration, light in unit weight, higher in efficiency, and more reliable in sealing
function. When machine piston moves back and forth inside the cylinder, the
lubricating oil is sealed by intensive magnetic particles that are firmly bonded in
the inner wall surface of magnet steel as lubricating oil move toward the seal. As
soon as lubrication oil has been blocked by magnetic particles, the oil droplets will
drop by its gravity to the bottom container in main crankshaft chamber that can
keep lubricating oil in crankshaft chamber from entering the compressive gas
cylinder. Also the gas leaking can be significantly reduced because it is very

130 8 Magnetic Sealing System
Fig. 8.1 Full view of new high-pressure gas compressive and filtration system
Fig. 8.2 3D cross-section

view of new high-pressure
gas compressive system
difficult for gas to penetrate through the firmly bonded magnetic particle layers. To
design and develop this new magnetic sealing system, two important factors that
must be taken account in order to maintain its reliable function are magnetic flux
density and material magnetic stability. Therefore the magnetic flux in the magnetic
circuit of this sealing mechanism should be kept reliable over a long time period
and material magnetic field should be extremely stable enough to handle the
8.2 Computer-Aided Simulation on Magnetic Sealing System 131
external magnetic field variation, temperature fluctuation, mechanical vibration,

unexpected shock, and severe environmental changes. The higher magnetic flux
density Br, higher magnetic field intensity Hg, and larger product of magnetism and
energy (BH)large in magnetic circuit design are targeted to maintain their peak
values in this new magnetic sealing system.
8.2 Computer-Aided Simulation on Magnetic Sealing System
The magnetic circuit in this sealing mechanism can be considered in static condi-
tion so that the ampere enclosed circuit and H–B curve are able to be used to
analyze the functionality of this rare-earth magnet steel. The magnetic circuit in this
magnetic sealing system can be assumed as a series magnetic circuit mainly
consisting of magnet steel and sealing gap. The following equations can be derived
based on Fig. 8.3 (Ekren et al. 2011):
H L þ H g Lg ¼ 0 ð8:1Þ
Lg Φ
HL¼ ð8:2Þ
U 0 Ag
The magnetic curve in magnetic circuit is shown in Fig. 8.4.

If Fm(Φ) ¼ H L, the intersection point between function {Fm(Φ)} and line of
{[Lg/(U0 Ag)] Φ} at vertical coordinate system is the magnetic flux in sealing
gap that needs to be determined. The sealing gap reduces from Lg to Lg0 if more
magnetic particles are put into the gap of magnetic circuit. As the thickness of
magnetic particle layer in the gap between contact surfaces of magnet steel and
shaft to be sealed varies from 0 to b, the functioning point of magnet steel varies
Fig. 8.3 2D cross-section

view of new high-pressure
gas compressive system
Fig. 8.4 Magnetic curve of

circuit
along the line QK and magnetic flux in sealing gap can be solved. The coefficient of
magnetic efficiency ηeff can be applied to verify if the magnetic field in sealing
mechanism is correctly designed (Evans et al. 2006):
Bg 2 V g
ηeff ¼ ð8:3Þ
ðB H Þmax V
A higher ηeff value shows more reliable magnetic circuit design. The normal ηeff
value is around 40 % in standard spec. The computational simulation indicates that
the ηeff value in this new magnetic sealing mechanism is 48.8 % which confirms the
proper magnetic circuit design in this newly developed magnetic sealing system.
Figure 8.5 shows the cross-section view of magnetic steel in this sealing system.
The mathematical equation of calculating sealing capacity ΔP can be derived from
energy balance law (Feil-Seifer et al. 2007).
Based on diagram in Fig. 8.5, R1 ¼ sin ðαÞ, R2 ¼ sin ðβÞ, S1 ¼ R1 α, and
2b 2b
S2 ¼ R2 β.
So, h i
β 0
α
ΔS ¼ S2 S1 ¼ sin ðβÞ sin ðαÞ 2 b and OO ¼ 2 β ½ctg ðαÞ ctg ðβÞ.
Since the work done by each magnetic force line equals to {T ΔS}, total work
done by all magnetic force lines in magnetic circuit is

β α
W ML ¼ B D T 2b ð8:4Þ
sin ðβÞ sin ðαÞ
And the work done by gaseous media pressure exerted to the body of magnetic
particles is
" #
sin ðαÞ þ π ½ cos ðαÞ 22
W GP ¼ 4 b ΔP 2
sin ðαÞ
ð8:5Þ
8 sin ðαÞ 4
Fig. 8.5 Cross-section view

of magnetic steel
Based on the energy balance law, the work done by magnetic force lines applied
in magnetic circuit should equal to the work done by gaseous media pressure
applied to the body of magnetic particles. So,
1
B D T ½ sin ðαÞ α
ΔP ¼ 2 ð8:6Þ
2 b ð sin αÞ þ α8 ½ cos 2 ðαÞ 4 cos ðαÞ þ 3
The above equation can be analyzed using computer-aided modeling and numer-
ical simulation. The stress and deflection profiles of major components in this new
magnetic sealing system are shown in Figs. 8.6, 8.7, 8.8, 8.9, 8.10, 8.11, 8.12, 8.13,
8.14, 8.15, 8.16, 8.17, 8.18, 8.19, and 8.20.
stress and deflection of aluminum adaptor in this new magnetic sealing system. The
analytic results show that the maximum stress of 2,923.21 psi in this aluminum
adaptor is less than the material yield strength and maximum deflection of
The computer-aided simulation and analysis in Figs. 8.10 and 8.11 tell the stress
and deflection of Armco iron ring in this new magnetic sealing system. The analytic
results present that the maximum stress of 2,428.89 psi in this Armco iron ring is
less than the material yield strength and maximum deflection of 0.00001 in. is
the stress and deflection of compressive unit in this new magnetic sealing system.
The analytic results indicate that the maximum stress of 19,376.24 psi in this
compressive unit is less than the material yield strength of 36,000 psi and maximum
deflection of 0.00105 in. is within material allowable deflection limit.
Fig. 8.6 Aluminum adaptor
Fig. 8.7 Stress profile in aluminum adaptor
The computer-aided simulation and analysis in Figs. 8.16 and 8.17 state the
stress and deflection of piston shaft in this new magnetic sealing system. The
analytic results display that the maximum stress of 19,484.07 psi in this piston
shaft is less than the material yield strength of 36,000 psi and maximum deflection
of 0.00021 in. is within material allowable deflection limit.
Fig. 8.8 Deflection profile in aluminum adaptor
Fig. 8.9 Armco iron ring

Fig. 8.10 Stress profile in Armco iron ring
Fig. 8.11 Deflection profile in Armco iron ring

Fig. 8.12 Compressive unit
Fig. 8.13 Stress profile in compressive unit

Fig. 8.14 Deflection profile in compressive unit
Fig. 8.15 Piston shaft

Fig. 8.16 Stress profile in piston shaft
Fig. 8.17 Deflection profile in piston shaft

Fig. 8.18 Rare-earth

magnetic steel
Fig. 8.19 Stress profile in rare-earth magnetic steel

Fig. 8.20 Deflection profile in rare-earth magnetic steel
stress and deflection of rare-earth magnetic steel in this new magnetic sealing
system. The analytic results tell that the maximum stress of 2,963.27 psi in this
rare earth magnetic steel is less than the material yield strength and maximum
These above computational simulation results demonstrate that the maximum
stresses on these major components are all less than the material yield stress and
maximum material deflections are all within material allowable deformation
limits. The seal capacity of this new magnetic sealing system can keep the oil
leakage from chamber of crankshaft into the gaseous chamber of cooling system
and reciprocating machineries. The computational solutions verify that this newly
developed magnetic sealing system can work properly for better sealing
functions.
8.3 Experiment on Magnetic Sealing System
The newly designed magnetic sealing system is prototyped and tested to compare
and verify the results from computer-aided simulation. Table 8.1 demonstrates the
prototype testing results of aluminum adaptor in this new magnetic sealing system.
The prototype experimental results of aluminum adaptor in Table 8.1 verify the
2,923.21 psi and maximum deflection 0.00001 in. that are represented, respectively,
Table 8.2 expresses the prototype testing results of Armco iron ring in this new
magnetic sealing system.
The prototype experimental results of Armco iron ring in Table 8.2 confirm the
2,428.89 psi and maximum deflection 0.00001 in. that are indicated, respectively, in
Figs. 8.10 and 8.11 by computer-aided modeling and numerical simulation.
Table 8.3 records the prototype testing results of compressive unit in this new
magnetic sealing system.

testing of aluminum of experiment stress (psi) deflection (in.)
adaptor in this new
1 2,923.24 0.00002
magnetic sealing system
2 2,923.18 0.00001
3 2,923.27 0.00001
4 2,923.35 0.00002
5 2,923.38 0.00001
6 2,923.44 0.00002
7 2,923.49 0.00001
8 2,923.48 0.00002
9 2,923.47 0.00002
10 2,923.36 0.00001
11 2,923.24 0.00001
12 2,923.29 0.00001
13 2,923.37 0.00001
14 2,923.39 0.00002
15 2,923.47 0.00003
16 2,923.38 0.00001
17 2,923.48 0.00002
18 2,923.45 0.00001
19 2,923.38 0.00001
20 2,923.35 0.00002
Average 2,923.37 0.00002
8.3 Experiment on Magnetic Sealing System 143

testing of Armco iron ring of experiment stress (psi) deflection (in.)
in this new magnetic
1 2,428.89 0.00002
sealing system
2 2,428.89 0.00001
3 2,428.89 0.00001
4 2,428.88 0.00002
5 2,428.91 0.00002
6 2,428.84 0.00001
7 2,428.78 0.00001
8 2,428.72 0.00001
9 2,428.68 0.00002
10 2,428.69 0.00001
11 2,428.59 0.00002
12 2,428.75 0.00002
13 2,428.72 0.00002
14 2,428.71 0.00001
15 2,428.73 0.00002
16 2,428.75 0.00002
17 2,428.78 0.00002
18 2,428.77 0.00001
19 2,428.75 0.00002
20 2,428.72 0.00001
Average 2,428.77 0.00002

testing of compressive unit of experiment stress (psi) deflection (in.)
in this new magnetic
1 19,376.25 0.00108
sealing system
2 19,376.24 0.00112
3 19,376.38 0.00104
4 19,376.39 0.00109
5 19,376.36 0.00112
6 19,376.54 0.00118
7 19,376.39 0.00115
8 19,376.37 0.00112
9 19,376.38 0.00108
10 19,376.48 0.00112
11 19,376.45 0.00111
12 19,376.37 0.00115
13 19,376.42 0.00117
14 19,376.39 0.00118
15 19,376.45 0.00116
16 19,376.38 0.00112
17 19,376.54 0.00102
18 19,376.45 0.00116
19 19,376.41 0.00112
20 19,376.38 0.00110
Average 19,376.40 0.00112

testing of piston shaft in of experiment stress (psi) deflection (in.)
this new magnetic sealing
1 19,484.12 0.00019
system
2 19,484.08 0.00020
3 19,484.11 0.00017
4 19,484.15 0.00015
5 19,484.18 0.00018
6 19,484.05 0.00016
7 19,484.16 0.00012
8 19,484.24 0.00013
9 19,484.29 0.00015
10 19,484.33 0.00017
11 19,484.38 0.00014
12 19,484.39 0.00013
13 19,484.35 0.00012
14 19,484.29 0.00015
15 19,484.24 0.00012
16 19,484.18 0.00011
17 19,484.26 0.00022
18 19,484.19 0.00018
19 19,484.17 0.00013
20 19,484.21 0.00014
Average 19,484.22 0.00015
The prototype experimental results of compressive unit in Table 8.3 prove the
normal function as the average maximum stress 19,376.40 psi and average maxi-
mum deflection 0.00112 in. are almost same as the results of maximum stress
19,376.24 psi and maximum deflection 0.00105 in. that are laid out, respectively,
Table 8.4 states the prototype testing results of piston shaft in this new magnetic
sealing system.
The prototype experimental results of piston shaft in Table 8.4 verify the proper
function because the average maximum stress 19,484.22 psi and average maximum
deflection 0.00015 in. are approximately equal to the results of maximum stress
19,484.07 psi and maximum deflection 0.00021 in. that are shown, respectively, in
Table 8.5 demonstrates the prototype testing results of rare-earth magnetic steel
in this new magnetic sealing system.
The prototype experimental results of rare-earth magnetic steel in Table 8.5
confirm the appropriate function as the average maximum stress 2,963.16 psi and
average maximum deflection 0.000012 in. are approximately same as the results of
presented, respectively, in Figs. 8.19 and 8.20 by computer-aided modeling and
8.4 Discussion and Future Improvement on Magnetic Sealing System 145

testing of rare-earth of experiment stress (psi) deflection (in.)
magnetic steel in this new
1 2,963.24 0.000008
magnetic sealing system
2 2,963.21 0.000004
3 2,963.18 0.000009
4 2,963.15 0.000011
5 2,963.21 0.000012
6 2,963.13 0.000010
7 2,963.14 0.000009
8 2,963.16 0.000014
9 2,963.21 0.000018
10 2,963.18 0.000015
11 2,963.12 0.000016
12 2,963.14 0.000013
13 2,963.15 0.000012
14 2,963.12 0.000015
15 2,963.15 0.000011
16 2,963.12 0.000012
17 2,963.21 0.000015
18 2,963.12 0.000012
19 2,963.11 0.000008
20 2,963.19 0.000009
Average 2,963.16 0.000012
8.4 Discussion and Future Improvement on Magnetic

Sealing System
Good sealing system can prevent liquid or gas from leaking in machinery to
improve performance and increase efficiency. A new magnetic sealing system has
been designed and developed with magnetic particles embedded in a working gap
between external rotational or reciprocating shaft and internal wall of rare-earth
magnetic steel. The magnetic circuit formed on the internal surface of magnetic
steel and external surface of rotational or reciprocating can dynamically seal the
working gap to avoid the lubrication oil or gaseous media leaks. In this new
magnetic sealing system design, the rotational or the reciprocating shafts can rotate
or reciprocate while being supported in a metal non-contact style which reduces the
frictional force significantly. Currently this new magnetic sealing system
demonstrates its strong dynamic sealing capability in rotating or reciprocating
machinery. The size of sealing unit is decreased since the components in sealing
unit are reduced. Future improvement will include modifying the working gap to
determine what geometry and dimension will get more intensified magnetic flux in
the magnetic circuit, performing more computational simulations to optimize the
sealing unit design, and investigating different materials for unit cost reduction.
Automated and High-Speed Packaging
System 9
9.1 Design of Automated and High-Speed Packaging

Machinery System
The automated packing machinery becomes more popular in many different

industries to reduce labor cost. This new packaging machinery system can auto-
matically load carton papers, open carton paper to the square box, seal the bottom
flap, seal top flap after putting the products into box, label print, and offload the
packing box to the loading area in the production line. Figure 9.1 shows the layout
of this new automated packaging assembly system. The details of full packaging
production sequence of this new packaging system are described as follows:
The carton papers are loaded into the loading channel and each carton paper is
sucked into the production inline from loading channel by vacuum cup. There is a
support plate at the front of vacuum cup and support plate is aligned with carton
paper. The carton paper falls down before vacuum cup picks it up. The soft spring
leaf in support plate can keep carton paper fixed while opening square box. At each
side of box bottom, there are two movable pushing plates that first move up to flatten
two box short flaps and flatten two long flaps thereafter. Two pushing plates move to
the left or the right separately and the box bottom is finally sealed by bottom sealing
mechanism. After sealing the box bottom, a pushing plate at the left side will drive
box to the next station to print label at two sides of box. A support plate at the top of
packing box is to make sure that the labels printed at two sides are horizontal with no
titled angle. To close and seal the top flaps of packing box after loading the products,
three mechanisms can be introduced including divider, pusher, and final curvature.
Before packing box moving to contact final curvature, the divider separates long
flaps of box top into two sides to keep them staying with the wall with no contact
with short flaps. The box continues to move from the left to the right until it contacts
the final curvature. The final curvatures are used for final closing of packing box at
the top and the curvature will close the flaps at the box top gradually. There are two
curvatures in final curvature mechanism: front curvature and rear curvature. The
front curvature is applied to push down the short flaps and simultaneously separate

148 9 Automated and High-Speed Packaging System
Fig. 9.1 Fully automated packaging assembly system
long flaps. This curvature is combined with two vertically and one horizontally
changed curvatures to keep gradual closing of short flaps. The rear curvature is
applied to gradually close two long flaps. The offloading mechanism is to load
finished packing box to the product loading area and rejecting mechanism is to reject
the packing box if some defects occurred during packing process.
9.2 Computer-Aided Simulation on Automated

and High-Speed Packaging Machinery System
There are various loading forces generated during automated packaging processes
including vibration, insertion, and packing. The computer-aided modeling and
simulation are applied to diagnose the mechanism function and verify the compo-
nent strength for solid performance. The vibration is caused by different forces
including mass inertia and internal shocking forces during kinematic movement.
The mathematical modeling shows the following equation (Isaev et al. 2005; Kundu
and Cohen 2008):
00
BBF ðFÞ M ðFÞ
M ð FÞ ¼ ¼ 0 ð9:1Þ
BOD ðFÞ M ðFÞ
Here, M ðFÞ ¼ BDODP ððFFÞÞ and M ðFÞ ¼ BDBFP ððFFÞÞ.

0 00
DP(F)—Fourier transform of pushing device.

BOD(F)—Fourier transform of output delivery moving acceleration.
BBF(F)—Fourier transform of base frame acceleration.
Figures 9.2, 9.3, 9.4, 9.5, 9.6, 9.7, 9.8, 9.9, 9.10, 9.11, 9.12, 9.13, 9.14, 9.15, 9.16,
9.17, 9.18, 9.19, 9.20, 9.21, 9.22, 9.23, 9.24, 9.25, and 9.26 display the computa-
tional simulation results in this new automated and high-speed packaging system.
9.2 Computer-Aided Simulation on Automated and High-Speed. . . 149
Fig. 9.2 Carton loading unit
Fig. 9.3 Stress profile in carton loading unit

Fig. 9.4 Deflection profile in carton loading unit
Fig. 9.5 Carton

separating unit
Fig. 9.6 Stress profile in carton separating unit
Fig. 9.7 Deflection profile in carton separating unit

Fig. 9.8 Carton bottom
closer
Fig. 9.9 Stress profile at base support in carton bottom closer

Fig. 9.10 Deflection profile at base support in carton bottom closer
Fig. 9.11 Stress profile at tension mechanism in carton bottom closer

Fig. 9.12 Deflection profile at tension mechanism in carton bottom closer
Fig. 9.13 Labeling unit

Fig. 9.14 Stress profile in labeling unit
Fig. 9.15 Deflection profile in labeling unit

Fig. 9.16 Carton top closer
Fig. 9.17 Stress profile at base support in carton top closer

Fig. 9.18 Deflection profile at base support in carton top closer
Fig. 9.19 Stress profile at tension mechanism in carton top closer

Fig. 9.20 Deflection profile at tension mechanism in carton top closer
Fig. 9.21 Offloading unit

Fig. 9.22 Stress profile in offloading unit
Fig. 9.23 Deflection profile in offloading unit

Fig. 9.24 Rejecting unit
Fig. 9.25 Stress profile in rejecting unit

9.2 Computer-Aided Simulation on Automated and High-Speed. . . 161
Fig. 9.26 Deflection profile in rejecting unit
stress and deflection of carton loading unit in this new automated and high-speed
packaging system. The analytic results demonstrate that the maximum stress of
16,596.73 psi in this carton loading unit is less than the material yield strength of
deflection limit.
stress and deflection of carton separating unit in this new automated and high-speed
packaging system. The analytic results state that the maximum stress of
18,255.09 psi in this carton separating unit is less than the material yield strength
deflection limit.
stress and deflection of carton bottom closer in this new automated and high-speed
13,816.01 psi in this carton bottom closer is less than the material yield strength
deflection limit.
stress and deflection of tension mechanism in carton bottom closer. The analytic
results state that the maximum stress of 17,087.09 psi in this tension mechanism is
stress and deflection of labeling unit in this new automated and high-speed packag-
ing system. The analytic results state that the maximum stress of 17,615.54 psi in
this labeling unit is less than the material yield strength of 36,000 psi and maximum
stress and deflection of base support of carton top closer in this new automated and
high-speed packaging system. The analytic results state that the maximum stress of
17,354.47 psi in this base support is less than the material yield strength of
deflection limit.
stress and deflection of tension mechanism of carton top closer in this new
automated and high-speed packaging system. The analytic results state that the
maximum stress of 17,270.99 psi in this tension mechanism of carton top closer is
stress and deflection of offloading unit in this new automated and high-speed
17,964.43 psi in this offloading unit is less than the material yield strength of
deflection limit.
stress and deflection of rejecting unit in this new automated and high-speed
17,984.14 psi in this rejecting unit is less than the material yield strength of
deflection limit.
The above computational simulation results displayed in these figures show
that the maximum stresses on these important components are all less than the
material yield stress and maximum material deflections are all within material
allowable deformation limits. The computational solutions confirm that this newly
developed automated and high-speed packaging system works well in packaging
applications.
9.3 Experiment on Automated and High-Speed Packaging Machinery System 163

Packaging Machinery System
The newly designed automated and high-speed packaging machinery system has
been prototyped and tested to compare and verify the results from computer-aided
simulation. Table 9.1 demonstrates the prototype testing results of carton loading
unit in this new automated and high-speed packaging machinery system.
The prototype experimental results of carton loading unit in Table 9.1 verify the
maximum deflection 0.00242 in. are close to the results of maximum stress
Table 9.2 expresses the prototype testing results of carton separating unit in this
new automated and high-speed packaging machinery system.
The prototype experimental results of carton separating unit in Table 9.2 confirm
the appropriate function since the average maximum stress 18,255.72 psi and
average maximum deflection 0.01656 in. are similar to the results of maximum
stress 18,255.09 psi and maximum deflection 0.01607 in. that are indicated, respec-
Table 9.3 records the prototype testing results of base support of carton bottom
closer unit in this new automated and high-speed packaging machinery system.

testing of carton loading of experiment stress (psi) deflection (in.)
unit in this new automated
1 16,595.78 0.00238
and high-speed packaging
machinery system 2 16,596.65 0.00256
3 16,594.38 0.00208
4 16,595.88 0.00255
5 16,596.98 0.00268
6 16,596.48 0.00212
7 16,596.55 0.00205
8 16,596.24 0.00286
9 16,594.95 0.00211
10 16,595.18 0.00202
11 16,596.35 0.00278
12 16,594.88 0.00266
13 16,595.18 0.00298
14 16,596.48 0.00206
15 16,594.65 0.00201
16 16,596.26 0.00256
17 16,596.59 0.00299
18 16,594.68 0.00245
19 16,596.22 0.00206
20 16,596.45 0.00236
Average 16,595.84 0.00242

testing of carton separating of experiment stress (psi) deflection (in.)
unit in this new automated
1 18,256.38 0.01655
3 18,255.59 0.01678
4 18,254.88 0.01599
5 18,255.18 0.01697
6 18,256.01 0.01678
7 18,255.09 0.01698
8 18,256.18 0.01638
9 18,255.48 0.01684
10 18,255.78 0.01678
11 18,256.35 0.01688
12 18,254.89 0.01598
13 18,255.85 0.01668
14 18,256.48 0.01695
15 18,255.88 0.01684
16 18,256.68 0.01597
17 18,254.99 0.01685
18 18,256.84 0.01678
19 18,254.98 0.01593
20 18,255.88 0.01648
Average 18,255.72 0.01656

testing of base support of experiment stress (psi) deflection (in.)
of carton bottom closer unit
1 13,816.01 0.00338
in this new automated
and high-speed packaging 2 13,816.01 0.00304
4 13,816.08 0.00368
5 13,815.18 0.00355
6 13,815.25 0.00299
7 13,816.11 0.00388
8 13,815.08 0.00398
9 13,816.15 0.00297
10 13,815.02 0.00378
11 13,815.18 0.00389
12 13,815.04 0.00395
13 13,816.15 0.00378
14 13,815.18 0.00296
15 13,815.06 0.00388
16 13,816.08 0.00393
17 13,815.15 0.00397
18 13,815.08 0.00298
19 13,815.12 0.00396
20 13,816.18 0.00388
Average 13,815.52 0.00357

testing of tension of experiment stress (psi) deflection (in.)
mechanism of carton
1 17,087.02 0.00502
bottom closer unit in this
new automated and high- 2 17,087.88 0.00555
speed packaging 3 17,088.89 0.00499
5 17,086.88 0.00505
6 17,087.99 0.00575
7 17,086.98 0.00498
8 17,087.85 0.00438
9 17,087.98 0.00525
10 17,086.78 0.00478
11 17,087.68 0.00418
12 17,087.79 0.00556
13 17,086.78 0.00448
14 17,087.84 0.00418
15 17,086.97 0.00435
16 17,087.84 0.00448
17 17,087.98 0.00505
18 17,087.88 0.00435
19 17,086.78 0.00438
20 17,087.75 0.00538
Average 17,087.60 0.00486
The prototype experimental results for base support of carton bottom closer unit
in Table 9.3 prove the normal function as the average maximum stress
13,815.52 psi and average maximum deflection 0.00357 in. are almost equal to
the results of maximum stress 13,816.01 psi and maximum deflection 0.00308 in.
that are laid out, respectively, in Figs. 9.9 and 9.10 by computer-aided modeling and
Table 9.4 states the prototype testing results of tension mechanism of carton
bottom closer unit in this new automated and high-speed packaging machinery
system.
The prototype experimental results for tension mechanism of carton bottom
closer unit in Table 9.4 verify the proper function because the average maximum
stress 17,087.60 psi and average maximum deflection 0.00486 in. are very similar
to the results of maximum stress 17,087.09 psi and maximum deflection 0.00535 in.
that are shown, respectively, in Figs. 9.11 and 9.12 by computer-aided modeling
and numerical simulation.
Table 9.5 demonstrates the prototype testing results of labeling unit in this new
automated and high-speed packaging machinery system.
The prototype experimental results of labeling unit in Table 9.5 confirm the

testing of labeling unit of experiment stress (psi) deflection (in.)
1 17,616.48 0.00318
3 17,616.84 0.00308
4 17,616.78 0.00305
5 17,615.29 0.00268
6 17,616.98 0.00368
7 17,615.44 0.00278
8 17,616.68 0.00301
9 17,616.68 0.00367
10 17,616.74 0.00303
11 17,615.18 0.00302
12 17,615.98 0.00298
13 17,615.54 0.00388
14 17,616.48 0.00288
15 17,615.25 0.00248
16 17,616.48 0.00317
17 17,616.78 0.00338
18 17,615.38 0.00278
19 17,616.88 0.00248
20 17,615.18 0.00378
Average 17,616.12 0.00314
17,615.54 psi and maximum deflection 0.00356 in. that are presented, respectively,
Table 9.6 demonstrates the prototype testing results of base support of carton top
closer unit in this new automated and high-speed packaging machinery system.
The prototype experimental results for base support of carton top closer unit in
represented, respectively, in Figs. 9.17 and 9.18 by computer-aided modeling and
Table 9.7 expresses the prototype testing results of tension mechanism of carton
top closer unit in this new automated and high-speed packaging machinery system.
The prototype experimental results for tension mechanism of carton top closer
unit in Table 9.7 verify the proper function because the average maximum stress
0.00340 in. that are indicated, respectively, in Figs. 9.19 and 9.20 by computer-
aided modeling and numerical simulation.
Table 9.8 records the prototype testing results of offloading unit in this new

testing of base support of experiment stress (psi) deflection (in.)
of carton top closer unit
1 17,354.08 0.00477
and high-speed packaging 2 17,354.68 0.00408
4 17,353.55 0.00498
5 17,354.54 0.00418
6 17,353.66 0.00499
7 17,353.48 0.00495
8 17,354.08 0.00498
9 17,354.11 0.00418
10 17,354.54 0.00496
11 17,353.57 0.00498
12 17,354.12 0.00408
13 17,354.88 0.00498
14 17,353.48 0.00492
15 17,353.38 0.00499
16 17,354.78 0.00419
17 17,353.55 0.00487
18 17,353.48 0.00489
19 17,354.18 0.00418
20 17,354.55 0.00448
Average 17,354.02 0.00468

testing of tension of experiment stress (psi) deflection (in.)
mechanism of carton
1 17,270.89 0.00395
top closer unit in this new
automated and high-speed 2 17,270.18 0.00388
packaging machinery 3 17,271.08 0.00339
system 4 17,270.24 0.00398
5 17,270.08 0.00385
6 17,271.05 0.00396
7 17,270.19 0.00338
8 17,270.25 0.00336
9 17,270.38 0.00399
10 17,271.08 0.00397
11 17,270.18 0.00338
12 17,270.27 0.00399
13 17,270.08 0.00387
14 17,271.02 0.00398
15 17,270.05 0.00339
16 17,270.12 0.00338
17 17,270.08 0.00398
18 17,271.05 0.00394
19 17,270.48 0.00398
20 17,271.05 0.00337
Average 17,270.49 0.00375

testing of offloading unit in of experiment stress (psi) deflection (in.)
this new automated and
1 17,964.25 0.00624
high-speed packaging
3 17,963.48 0.00618
4 17,964.18 0.00584
5 17,963.38 0.00602
6 17,964.12 0.00608
7 17,963.24 0.00579
8 17,964.54 0.00601
9 17,963.21 0.00635
10 17,964.48 0.00575
11 17,964.24 0.00584
12 17,963.18 0.00603
13 17,964.42 0.00608
14 17,964.11 0.00579
15 17,963.23 0.00601
16 17,964.78 0.00603
17 17,963.11 0.00566
18 17,964.68 0.00575
19 17,963.48 0.00602
20 17,964.54 0.00638
Average 17,963.96 0.00601
The prototype experimental results of offloading unit in Table 9.8 confirm

maximum stress 17,964.43 psi and maximum deflection 0.00631 in. that are laid
out, respectively, in Figs. 9.22 and 9.23 by computer-aided modeling and numerical
simulation.
Table 9.9 states the prototype testing results of rejecting unit in this new
The prototype experimental results of rejecting unit in Table 9.9 prove the
normal function as the average maximum stress 17,984.53 psi and average
17,984.14 psi and maximum deflection 0.00421 in. that are shown, respectively,
9.4 Discussion and Future Improvement on Automated and High-Speed. . . 169

testing of rejecting unit in of experiment stress (psi) deflection (in.)
this new automated and
1 17,984.24 0.00438
high-speed packaging
3 17,984.02 0.00455
4 17,984.18 0.00477
5 17,984.88 0.00495
6 17,984.95 0.00411
7 17,984.98 0.00488
8 17,984.09 0.00459
9 17,983.88 0.00411
10 17,984.48 0.00484
11 17,984.77 0.00488
12 17,984.05 0.00418
13 17,984.78 0.00415
14 17,984.95 0.00479
15 17,984.88 0.00499
16 17,984.08 0.00448
17 17,984.68 0.00415
18 17,984.97 0.00484
19 17,984.78 0.00498
20 17,984.08 0.00419
Average 17,984.53 0.00455

and High-Speed Packaging Machinery Systems
Automated packaging machines are the multi-axis mechanical systems that require
multiple interacting mechanisms to manipulate the components for final product
packages. It can help industry to minimize unnecessary human involvement, reduce
labor cost, improve packing quality, and increase productivity. The technology
improvement helps developing and making the automatic packing machine simpler
and more precised for accurate and flexible automatic packing operations. Future
improvement will focus on modifying this new system for quick changeover on
different product packing, easier tool and fixture adjustment, continuous workflow
maintenance, consistent production line balance, and simple equipment installation.
Part III
Biomedical Systems
Biomedical and Surgical Systems
10
10.1 Design of Biomedical and Surgical Systems
In this new open surgical instrument design, the surgiclip delivery mechanism is
improved if compared with conventional surgical instruments. The surgiclips are
moving to the front jaw pair through distal move of surgiclip pusher which can be
manipulated by instrument handles. When doctors and surgeons move instrument
handles together, the surgiclip will be driven forward and completely formed after
surgiclip pusher distally drives surgiclip into the guiding groove in the front jaw
pair. When doctors and surgeons free the instrument handles, the surgiclip pusher
automatically moves back to original location or starting position to catch next
surgiclip for next firing cycle. Since the advancing process of this surgiclip can be
easily and reliably manipulated in the new design, the highly required dimensional
tolerance control will be not necessary in making the instrumental components
during production process. This improvement can prevent the surgiclips from drop-
off, simplify the machining process, raise the production rate, and reduce the
manufacturing cost (Figs. 10.1 and 10.2).
This biomedical instrument is first positioned onto patient body tissues and then
surgiclips are distally moved into the guiding track of front jaw pair driven by
surgiclip pusher and the patient tissues securely clamped as doctors and surgeons
manipulate to close the instrument handles. As soon as doctors and surgeons free
the instrument handles, the front jaw pair will be open and surgiclip pusher and
driving mechanism move back to its initial locations. Compared with the traditional
surgiclip delivering mechanism, in which the surgiclips are moving forward into the
guiding track of jaw pair by compression spring that sometime accidentally drop off
the surgiclip from jaw pair track in the instrument, the surgiclip movement to the
guiding track of jaw pair in this new instrument design can be smoothly guided and
reliably controlled by surgeons. The driving mechanism that is connected to the
pivot point of instrument handles distally travels to move forward the surgiclip into

174 10 Biomedical and Surgical Systems
Fig. 10.1 New open surgiclip biomedical instrument
Fig. 10.2 Internal structure of new open surgiclip biomedical instrument
the guiding track of jaw pair and finally fully formed the surgiclip as doctors and
surgeons gradually bring the instrument handles together. Such surgiclip linear
movement can be smoothly and properly manipulated by surgeons to prevent the
surgiclips from accidental drop-off from instrumental guiding track. The repeated
prototype testing has demonstrated its stable and reliable performances of this new
biomedical instrument design with no surgiclip drop-off and hand force to operate
this new instrument is lower than the conventional biomedical surgiclip instrument.
10.1 Design of Biomedical and Surgical Systems 175
Fig. 10.3 Endo surgiclip biomedical instrument—view 1
Fig. 10.4 Endo surgiclip biomedical instrument—view 2
The newly designed endo surgiclip biomedical instrument is shown in Figs. 10.3,
10.4, and 10.5. It can deliver multiple surgiclips into front jaw guiding channel. The
surgiclips which sit in lower position are guided to move vertically inside curved
channel by moving block that is driven by surgiclip pusher. Since there must be no
gap between surgiclips, the moving block has to be pushed to continuously contact
the last surgiclip to keep distal movement of moving block only one-way direction.
Fig. 10.5 Internal driving mechanism of endo surgiclip biomedical instrument
The moving block consists of the block holder and two snaps which are driven
by hocking top and bottom compression springs. The top snap contacts the fixed
gear rack and bottom snap contacts the movable gear rack which can travel up
and down vertically.
At the start position, the movable gear rack moves from the right to the left. The
front tip of the bottom snap engages with the teeth in movable gear rack and top
snap slides over the teeth of movable gear rack. At step one, there is no relative
movement between moving block and movable gear rack but there is movement
between block holder and moving block. At step two, moving block distally moves
and movable gear rack stops. When movable gear rack moves back (from the left to
the right), the top snap engages the teeth in block holder and bottom snap slides
distally over the teeth on movable gear rack. At step three, there is no movement
between moving block and block holder but there is movement between movable
gear rack and moving block. At step four, the movable gear rack moves to its
original starting position and both snaps engage the teeth in movable gear rack.
During cyclic movement from step one to step four, the movable block distally
travels one clip distance along the surgiclip track.
The new design of this driving mechanism ensures one-way movement of
moving block along the distal motion of surgiclips. Since length of each surgiclip
is 0.256 in., the moving block needs to travel 0.276 in. to properly engage each
surgiclip in this new driving mechanism design. Each time when surgiclips distally
move one clip distance, the most front surgiclip of inline surgiclips will be pushed
into the guiding channel in instrument jaw pair for further formation. The surgiclip
pusher driven by driving mechanism moves distally to deliver surgiclip and travels
proximally to pick up next surgiclip. The front part of surgiclip pusher delivers
surgiclip into jaw pair and rear part links to the driving mechanism. In this new
design, the surgiclip pusher requires to distally move 0.98 in. from its original
10.2 Computer-Aided Simulation on Biomedical and Surgical Systems 177
position to deliver each surgiclip into final location of inside guiding channel in jaw
pair and move proximally back to its original position to pick up net surgiclip. The
driving mechanism supplies both 0.98 in. pusher movement and forces required to
overcome the frictional forces and weights of all components including moveable
gear rack, moving block, block holder, and surgiclip pusher.
10.2 Computer-Aided Simulation on Biomedical

and Surgical Systems
The computer-aided simulations on biomedical open surgiclip instrument and

biomedical endoscopic surgiclip instrument are described as follows.
10.2.1 Biomedical Open Surgiclip Instrument
The mathematic equation of force and energy balance in this new biomedical
open surgiclip instrument design can be demonstrated as follows (Kundu and
Cohen 2008):
Pload Glinear ¼ Q ω ð10:1Þ
Since the torque Q ¼ Ppivot LR,
Q ω ¼ Ppivot LR ω ¼ Ppivot Gangular ð10:2Þ
Therefore,
Pload Glinear ¼ Ppivot Gangular ð10:3Þ

Pload ¼ Gangular =Glinear Ppivot ¼ ðGRÞ Ppivot ð10:4Þ
Referring the geometry design of this new instrument:
Pfinger W ¼ Ppivot LR ð10:5Þ
The different operation force Pfinger can be determined by combining different

LR and W values. The computer-aided simulation can be applied to find out the
optimal combined values of LR and W. The computer-aided solution suggested that
the optimized performance of this new biomedical instrument will be achieved
when LR ¼ 4.78 in. and W ¼ 2.18 in. are selected.
From Eq. (7.3),
Pfinger 4:78 ¼ Ppivot 2:18

Fig. 10.6 Driving gear
Ppivot ¼ 2:192 Pfinger
From Eq. (7.2),
Pload ¼ ðGRÞ Ppivot ¼ ðGRÞ 2:192 Pfinger
The ratio of angular speed to linear speed (Gangular/Glinear) can be solved by

computer-aided simulation to determine the optimal instrument performance. The
one mechanical advantage of this new biomedical instrument can be determined
when instrument handle has been fully closed:
Mechanical advantage ¼ ðGRÞ 2:192 ð10:6Þ
¼ ð0:04838=0:03538Þ 2:192 ¼ 2:997
This result indicates that when 20 lbf forces are required to fully form the
biomedical surgiclip, the surgeons need to put 3.34 lbf forces to fully close the
instrument handle which is less than the normal spec of 4 lbf in surgical operation
procedure. This will ease doctors and surgeons in their medical treatments and
surgical operations.
Figures 10.6, 10.7, 10.8, 10.9, 10.10, 10.11, 10.12, 10.13, 10.14, 10.15, 10.16,
10.17, 10.18, 10.19, 10.20, 10.21, 10.22, 10.23, 10.24, 10.25, 10.26, 10.27, 10.28,
10.29, 10.30, and 10.31 display the stress and deflection profiles of critical
components in this new biomedical open surgiclip instrument.
stress and deflection of driving gear in this new biomedical open surgical instru-
ment. The analytic results state that the maximum stress of 23,663.32 psi in this
driving gear is less than the material yield strength of 36,000 psi and maximum
stress and deflection of trigger in this new biomedical open surgical instrument. The
analytic results state that the maximum stress of 1,380.27 psi in this trigger is less
than the material yield strength and maximum deflection of 0.00077 in. is within
Fig. 10.7 Stress profile of driving gear
Fig. 10.8 Deflection profile of driving gear

Fig. 10.9 Trigger
Fig. 10.10 Stress profile of trigger

Fig. 10.11 Deflection profile of trigger
Fig. 10.12 Instrument front

end of internal shaft
The following diagram shows the stress profile of internal driving shaft when
surgeon manipulates patient body tissues during surgical procedures.
stress and deflection of front end of internal shaft in this new biomedical open
surgical instrument. The analytic results display that the maximum stress of
Fig. 10.13 Stress profile of instrument front end of internal shaft
Fig. 10.14 Deflection profile of instrument front end of internal shaft

Fig. 10.15 Instrument

internal shaft
Fig. 10.16 Stress profile of instrument internal shaft

Fig. 10.17 Deflection profile of instrument internal shaft
Fig. 10.18 Instrument jaw

in closing tissue
Fig. 10.19 Stress profile of instrument jaw in closing tissue
Fig. 10.20 Deflection profile of instrument jaw in closing tissue

Fig. 10.21 Stress profile of instrument jaw in thick tissue manipulation
Fig. 10.22 Deflection profile of instrument jaw in thick tissue manipulation

Fig. 10.23 Instrument surgiclip pusher
Fig. 10.24 Stress profile of instrument surgiclip pusher

Fig. 10.25 Deflection profile of instrument surgiclip pusher

external shaft
Fig. 10.27 Stress profile of instrument external shaft
Fig. 10.28 Deflection profile of instrument external shaft

Fig. 10.29 Driving link
Fig. 10.30 Stress profile of driving link

Fig. 10.31 Deflection profile of driving link
23,110.67 psi in this front end of internal shaft is less than the material yield
The following diagram shows the stress profile of internal driving shaft when
surgeon delivers surgiclips distally during surgical procedures.
stress and deflection of instrument internal shaft in this new biomedical open
surgical instrument. The analytic results demonstrate that the maximum stress of
22,542.71 psi in this instrument internal shaft is less than the material yield strength
deflection limit.
The following diagram shows the stress profile of instrument front jaw when
surgeon forms the surgiclips during surgical procedures.
The computer-aided simulation and analysis in Figs. 10.19 and 10.20 indicate
the stress and deflection of front jaw (closing tissue) in this new biomedical open
surgical instrument. The analytic results state that the maximum stress of
16,300.16 psi in this front jaw (closing tissue) is less than the material yield strength
deflection limit.
The following diagram shows the stress profile of instrument front jaw when
surgeon manipulates the thick tissues during surgical procedures.
stress and deflection of front jaw (thick tissue manipulation) in this new biomedical
open surgical instrument. The analytic results show that the maximum stress of
23,995.81 psi in this front jaw (thick tissue manipulation) is less than the material
yield strength of 36,000 psi and maximum deflection of 0.00875 in. is within
The following diagram shows the stress profile of instrument surgiclip driving
pusher when surgeon delivers the surgiclip during surgical procedures.
stress and deflection of surgiclip pusher in this new biomedical open surgical
instrument. The analytic results demonstrate that the maximum stress of
21,389.27 psi in this surgiclip pusher is less than the material yield strength of
deflection limit.
The following diagram shows the stress profile of instrument external shaft when
surgeon manipulates patient tissues during surgical procedures.
the stress and deflection of external shaft in this new biomedical open surgical
instrument. The analytic results state that the maximum stress of 23,481.61 psi in
this external shaft is less than the material yield strength of 36,000 psi and
maximum deflection of 0.00675 in. is within material allowable deflection limit.
The following diagram shows the stress profile of instrument driver link when
surgeon operates the device during surgical procedures.
stress and deflection of driving link in this new biomedical open surgical instru-
ment. The analytic results show that the maximum stress of 24,154.42 psi in this
driving link is less than the material yield strength of 36,000 psi and maximum
The above computer-aided simulation results displayed that the maximum
stresses on these critical components are all below the material yield stress and
The above analytic solutions have confirmed the good function and reliable quality
of this newly developed biomedical open surgiclip instrument.
10.2.2 Biomedical Endoscopic Surgiclip Instrument
The computer-aided kinematic simulations of multiple instrument setup have been

performed on this new biomedical endoscopic surgiclip instrument to determine the
optimal system design, with analytic result shown in Fig. 10.32.
Fig. 10.32 Angular/linear speed vs. time in new biomedical endoscopic instrument
The multiple instrument setups have been analyzed based on the above compu-
tational simulation and the optimal system design can be achieved when mechani-
cal advantage of this new instrument equals to 2.878, as shown in the following
equation (White 2003):
MA ¼ ðVRÞ 2:218 ¼ ð0:04851=0:03738Þ 2:218 ¼ 2:878 ð10:7Þ
This result indicates that when 20 lbf forces are required to fully close the
biomedical endoscopic surgiclip, the surgeons only need to apply 3.475 lbf forces
that are lower than the normal spec of 4 lbf in surgical operation procedure. This
will benefit physicians and surgeons in the medical treatments and surgical opera-
tion procedures. Figures 10.33, 10.34, 10.35, 10.36, 10.37, 10.38, 10.39, 10.40,
10.41, 10.42, 10.43, 10.44, 10.45, 10.46, 10.47, 10.48, 10.49, 10.50, 10.51, 10.52,
10.53, 10.54, 10.55, 10.56, 10.57, 10.58, 10.59, 10.60, 10.61, 10.62, 10.63, 10.64,
10.65, 10.66, 10.67, 10.68, 10.69, 10.70, 10.71, 10.72, 10.73, 10.74, 10.75, and
10.76 display the stress and deflection profiles of major components in this newly
developed biomedical endoscopic surgiclip instrument.
The computer-aided simulation and analysis in Figs. 10.34 and 10.35 tell the
stress and deflection of surgiclip pusher in this new biomedical endoscopic surgical
instrument. The analytic results present that the maximum stress of 12,113.39 psi in
Fig. 10.33 Surgiclip pusher
Fig. 10.34 Stress profile of surgiclip pusher

Fig. 10.35 Deflection profile of surgiclip pusher
Fig. 10.36 Gear_1

Fig. 10.37 Stress profile of gear_1
Fig. 10.38 Deflection profile of gear_1

Fig. 10.39 Gear_2

Fig. 10.42 Gear_3


Fig. 10.45 Gear_4

Fig. 10.48 Rack gear

Fig. 10.49 Stress profile of rack gear
Fig. 10.50 Deflection profile of rack gear

Fig. 10.51 Gear link
Fig. 10.52 Stress profile of gear link

Fig. 10.53 Deflection profile of gear link

handle trigger
Fig. 10.55 Stress profile of instrument handle trigger
Fig. 10.56 Deflection profile of instrument handle trigger

handle
Fig. 10.58 Stress profile of instrument handle

Fig. 10.59 Deflection profile of instrument handle
Fig. 10.60 Front end

of inside shaft
Fig. 10.61 Stress profile of front end in inside shaft
Fig. 10.62 Deflection profile of front end in inside shaft

Fig. 10.63 Inside shaft
Fig. 10.64 Stress profile of inside shaft

Fig. 10.65 Deflection profile of inside shaft

front jaw
Fig. 10.67 Stress profile of jaw in closing the tissues
Fig. 10.68 Deflection profile of jaw in closing the tissues

Fig. 10.69 Stress profile of instrument jaw in thick tissue manipulation
Fig. 10.70 Deflection profile of instrument jaw in thick tissue manipulation


surgiclip pusher
Fig. 10.72 Stress profile of instrument surgiclip pusher

Fig. 10.73 Deflection profile of instrument surgiclip pusher
Fig. 10.74 External shaft

Fig. 10.75 Stress profile of external shaft
Fig. 10.76 Deflection profile of external shaft

this surgiclip pusher is less than the material yield strength of 36,000 psi and
The computer-aided simulation and analysis in Figs. 10.37 and 10.38 demon-
strate the stress and deflection of gear_1 in this new biomedical endoscopic surgical
instrument. The analytic results indicate that the maximum stress of 16,516.93 psi
in this gear_1 is less than the material yield strength of 36,000 psi and maximum
stress and deflection of gear_2 in this new biomedical endoscopic surgical instru-
ment. The analytic results display that the maximum stress of 16,482.03 psi in this
gear_2 is less than the material yield strength of 36,000 psi and maximum deflection
ment. The analytic results tell that the maximum stress of 16,973.09 psi in this
gear_3 is less than the material yield strength of 36,000 psi and maximum deflection
ment. The analytic results demonstrate that the maximum stress of 15,742.11 psi in
this gear_4 is less than the material yield strength of 36,000 psi and maximum
the stress and deflection of rack gear in this new biomedical endoscopic surgical
instrument. The analytic results state that the maximum stress of 37,491.63 psi in
this rack gear is less than the material yield strength of 50,000 psi and maximum
stress and deflection of gear link in this new biomedical endoscopic surgical
instrument. The analytic results show that the maximum stress of 18,905.80 psi in
this gear link is less than the material yield strength of 36,000 psi and maximum
stress and deflection of handle trigger in this new biomedical endoscopic surgical
this handle trigger is less than the material yield strength of 36,000 psi and
The computer-aided simulation and analysis in Figs. 10.58 and 10.59 demon-
strate the stress and deflection of handle in this new biomedical endoscopic surgical
instrument. The analytic results indicate that the maximum stress of 17,400.49 psi
in this handle is less than the material yield strength of 36,000 psi and maximum
stress and deflection of front end of inside shaft in this new biomedical endoscopic
surgical instrument. The analytic results display that the maximum stress of
10.3 Experiment on Biomedical and Surgical Systems 217
18,835.02 psi in this front end of inside shaft is less than the material yield strength
deflection limit.
stress and deflection of inside shaft in this new biomedical endoscopic surgical
instrument. The analytic results tell that the maximum stress of 18,835.02 psi in this
inside shaft is less than the material yield strength of 36,000 psi and maximum
stress and deflection of jaw (closing tissue) in this new biomedical endoscopic
surgical instrument. The analytic results demonstrate that the maximum stress of
19,832.97 psi in this jaw (closing tissue) is less than the material yield strength of
deflection limit.
the stress and deflection of jaw (thick tissue manipulation) in this new biomedical
endoscopic surgical instrument. The analytic results state that the maximum stress
of 22,916.18 psi in this jaw (thick tissue manipulation) is less than the material yield
The computer-aided simulation and analysis in Figs. 10.72 and 10.73 display
the stress and deflection of surgiclip pusher in this new biomedical endoscopic
surgical instrument. The analytic results show that the maximum stress of
20,542.72 psi in this surgiclip pusher is less than the material yield strength of
deflection limit.
stress and deflection of external shaft in this new biomedical endoscopic surgical
this external shaft is less than the material yield strength of 36,000 psi and
These computational simulation results show that the maximum stresses on these
critical components are all less than the material yield stress and maximum material
deflections are all within material allowable deformation limits. The computational
solutions confirm that this newly developed biomedical endoscopic surgiclip instru-
ment can function properly and reliably to assist doctors and surgeons in their
medical treatments and surgical operations.
10.3 Experiment on Biomedical and Surgical Systems
Two newly designed biomedical and surgical systems are being prototyped and
tested to compare and verify the results from computer-aided simulation.

testing of driving gear of experiment stress (psi) deflection (in.)
in this new biomedical
1 23,663.45 0.00071
open surgiclip instrument
2 23,663.38 0.00068
3 23,663.76 0.00065
4 23,663.75 0.00078
5 23,663.69 0.00069
6 23,663.78 0.00065
7 23,663.24 0.00067
8 23,663.29 0.00068
9 23,663.59 0.00063
10 23,663.79 0.00061
11 23,663.88 0.00062
12 23,663.97 0.00065
13 23,663.98 0.00061
14 23,663.54 0.00062
15 23,663.84 0.00063
16 23,663.95 0.00062
17 23,663.66 0.00061
18 23,663.88 0.00063
19 23,663.59 0.00062
20 23,663.65 0.00061
Average 23,663.68 0.00065
10.3.1 Experiment on Biomedical Open Surgiclip Instrument
Table 10.1 records the prototype testing results of driving gear in this new biomed-
ical open surgiclip instrument.
The prototype experimental results of driving gear in Table 10.1 verify the
maximum deflection 0.00065 in. are approximately equal to the results of maxi-
mum stress 23,663.32 psi and maximum deflection 0.00077 in. that are laid out,
respectively, in Figs. 10.7 and 10.8 by computer-aided modeling and numerical
simulation.
Table 10.2 lays out the prototype testing results of trigger in this new biomedical
open surgiclip instrument.
The prototype experimental results of trigger in Table 10.2 confirm the appro-
priate function since the average maximum stress 1,380.64 psi and average maxi-
mum deflection 0.01920 in. are approximately same as the results of maximum
stress 1,380.27 psi and maximum deflection 0.01944 in. that are displayed, respec-
simulation.
Table 10.3 shows the prototype testing results of instrument front end of internal
shaft in this new biomedical open surgiclip instrument.

testing of trigger in this of experiment stress (psi) deflection (in.)
new biomedical open
1 1,380.37 0.01924
surgiclip instrument
2 1,380.48 0.01918
3 1,380.77 0.01948
4 1,380.78 0.01915
5 1,380.25 0.01924
6 1,380.24 0.01918
7 1,380.59 0.01916
8 1,380.78 0.01922
9 1,380.98 0.01921
10 1,380.89 0.01924
11 1,380.22 0.01908
12 1,380.21 0.01911
13 1,380.78 0.01912
14 1,380.84 0.01916
15 1,380.85 0.01924
16 1,380.77 0.01918
17 1,380.88 0.01917
18 1,380.78 0.01919
19 1,380.65 0.01921
20 1,380.67 0.01922
Average 1,380.64 0.01920

testing of instrument front of experiment stress (psi) deflection (in.)
end of internal shaft in this
1 23,110.47 0.00154
new biomedical open
surgiclip instrument 2 23,110.48 0.00148
3 23,110.38 0.00159
4 23,110.39 0.00154
5 23,110.68 0.00157
6 23,110.55 0.00159
7 23,110.54 0.00156
8 23,110.39 0.00155
9 23,110.35 0.00159
10 23,110.48 0.00157
11 23,110.43 0.00159
12 23,110.35 0.00155
13 23,110.38 0.00157
14 23,110.36 0.00156
15 23,110.33 0.00159
16 23,110.31 0.00157
17 23,110.41 0.00159
18 23,110.32 0.00156
19 23,110.44 0.00155
20 23,110.48 0.00154
Average 23,110.43 0.00156

testing of instrument of experiment stress (psi) deflection (in.)
internal shaft in this new
1 22,542.61 0.00159
biomedical open surgiclip
instrument 2 22,542.52 0.00155
3 22,542.48 0.00148
4 22,542.57 0.00149
5 22,542.38 0.00159
6 22,542.39 0.00157
7 22,542.62 0.00161
8 22,542.55 0.00162
9 22,542.54 0.00164
10 22,542.61 0.00159
11 22,542.54 0.00165
12 22,542.48 0.00163
13 22,542.54 0.00162
14 22,542.62 0.00165
15 22,542.36 0.00164
16 22,542.38 0.00165
17 22,542.39 0.00164
18 22,542.44 0.00165
19 22,542.49 0.00163
20 22,542.52 0.00161
Average 22,542.50 0.00161
The prototype experimental results for instrument front end of internal shaft in
and average maximum deflection 0.00156 in. are similar to the results of maximum
stress 23,110.67 psi and maximum deflection 0.00144 in. that are exhibited,
simulation.
Table 10.4 presents the prototype testing results of instrument internal shaft in
this new biomedical open surgiclip instrument.
The prototype experimental results of instrument internal shaft in Table 10.4
verify the proper function because the average maximum stress 22,542.50 psi and
average maximum deflection 0.00161 in. are almost equal to the results of maxi-
mum stress 22,542.71 psi and maximum deflection 0.00152 in. that are depicted,
simulation.
Table 10.5 represents the prototype testing results of instrument jaw when fully
closing surgiclip to secure the tissues by using this new biomedical open surgiclip
instrument.
The prototype experimental results of instrument jaw (to finally form the
surgiclip to secure the tissues) in Table 10.5 confirm the appropriate function
since the average maximum stress 18,300.47 psi and average maximum deflection

testing of instrument jaw of experiment stress (psi) deflection (in.)
when fully closing
1 18,300.25 0.00424
surgiclip to secure the
tissues by using this new 2 18,300.24 0.00429
biomedical open surgiclip 3 18,300.11 0.00433
instrument 4 18,300.54 0.00438
5 18,300.48 0.00439
6 18,300.39 0.00435
7 18,300.38 0.00444
8 18,300.54 0.00448
9 18,300.55 0.00449
10 18,300.45 0.00446
11 18,300.56 0.00445
12 18,300.49 0.00448
13 18,300.48 0.00449
14 18,300.55 0.00418
15 18,300.65 0.00424
16 18,300.57 0.00447
17 18,300.56 0.00449
18 18,300.59 0.00446
19 18,300.48 0.00436
20 18,300.45 0.00438
Average 18,300.47 0.00439
0.00439 in. are very similar to the results of maximum stress 18,300.15 psi and
maximum deflection 0.00421 in. that are depicted, respectively, in Figs. 10.19 and
10.20 by computer-aided modeling and numerical simulation.
Table 10.6 expresses the prototype testing results of instrument jaw in thick
tissue manipulation by using this new biomedical open surgiclip instrument.
The prototype experimental results of instrument jaw (to manipulate the thick
tissue) in Table 10.6 prove the normal function as the average maximum stress
23,995.52 psi and average maximum deflection 0.00863 in. are closely equal to the
are indicated, respectively, in Figs. 10.21 and 10.22 by computer-aided modeling
Table 10.7 records the prototype testing results of instrument surgiclip pusher in
this new biomedical open surgiclip instrument.
The prototype experimental results of instrument surgiclip pusher in Table 10.7
average maximum deflection 0.03121 in. are almost same as the results of maxi-
mum stress 21,389.27 psi and maximum deflection 0.03106 in. that are laid out,
simulation.
testing of instrument jaw of experiment stress (psi) deflection (in.)
in thick tissue manipulation
1 23,995.75 0.00866
by using this new
biomedical open surgiclip 2 23,995.71 0.00862
instrument 3 23,995.55 0.00861
4 23,995.59 0.00876
5 23,995.48 0.00871
6 23,995.44 0.00868
7 23,995.42 0.00862
8 23,995.38 0.00861
9 23,995.39 0.00862
10 23,995.49 0.00863
11 23,995.54 0.00865
12 23,995.57 0.00861
13 23,995.44 0.00860
14 23,995.48 0.00861
15 23,995.54 0.00860
16 23,995.51 0.00863
17 23,995.55 0.00862
18 23,995.48 0.00861
19 23,995.51 0.00860
20 23,995.54 0.00862
Average 23,995.52 0.00863

surgiclip pusher in this new
1 21,389.37 0.03108
instrument 2 21,389.38 0.03112
3 21,389.29 0.03118
4 21,389.39 0.03116
5 21,389.48 0.03115
6 21,389.54 0.03124
7 21,389.52 0.03125
8 21,389.51 0.03118
9 21,389.50 0.03125
10 21,389.49 0.03124
11 21,389.48 0.03126
12 21,389.44 0.03122
13 21,389.47 0.03123
14 21,389.46 0.03125
15 21,389.39 0.03121
16 21,389.54 0.03124
17 21,389.50 0.03125
18 21,389.51 0.03124
19 21,389.48 0.03120
20 21,389.44 0.03118
Average 21,389.46 0.03121

external shaft in this new
1 23,481.55 0.00684
instrument 2 23,481.51 0.00688
3 23,481.48 0.00695
4 23,481.55 0.00699
5 23,481.44 0.00698
6 23,481.42 0.00695
7 23,481.38 0.00699
8 23,481.24 0.00697
9 23,481.35 0.00698
10 23,481.37 0.00688
11 23,481.41 0.00690
12 23,481.24 0.00689
13 23,481.29 0.00684
14 23,481.35 0.00686
15 23,481.38 0.00689
16 23,481.36 0.00695
17 23,481.33 0.00698
18 23,481.38 0.00695
19 23,481.44 0.00689
20 23,481.42 0.00691
Average 23,481.39 0.00692
Table 10.8 states the prototype testing results of instrument external shaft in this
new biomedical open surgiclip instrument.
The prototype experimental results of instrument external shaft in Table 10.8
confirm the appropriate function since the average maximum stress 23,481.39 psi
and average maximum deflection 0.00692 in. are approximately equal to the results
shown, respectively, in Figs. 10.27 and 10.28 by computer-aided modeling and
Table 10.9 demonstrates the prototype testing results of instrument driving link
in this new biomedical open surgiclip instrument.
The prototype experimental results of instrument driving link in Table 10.9
prove the normal function as the average maximum stress 24,154.17 psi and
presented, respectively, in Figs. 10.30 and 10.31 by computer-aided modeling

driving link in this new
1 24,154.33 0.00050
instrument 2 24,154.22 0.00048
3 24,154.12 0.00055
4 24,154.11 0.00057
5 24,154.18 0.00059
6 24,154.08 0.00055
7 24,154.22 0.00057
8 24,154.08 0.00059
9 24,154.07 0.00055
10 24,154.12 0.00057
11 24,154.09 0.00056
12 24,154.10 0.00059
13 24,154.32 0.00054
14 24,154.17 0.00055
15 24,154.24 0.00057
16 24,154.15 0.00059
17 24,154.18 0.00057
18 24,154.20 0.00056
19 24,154.17 0.00059
20 24,154.19 0.00057
Average 24,154.17 0.00056
10.3.2 Experiment on Biomedical Endoscopic Surgiclip System
Table 10.10 demonstrates the prototype testing results of instrument surgiclip

pusher in this new biomedical endoscopic surgiclip instrument.
average maximum deflection 0.00084 in. are close to the results of maximum stress
simulation.
Table 10.11 expresses the prototype testing results of instrument gear_1 in this
new biomedical endoscopic surgiclip instrument.
The prototype experimental results of instrument gear_1 in Table 10.11 confirm
average maximum deflection 0.00051 in. are similar to the results of maximum
stress 16,516.93 psi and maximum deflection 0.00034 in. that are indicated,
simulation.
surgiclip pusher in this new
1 12,113.38 0.00066
biomedical endoscopic
3 12,113.85 0.00078
4 12,113.78 0.00082
5 12,113.39 0.00097
6 12,114.15 0.00065
7 12,114.18 0.00088
8 12,113.16 0.00093
9 12,113.18 0.00084
10 12,113.89 0.00082
11 12,113.98 0.00095
12 12,113.76 0.00098
13 12,113.24 0.00086
14 12,113.22 0.00084
15 12,113.78 0.00092
16 12,113.32 0.00095
17 12,114.38 0.00095
18 12,113.88 0.00088
19 12,113.99 0.00065
20 12,113.18 0.00069
Average 12,113.70 0.00084

gear_1 in this new
1 16,516.77 0.00039
3 16,516.17 0.00045
4 16,516.08 0.00049
5 16,516.98 0.00054
6 16,516.38 0.00032
7 16,516.18 0.00057
8 16,515.98 0.00055
9 16,515.38 0.00059
10 16,516.12 0.00055
11 16,517.15 0.00059
12 16,516.02 0.00057
13 16,516.17 0.00059
14 16,516.38 0.00054
15 16,516.98 0.00059
16 16,516.24 0.00059
17 16,516.18 0.00057
18 16,516.01 0.00048
19 16,516.99 0.00039
20 16,516.78 0.00036
Average 16,516.39 0.00051

gear_2 in this new
1 16,482.13 0.00022
3 16,481.38 0.00038
4 16,482.03 0.00032
5 16,481.84 0.00038
6 16,481.35 0.00036
7 16,481.11 0.00035
8 16,481.12 0.00038
9 16,482.33 0.00032
10 16,481.33 0.00039
11 16,481.45 0.00037
12 16,481.08 0.00026
13 16,482.01 0.00029
14 16,482.05 0.00039
15 16,481.24 0.00038
16 16,481.15 0.00039
17 16,481.38 0.00035
18 16,481.48 0.00029
19 16,482.15 0.00037
20 16,482.01 0.00025
Average 16,481.62 0.00033
Table 10.12 records the prototype testing results of instrument gear_2 in this new
biomedical endoscopic surgiclip instrument.
The prototype experimental results of instrument gear_2 in Table 10.12 prove
the normal function as the average maximum stress 16,481.62 psi and average
maximum deflection 0.00033 in. are almost equal to the results of maximum stress
16,482.03 psi and maximum deflection 0.00019 in. that are laid out, respectively, in
Table 10.13 states the prototype testing results of instrument gear_3 in this new
The prototype experimental results of instrument gear_3 in Table 10.13 verify
the proper function because the average maximum stress 16,973.55 psi and average
16,973.09 psi and maximum deflection 0.00016 in. that are shown, respectively, in
Table 10.14 demonstrates the prototype testing results of instrument gear_4 in
this new biomedical endoscopic surgiclip instrument.
The prototype experimental results of instrument gear_4 in Table 10.14 confirm
average maximum deflection 0.00029 in. are closely equal to the results of maxi-
mum stress 15,742.11 psi and maximum deflection 0.00017 in. that are presented,
gear_3 in this new
1 16,973.24 0.00018
3 16,973.89 0.00027
4 16,973.78 0.00019
5 16,973.65 0.00033
6 16,973.05 0.00038
7 16,973.88 0.00039
8 16,973.79 0.00024
9 16,973.99 0.00029
10 16,973.01 0.00039
11 16,973.97 0.00037
12 16,973.95 0.00038
13 16,973.04 0.00018
14 16,973.89 0.00037
15 16,973.88 0.00036
16 16,973.86 0.00039
17 16,973.03 0.00038
18 16,973.88 0.00037
19 16,973.19 0.00015
20 16,973.07 0.00019
Average 16,973.55 0.00030

gear_4 in this new
1 15,742.01 0.00019
3 15,741.38 0.00024
4 15,741.15 0.00029
5 15,742.14 0.00018
6 15,741.09 0.00025
7 15,742.15 0.00033
8 15,741.24 0.00038
9 15,741.05 0.00039
10 15,742.18 0.00018
11 15,741.24 0.00027
12 15,741.25 0.00039
13 15,741.18 0.00035
14 15,741.48 0.00037
15 15,742.12 0.00027
16 15,742.11 0.00038
17 15,741.24 0.00039
18 15,741.38 0.00033
19 15,742.02 0.00029
20 15,742.19 0.00015
Average 15,741.63 0.00029

testing of instrument gear of experiment stress (psi) deflection (in.)
rack in this new biomedical
1 37,491.24 0.00438
endoscopic surgiclip
instrument 2 37,491.08 0.00412
3 37,491.83 0.00418
4 37,490.33 0.00454
5 37,490.84 0.00402
6 37,491.18 0.00408
7 37,491.05 0.00411
8 37,491.21 0.00449
9 37,491.12 0.00403
10 37,491.88 0.00412
11 37,491.06 0.00405
12 37,491.11 0.00402
13 37,490.33 0.00408
14 37,491.02 0.00416
15 37,491.14 0.00417
16 37,491.24 0.00419
17 37,491.73 0.00455
18 37,490.55 0.00402
19 37,491.78 0.00438
20 37,491.54 0.00451
Average 37,491.16 0.00421

simulation.
Table 10.15 demonstrates the prototype testing results of instrument gear rack in
The prototype experimental results of instrument gear rack in Table 10.15 prove
maximum deflection 0.00421 in. are almost same as the results of maximum stress
simulation.
Table 10.16 expresses the prototype testing results of instrument gear link in this
new biomedical endoscopic surgiclip instrument.
The prototype experimental results of instrument gear link in Table 10.16 verify
the proper function because the average maximum stress 18,905.29 psi and average
maximum deflection 0.00032 in. are approximately equal to the results of maxi-
mum stress 18,905.80 psi and maximum deflection 0.00023 in. that are indicated,
simulation.
Table 10.17 records the prototype testing results of instrument handle trigger in
testing of instrument gear of experiment stress (psi) deflection (in.)
link in this new biomedical
1 18,905.25 0.00024
endoscopic surgiclip
instrument 2 18,905.78 0.00029
3 18,904.55 0.00038
4 18,904.88 0.00037
5 18,904.85 0.00039
6 18,905.90 0.00027
7 18,905.48 0.00025
8 18,904.68 0.00021
9 18,904.88 0.00038
10 18,905.18 0.00037
11 18,905.38 0.00035
12 18,905.08 0.00029
13 18,905.24 0.00039
14 18,905.84 0.00029
15 18,905.12 0.00022
16 18,905.16 0.00038
17 18,905.98 0.00037
18 18,905.18 0.00039
19 18,905.44 0.00029
20 18,905.98 0.00021
Average 18,905.29 0.00032

handle trigger in this new
1 4,686.98 0.00092
3 4,686.09 0.00091
4 4,686.12 0.00088
5 4,686.24 0.00084
6 4,686.11 0.00081
7 4,687.19 0.00092
8 4,686.38 0.00083
9 4,686.05 0.00082
10 4,686.18 0.00084
11 4,686.38 0.00081
12 4,686.54 0.00083
13 4,687.29 0.00092
14 4,687.24 0.00081
15 4,686.48 0.00085
16 4,686.12 0.00082
17 4,686.08 0.00081
18 4,686.11 0.00091
19 4,686.77 0.00082
20 4,687.26 0.00093
Average 4,686.52 0.00086

handle in this new
1 17,400.48 0.00072
3 17,400.42 0.00068
4 17,401.09 0.00066
5 17,401.55 0.00065
6 17,400.88 0.00071
7 17,401.68 0.00078
8 17,400.99 0.00065
9 17,400.77 0.00063
10 17,400.98 0.00061
11 17,400.89 0.00062
12 17,400.84 0.00064
13 17,400.24 0.00062
14 17,400.48 0.00064
15 17,400.99 0.00068
16 17,400.88 0.00071
17 17,401.55 0.00065
18 17,401.24 0.00062
19 17,400.78 0.00069
20 17,400.42 0.00072
Average 17,400.90 0.00067
The prototype experimental results of instrument handle trigger in Table 10.17

and average maximum deflection 0.00086 in. are approximately same as the results
of maximum stress 4,686.99 psi and maximum deflection 0.00097 in. that are laid
out, respectively, in Figs. 10.55 and 10.56 by computer-aided modeling and numer-
ical simulation.
Table 10.18 states the prototype testing results of instrument handle in this new
The prototype experimental results of instrument handle in Table 10.18 prove
17,400.49 psi and maximum deflection 0.00074 in. that are shown, respectively
Table 10.19 demonstrates the prototype testing results of instrument front end of
inside shaft in this new biomedical endoscopic surgiclip instrument.
The prototype experimental results for instrument front end of inside shaft in
Table 10.19 verify the proper function because the average maximum stress
18,835.57 psi and average maximum deflection 0.00113 in. are similar to the results

end of inside shaft in this
1 18,835.32 0.00104
new biomedical
endoscopic surgiclip 2 18,835.12 0.00101
instrument 3 18,835.82 0.00135
4 18,834.89 0.00111
5 18,835.88 0.00118
6 18,835.97 0.00124
7 18,835.89 0.00101
8 18,835.54 0.00108
9 18,834.88 0.00112
10 18,835.86 0.00119
11 18,835.88 0.00118
12 18,835.75 0.00119
13 18,835.98 0.00117
14 18,834.78 0.00115
15 18,835.84 0.00101
16 18,835.88 0.00116
17 18,835.95 0.00119
18 18,835.91 0.00118
19 18,835.48 0.00109
20 18,834.75 0.00103
Average 18,835.57 0.00113
presented, respectively, in Figs. 10.61 and 10.62 by computer-aided modeling and

Table 10.20 demonstrates the prototype testing results of instrument inside shaft
in this new biomedical endoscopic surgiclip instrument.
The prototype experimental results of instrument inside shaft in Table 10.20
confirm the normal function since the average maximum stress 20,118.55 psi and
average maximum deflection 0.04334 in. are almost equal to the results of maxi-
simulation.
Table 10.21 expresses the prototype testing results of instrument front jaw
(forming surgiclip to secure the tissues) by using this new biomedical endoscopic
surgiclip instrument.
The prototype experimental results of instrument front jaw (forming surgiclip to
secure the tissues by using this new biomedical endoscopic surgiclip instrument) in
Table 10.21 prove the normal function as the average maximum stress
19,832.61 psi and average maximum deflection 0.00651 in. are very similar to the
are indicated, respectively, in Figs. 10.67 and 10.68 by computer-aided modeling
testing of instrument inside of experiment stress (psi) deflection (in.)
shaft in this new
1 20,118.85 0.04338
3 20,118.98 0.04317
4 20,118.25 0.04348
5 20,118.18 0.04338
6 20,118.35 0.04309
7 20,118.38 0.04354
8 20,118.12 0.04378
9 20,118.08 0.04368
10 20,118.11 0.04324
11 20,118.78 0.04338
12 20,118.66 0.04309
13 20,118.54 0.04333
14 20,118.99 0.04338
15 20,118.45 0.04354
16 20,118.84 0.04348
17 20,118.68 0.04329
18 20,118.78 0.04312
19 20,118.99 0.04308
20 20,118.84 0.04319
Average 20,118.55 0.04334

jaw (forming surgiclip to
1 19,832.88 0.00655
secure the tissues) by using
this new biomedical 2 19,832.99 0.00688
instrument 4 19,832.54 0.00624
5 19,832.32 0.00618
6 19,832.38 0.00616
7 19,832.18 0.00635
8 19,832.24 0.00638
9 19,832.27 0.00633
10 19,832.77 0.00688
11 19,832.38 0.00668
12 19,832.55 0.00617
13 19,832.48 0.00618
14 19,832.45 0.00666
15 19,832.98 0.00648
16 19,832.54 0.00677
17 19,832.95 0.00679
18 19,832.91 0.00668
19 19,832.78 0.00669
20 19,832.79 0.00675
Average 19,832.61 0.00651

jaw (to manipulate thick
1 22,916.17 0.00912
tissues) by using this new
biomedical endoscopic 2 22,916.24 0.00924
4 22,916.55 0.00938
5 22,916.68 0.00945
6 22,916.77 0.00955
7 22,916.78 0.00948
8 22,916.44 0.00937
9 22,916.80 0.00976
10 22,916.56 0.00985
11 22,916.88 0.00973
12 22,916.15 0.00908
13 22,916.69 0.00918
14 22,916.54 0.00943
15 22,916.23 0.00901
16 22,916.78 0.00911
17 22,916.54 0.00905
18 22,916.78 0.00924
19 22,916.33 0.00915
20 22,916.52 0.00931
Average 22,916.55 0.00933
Table 10.22 records the prototype testing results of instrument front jaw
(to manipulate thick tissues) by using this new biomedical endoscopic surgiclip
instrument.
The prototype experimental results of instrument front jaw (to manipulate thick
tissues by using this new biomedical endoscopic surgiclip instrument) in
Table 10.22 verify the proper function because the average maximum stress
22,916.55 psi and average maximum deflection 0.00933 in. are closely equal to
the results of maximum stress 22,916.18 psi and maximum deflection 0.00903 in.
that are indicated, respectively, in Figs. 10.69 and 10.70 by computer-aided
modeling and numerical simulation.
Table 10.23 shows the prototype testing results of instrument surgiclip pusher by
using this new biomedical endoscopic surgiclip instrument.
displayed, respectively, in Figs. 10.72 and 10.73 by computer-aided modeling
Table 10.24 demonstrates the prototype testing results of instrument external
shaft in this new biomedical endoscopic surgiclip instrument.
surgiclip pusher by using
1 20,542.62 0.00427
this new biomedical
instrument 3 20,542.71 0.00448
4 20,542.52 0.00457
5 20,542.44 0.00478
6 20,542.17 0.00465
7 20,542.18 0.00479
8 20,542.24 0.00488
9 20,542.22 0.00459
10 20,542.38 0.00467
11 20,542.44 0.00478
12 20,542.48 0.00487
13 20,542.66 0.00449
14 20,542.54 0.00438
15 20,542.43 0.00444
16 20,542.38 0.00479
17 20,542.78 0.00432
18 20,542.33 0.00425
19 20,542.45 0.00438
20 20,542.47 0.00451
Average 20,542.45 0.00456

external shaft in this new
1 12,922.44 0.00078
3 12,922.18 0.00075
4 12,922.23 0.00071
5 12,922.57 0.00078
6 12,922.31 0.00072
7 12,922.11 0.00071
8 12,922.19 0.00073
9 12,922.59 0.00082
10 12,922.22 0.00073
11 12,922.08 0.00075
12 12,922.17 0.00071
13 12,922.24 0.00072
14 12,922.38 0.00071
15 12,922.27 0.00073
16 12,922.38 0.00071
17 12,922.57 0.00073
18 12,922.12 0.00072
19 12,922.12 0.00071
20 12,922.27 0.00075
Average 12,922.28 0.00074
10.4 Discussion and Future Improvement on Biomedical and Surgical Systems 235
The prototype experimental results of instrument external shaft in Table 10.24

prove the normal function as the average maximum stress 12,922.28 psi and
average maximum deflection 0.00074 in. are almost same as the results of maxi-
simulation.
10.4 Discussion and Future Improvement on Biomedical

and Surgical Systems
New biomedical open and endoscopic surgiclip instruments have been designed
and developed to improve the medical treatment and operation performance during
complex medical practices targeting the minimally body-invasive, reliable, and safe
medical approaches. The goal of improved biomedical and surgical instruments is
to help doctors and surgeons more easily and efficiently handle the patient treat-
ment. The future improvement of biomedical open and endoscopic surgiclip instru-
ment will focus on design simplification and ergonomic satisfaction for consistent
function so that doctors can well control and precisely manipulate the medical
instruments. Other efforts will be put to modify the front-end mechanism to benefit
doctors and surgeons by providing more clear visualization. More clinic field
experiment will be planned for further evaluation.
Conclusion
Computer-aided design, 3D modeling, and engineering analysis apply the

computer-related technologies and provide scientists, engineers, and technical
professionals with research- and engineering-friendly methodologies to efficiently
support business product design procedures, engineering documentation,
manufacturing drawing, and production processes. The continuous development
of computer-aided design, 3D modeling, and engineering analytic technologies will
benefit business enterprises, engineering firms, and industrial groups to economi-
cally reduce the cost, efficiently shorten the cyclic time, flexibly manipulate the
complex 3D geometrical design by computer to avoid unnecessary part making in
early system design stages, and effectively perform important engineering analysis
to improve designed system quality. The multiple design case studies using
computer-aided design applications, 3D modeling, and engineering analysis based
on author’s research experiences have been introduced in this book. The computer-
aided design, numerical simulation, and engineering analytic results included in this
book have shown that the computer-aided design and analytic technologies are
playing extremely critical fiscal and technological roles in scientific researches,
technical renovation, system and product design and development, and industrial
and engineering applications. The computer-aided design and engineering analytic
technologies bring broad revolution to the business enterprises with its adjustable,
flexible, manipulative, reliable, sustainable, and cost-effective control technologies.
Multiple case studies of computer-aided design, 3D modeling, and engineering
analysis in this book can help to understand and develop more efficient and
functional systems to flexibly and convertibly maintain reproducible product qual-
ity, shorten required production time, accelerate material-manipulating process,
and modify work flow to meet customer needs in their product requirement. Both
computer-aided analysis and prototype experiment of different newly designed
products that introduced in this book show very close results which validate the
credibility and feasibility of fundamental design, 3D modeling, analytic academics,
computational simulation, prototyping, and experimental techniques proposed in
this book.

Experimentation, DOI 10.1007/978-3-319-05921-1
Biography
Dr. Jeremy (Zheng) Li is an associate professor of mechanical engineering in

the University of Bridgeport. His researches include design and development of
robotic systems, automated manufacturing, biomedical and surgical instruments,
automated and high-speed machinery, sustainable energy systems (solar panel,
wind power, and green energy storage), thermal and flow systems, and structure
and stress analysis.
Contact e-mail address: [email protected]

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Index
A D
Aerodynamic, 5, 27, 28, 30 Deformation profile, 42–43, 77, 78
Automated manufacturing, 8–9, 95–121, Design modification, 2, 25, 117, 118,
127, 138 140, 157
Automated mechanism, 96–102, 105–107, Design simplification, 8, 25, 86, 108, 243
115–119, 190, 193 3-D modeling, 1–3, 27, 30, 32, 39, 41, 122
Automated production, 9, 12, 95, 97, 98, 101,
103–104, 117–118, 121, 127, 138, 172
Automation, 2, 3, 10–12, 17, 39, 73, 74, E
163–195, 199 Endoscopic, 203, 211–223, 232–236,
238–241, 243
Energy-efficient, 3, 12, 86, 124, 140
B Energy-saving, 3, 7–8, 17, 73–92
Biomedical, 203, 211–223, 232–236, Engineering efficiency, 2
238–241, 243 Environment conservation, 86
Environment-friendly, 35
Ergonomic satisfaction, 13, 243
C Evaluation, 12, 95, 140, 244
Cheaper reconfiguration, 118 Experimental comparison, 44, 80, 109, 137,
Clear visualization, 13, 244 151, 168, 222
Clinic treatment, 244 Experimentation, 22–25, 33–36, 44–50, 63–71,
Computational simulation, 19, 30, 44, 50, 78, 80–86, 109–119, 122, 132–141,
102, 105, 107–115, 122, 125–127, 146, 151–156, 168–172, 222–244
150, 157, 165, 167, 221
Computer aided design (CAD), 1–3, 9, 27, 30,
39, 102 F
Computer modeling, 9, 17, 19, 21, 22, 25, 27, Feasibility, 5, 33
30, 33, 34, 39, 41, 52, 80, 82, 84, Finite element analysis, 30
101–103, 110, 115, 122, 126, 133–135, Functionality, 2, 4, 6, 9–11, 13, 21, 22, 24,
138, 139, 147, 151, 153, 154, 156, 164, 28, 30, 33, 34, 39, 40, 44–46, 48–50,
168–171, 224, 226, 228, 230, 232, 73–76, 78, 80, 82, 84, 86, 95, 97, 98,
234–236, 238–241, 243 103–104, 109–110, 113, 115–118,
Cost-economic, 3 124, 126, 132–135, 138–140,
Cost-effective, 3, 12, 18, 35, 95, 97, 108, 118, 143–145, 150, 151, 154, 156,
119, 140 164, 168–171, 211, 221, 222, 224,
Cost reduction, 8, 9, 25, 86, 119, 157, 163, 226, 228, 230, 232–234, 236,
172, 199 238–241, 243

254 Index
G R
Global warning, 5, 86 Radiated flux, 19
Green energy, 5, 17–18, 27, 33 Reliability, 4, 10–13, 33, 50, 73, 78, 86, 95–98,
118, 121, 132, 140, 143, 144, 146, 199,
200, 211, 221, 243
H Robotic control, 9, 10, 122, 139
High speed machinery, 17 Robotics, 9–10, 17, 96, 121–141
High speed production, 17, 98, 101, 117,
118, 138
S
Safe interaction, 13
K Snow load, 19, 21
Kinematic motion, 10, 126, 132, 137 Solar energy, 3–6, 17–25, 39
Kinetic energy, 4, 27 Solar intensity, 19, 20, 22, 23
Solar power, 50
Solar system, 6, 18, 21, 39
L Solar tracking, 6, 39–41, 44, 50–52
Labor reduction, 8, 9, 163, 172 Stress profile, 22, 31, 32, 34, 41, 43, 46, 48,
Leakage prevention, 11, 156, 157 50, 52, 55, 57, 59, 61, 78, 80, 82, 84,
86, 103, 105, 107, 109, 111, 113, 131,
133, 135, 148, 150, 152, 154, 156,
M 166, 169, 172, 174, 176, 179, 181,
Magnetic sealing, 10–11, 17, 143–162 183, 185, 204, 205, 207, 209, 211,
Manufacturing control, 2, 3, 8, 98, 104, 119 213, 215, 217, 219, 221, 224, 226,
Mechanical advantage, 204, 211 228, 230, 232, 234, 236, 238, 241,
Medical treatment, 7, 13, 204, 213, 221, 243 243, 245, 247, 249, 251, 253
Minimized body-invasive, 13, 242 Structural analysis, 2, 3, 12, 30, 39, 102, 105, 127
Structural strength, 3, 5, 21, 39, 127, 138
Sunlight energy, 3–6, 50
O Surgical, 7, 13, 17, 199–278
Optimal design, 140, 157, 211 Surgical procedure, 10, 13, 122, 204, 205, 207,
Optimization, 2–3, 8, 28, 50, 121–122, 126, 209, 213
157, 203 Sustainable energy, 17, 33
Systematic balance, 86
Systematic efficiency, 8, 12, 36, 73, 86, 95,
P 118, 124
Performance, 1–3, 8, 10, 12, 13, 27, 28, 30, 39, Systematic flexibility, 117, 121
44, 50, 73, 86, 102, 105, 108, 118, 121,
125, 127, 137, 143, 156, 157, 164, 200,
203, 204, 211, 243 T
Precise manipulation, 243 Testing methodology, 50
Process optimization, 2 Tolerance control, 2, 3, 98, 104, 108, 119, 199
Prototyping, 22–24, 27, 28, 33, 34, 36–39, Turbine efficiency, 36
44–46, 48–50, 73, 80, 82, 84, 88–92, 95,
97, 109, 110, 112, 114–122, 132–141,
143, 151, 154, 156, 158–162, 168–171, V
187–195, 200, 222, 224, 226, 228, 230, Validation, 39, 122
232–236, 238–241, 255–278 Verification, 5, 19, 22, 27, 34, 44, 45, 48, 73,
76, 80, 84, 109, 115, 116, 126, 127, 133,
134, 138, 143, 146, 150, 151, 154, 164,
Q 168, 169, 171, 222, 226, 228, 232, 234,
Quality consistence, 9 238–240
Quick changeover, 172 Vibration-reduction, 73, 86, 118
Index 255
W Wind power energy, 32–33, 35, 36

Water distillation, 3–4, 17–25 Wind turbine, 4, 5, 27–38
Wind load, 6, 19, 21, 40
Wind power, 4–5, 27–38

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Jeremy Zheng Li

ISBN 978-3-319-05920-4 ISBN 978-3-319-05921-1 (eBook)

# Springer International Publishing Switzerland 2015

Printed on acid-free paper

Springer is part of Springer Science+Business Media (www.springer.com)

Computer-aided design (CAD), 3D modeling, and engineering analysis can be

prototype experiment. The case studies include design and development of

Bridgeport, CT, USA Jeremy Zheng Li

Part I Energy Systems

2 Solar Energy System for Water Distillation . . . . . . . . . . . . . . . . . . 17

4 Solar Panel Tracking System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Part II Automated Systems

6 Automated and High-Speed Manufacturing System . . . . . . . . . . . . 85

8 Magnetic Sealing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Part III Biomedical Systems

10 Biomedical and Surgical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . 173

3D modeling can perform mathematic and geometric analysis on 3D object surfaces

# Springer International Publishing Switzerland 2015 1

1.1 Solar Energy System for Water Distillation

1.2 Wind Power Turbine System

1.3 Solar Panel Tracking System

1.4 Energy-Saving Cooling System

1.5 Automated and High-Speed Manufacturing Systems

Automated machinery system is to apply various control systems to control and

assembly, food processing, automated welding, and many other industrial

1.6 Robotic System for Industrial Applications

Robotic technology is a technical field dealing with engineering design,

1.7 Magnetic Sealing System

physical barrier to prevent leaking (González-Jorge et al. 2005; Mitamura

1.8 Automated and High-Speed Packaging Machinery System

The packaging engineering and technology is a technical field ranging from

1.9 Biomedical and Surgical Systems

2.1 Design of Solar Energy System for Water Distillation

# Springer International Publishing Switzerland 2015 17

Fig. 2.1 Newly developed green (solar) energy distillation system

2.2 Computer-Aided Simulation of Solar Energy System

Fig. 2.2 Computer-aided FEA meshing in new solar distillation system

where qz—effective velocity pressure, KD—wind directionality factor, KZ—

where PF—snow load, CE—exposure factor, CT—thermal factor, IS—importance

2.3 Experiment on Solar Energy System for Water Distillation

Table 2.1 Prototype Time (h) Solar radiation intensity (W/m2)

Table 2.2 Prototype Time (h) Distilled water output (ml)

Table 2.3 Prototype Number Maximum Maximum

2.4 Discussion and Future Improvement of Solar

3.1 Design of New Wind Power Turbine System

# Springer International Publishing Switzerland 2015 27

Fig. 3.1 Wind power turbine

Fig. 3.2 Wind power turbine

Fig. 3.3 Driver gear design

Fig. 3.4 Turbine blade

3.2 Computer-Aided Simulation of Wind Power

ρAIR ANET DLIFT S2RESULTANT

Here, ρAIR—density of incoming air, ANET—net surface area of turbine blade,

DPOWER ρAIR ASWEPT S3WIND

Fig. 3.6 Computational modeling of stress profile in turbine blade

Fig. 3.7 Computational modeling of deflection profile in turbine blade

3.3 Experiment on Wind Power Turbine System

Table 3.1 Prototype Number Maximum Maximum

Table 3.2 Prototype Number Maximum Maximum

ðPe Pme Þ A ¼ FF ð5:4Þ