Caracterización de un robot para aplicaciones de mecanizado con requerimientos de tolerancias

El presente Trabajo fin Fin de Máster, versa sobre una caracterización preliminar del comportamiento de un robot de tipo industrial, configurado por 4 eslabones y 4 grados de libertad, y sometido a fuerzas de mecanizado en su extremo. El entorno de trabajo planteado es el de plantas de fabricación de piezas de aleaciones de aluminio para automoción. Este tipo de componentes parte de un primer proceso de fundición que saca la pieza en bruto. Para series medias y altas, en función de las propiedades mecánicas y plásticas requeridas y los costes de producción, la inyección a alta presión (HPDC) y la fundición a baja presión (LPC) son las dos tecnologías más usadas en esta primera fase. Para inyección a alta presión, las aleaciones de aluminio más empleadas son, en designación simbólica según norma EN 1706 (entre paréntesis su designación numérica); EN AC AlSi9Cu3(Fe) (EN AC 46000) , EN AC AlSi9Cu3(Fe)(Zn) (EN AC 46500), y EN AC AlSi12Cu1(Fe) (EN AC 47100). Para baja presión, EN AC AlSi7Mg0,3 (EN AC 42100). En los 3 primeros casos, los límites de Silicio permitidos pueden superan el 10%. En el cuarto caso, es inferior al 10% por lo que, a los efectos de ser sometidas a mecanizados, las piezas fabricadas en aleaciones con Si superior al 10%, se puede considerar que son equivalentes, diferenciándolas de la cuarta. Las tolerancias geométricas y dimensionales conseguibles directamente de fundición, recogidas en normas como ISO 8062 o DIN 1688-1, establecen límites para este proceso. Fuera de esos límites, las garantías en conseguir producciones con los objetivos de ppms aceptados en la actualidad por el mercado, obligan a ir a fases posteriores de mecanizado. Aquellas geometrías que, funcionalmente, necesitan disponer de unas tolerancias geométricas y/o dimensionales definidas acorde a ISO 1101, y no capaces por este proceso inicial de moldeado a presión, deben ser procesadas en una fase posterior en células de mecanizado. En este caso, las tolerancias alcanzables para procesos de arranque de viruta se recogen en normas como ISO 2768. Las células de mecanizado se componen, por lo general, de varios centros de control numérico interrelacionados y comunicados entre sí por robots que manipulan las piezas en proceso de uno a otro. Dichos robots, disponen en su extremo de una pinza utillada para poder coger y soltar las piezas en los útiles de mecanizado, las mesas de intercambio para cambiar la pieza de posición o en utillajes de equipos de medición y prueba, o en cintas de entrada o salida. La repetibilidad es alta, de centésimas incluso, definida según norma ISO 9283. El problema es que, estos rangos de repetibilidad sólo se garantizan si no se hacen esfuerzos o éstos son despreciables (caso de mover piezas). Aunque las inercias de mover piezas a altas velocidades hacen que la trayectoria intermedia tenga poca precisión, al inicio y al final (al coger y dejar pieza, p.e.) se hacen a velocidades relativamente bajas que hacen que el efecto de las fuerzas de inercia sean menores y que permiten garantizar la repetibilidad anteriormente indicada. No ocurre así si se quitara la garra y se intercambia con un cabezal motorizado con una herramienta como broca, mandrino, plato de cuchillas, fresas frontales o tangenciales… Las fuerzas ejercidas de mecanizado generarían unos pares en las uniones tan grandes y tan variables que el control del robot no sería capaz de responder (o no está preparado, en un principio) y generaría una desviación en la trayectoria, realizada a baja velocidad, que desencadenaría en un error de posición (ver norma ISO 5458) no asumible para la funcionalidad deseada. Se podría llegar al caso de que la tolerancia alcanzada por un pretendido proceso más exacto diera una dimensión peor que la que daría el proceso de fundición, en principio con mayor variabilidad dimensional en proceso (y por ende con mayor intervalo de tolerancia garantizable). De hecho, en los CNCs, la precisión es muy elevada, (pudiéndose despreciar en la mayoría de los casos) y no es la responsable de, por ejemplo la tolerancia de posición al taladrar un agujero. Factores como, temperatura de la sala y de la pieza, calidad constructiva de los utillajes y rigidez en el amarre, error en el giro de mesas y de colocación de pieza, si lleva agujeros previos o no, si la herramienta está bien equilibrada y el cono es el adecuado para el tipo de mecanizado… influyen más. Es interesante que, un elemento no específico tan común en una planta industrial, en el entorno anteriormente descrito, como es un robot, el cual no sería necesario añadir por disponer de él ya (y por lo tanto la inversión sería muy pequeña), puede mejorar la cadena de valor disminuyendo el costo de fabricación. Y si se pudiera conjugar que ese robot destinado a tareas de manipulación, en los muchos tiempos de espera que va a disfrutar mientras el CNC arranca viruta, pudiese coger un cabezal y apoyar ese mecanizado; sería doblemente interesante. Por lo tanto, se antoja sugestivo poder conocer su comportamiento e intentar explicar qué sería necesario para llevar esto a cabo, motivo de este trabajo. La arquitectura de robot seleccionada es de tipo SCARA. La búsqueda de un robot cómodo de modelar y de analizar cinemática y dinámicamente, sin limitaciones relevantes en la multifuncionalidad de trabajos solicitados, ha llevado a esta elección, frente a otras arquitecturas como por ejemplo los robots antropomórficos de 6 grados de libertad, muy populares a nivel industrial. Este robot dispone de 3 uniones, de las cuales 2 son de tipo par de revolución (1 grado de libertad cada una) y la tercera es de tipo corredera o par cilíndrico (2 grados de libertad). La primera unión, de tipo par de revolución, sirve para unir el suelo (considerado como eslabón número 1) con el eslabón número 2. La segunda unión, también de ese tipo, une el eslabón número 2 con el eslabón número 3. Estos 2 brazos, pueden describir un movimiento horizontal, en el plano X-Y. El tercer eslabón, está unido al eslabón número 4 por la unión de tipo corredera. El movimiento que puede describir es paralelo al eje Z. El robot es de 4 grados de libertad (4 motores). En relación a los posibles trabajos que puede realizar este tipo de robot, su versatilidad abarca tanto operaciones típicas de manipulación como operaciones de arranque de viruta. Uno de los mecanizados más usuales es el taladrado, por lo cual se elige éste para su modelización y análisis. Dentro del taladrado se elegirá para acotar las fuerzas, taladrado en macizo con broca de diámetro 9 mm. El robot se ha considerado por el momento que tenga comportamiento de sólido rígido, por ser el mayor efecto esperado el de los pares en las uniones. Para modelar el robot se utiliza el método de los sistemas multicuerpos. Dentro de este método existen diversos tipos de formulaciones (p.e. Denavit-Hartenberg). D-H genera una cantidad muy grande de ecuaciones e incógnitas. Esas incógnitas son de difícil comprensión y, para cada posición, hay que detenerse a pensar qué significado tienen. Se ha optado por la formulación de coordenadas naturales. Este sistema utiliza puntos y vectores unitarios para definir la posición de los distintos cuerpos, y permite compartir, cuando es posible y se quiere, para definir los pares cinemáticos y reducir al mismo tiempo el número de variables. Las incógnitas son intuitivas, las ecuaciones de restricción muy sencillas y se reduce considerablemente el número de ecuaciones e incógnitas. Sin embargo, las coordenadas naturales “puras” tienen 2 problemas. El primero, que 2 elementos con un ángulo de 0 o 180 grados, dan lugar a puntos singulares que pueden crear problemas en las ecuaciones de restricción y por lo tanto han de evitarse. El segundo, que tampoco inciden directamente sobre la definición o el origen de los movimientos. Por lo tanto, es muy conveniente complementar esta formulación con ángulos y distancias (coordenadas relativas). Esto da lugar a las coordenadas naturales mixtas, que es la formulación final elegida para este TFM. Las coordenadas naturales mixtas no tienen el problema de los puntos singulares. Y la ventaja más importante reside en su utilidad a la hora de aplicar fuerzas motrices, momentos o evaluar errores. Al incidir sobre la incógnita origen (ángulos o distancias) controla los motores de manera directa. El algoritmo, la simulación y la obtención de resultados se ha programado mediante Matlab. Para realizar el modelo en coordenadas naturales mixtas, es preciso modelar en 2 pasos el robot a estudio. El primer modelo se basa en coordenadas naturales. Para su validación, se plantea una trayectoria definida y se analiza cinemáticamente si el robot satisface el movimiento solicitado, manteniendo su integridad como sistema multicuerpo. Se cuantifican los puntos (en este caso inicial y final) que configuran el robot. Al tratarse de sólidos rígidos, cada eslabón queda definido por sus respectivos puntos inicial y final (que son los más interesantes para la cinemática y la dinámica) y por un vector unitario no colineal a esos 2 puntos. Los vectores unitarios se colocan en los lugares en los que se tenga un eje de rotación o cuando se desee obtener información de un ángulo. No son necesarios vectores unitarios para medir distancias. Tampoco tienen por qué coincidir los grados de libertad con el número de vectores unitarios. Las longitudes de cada eslabón quedan definidas como constantes geométricas. Se establecen las restricciones que definen la naturaleza del robot y las relaciones entre los diferentes elementos y su entorno. La trayectoria se genera por una nube de puntos continua, definidos en coordenadas independientes. Cada conjunto de coordenadas independientes define, en un instante concreto, una posición y postura de robot determinada. Para conocerla, es necesario saber qué coordenadas dependientes hay en ese instante, y se obtienen resolviendo por el método de Newton-Rhapson las ecuaciones de restricción en función de las coordenadas independientes. El motivo de hacerlo así es porque las coordenadas dependientes deben satisfacer las restricciones, cosa que no ocurre con las coordenadas independientes. Cuando la validez del modelo se ha probado (primera validación), se pasa al modelo 2. El modelo número 2, incorpora a las coordenadas naturales del modelo número 1, las coordenadas relativas en forma de ángulos en los pares de revolución (3 ángulos; ϕ1, ϕ 2 y ϕ3) y distancias en los pares prismáticos (1 distancia; s). Estas coordenadas relativas pasan a ser las nuevas coordenadas independientes (sustituyendo a las coordenadas independientes cartesianas del modelo primero, que eran coordenadas naturales). Es necesario revisar si el sistema de vectores unitarios del modelo 1 es suficiente o no. Para este caso concreto, se han necesitado añadir 1 vector unitario adicional con objeto de que los ángulos queden perfectamente determinados con las correspondientes ecuaciones de producto escalar y/o vectorial. Las restricciones habrán de ser incrementadas en, al menos, 4 ecuaciones; una por cada nueva incógnita. La validación del modelo número 2, tiene 2 fases. La primera, al igual que se hizo en el modelo número 1, a través del análisis cinemático del comportamiento con una trayectoria definida. Podrían obtenerse del modelo 2 en este análisis, velocidades y aceleraciones, pero no son necesarios. Tan sólo interesan los movimientos o desplazamientos finitos. Comprobada la coherencia de movimientos (segunda validación), se pasa a analizar cinemáticamente el comportamiento con trayectorias interpoladas. El análisis cinemático con trayectorias interpoladas, trabaja con un número mínimo de 3 puntos máster. En este caso se han elegido 3; punto inicial, punto intermedio y punto final. El número de interpolaciones con el que se actúa es de 50 interpolaciones en cada tramo (cada 2 puntos máster hay un tramo), resultando un total de 100 interpolaciones. El método de interpolación utilizado es el de splines cúbicas con condición de aceleración inicial y final constantes, que genera las coordenadas independientes de los puntos interpolados de cada tramo. Las coordenadas dependientes se obtienen resolviendo las ecuaciones de restricción no lineales con el método de Newton-Rhapson. El método de las splines cúbicas es muy continuo, por lo que si se desea modelar una trayectoria en el que haya al menos 2 movimientos claramente diferenciados, es preciso hacerlo en 2 tramos y unirlos posteriormente. Sería el caso en el que alguno de los motores se desee expresamente que esté parado durante el primer movimiento y otro distinto lo esté durante el segundo movimiento (y así sucesivamente). Obtenido el movimiento, se calculan, también mediante fórmulas de diferenciación numérica, las velocidades y aceleraciones independientes. El proceso es análogo al anteriormente explicado, recordando la condición impuesta de que la aceleración en el instante t= 0 y en instante t= final, se ha tomado como 0. Las velocidades y aceleraciones dependientes se calculan resolviendo las correspondientes derivadas de las ecuaciones de restricción. Se comprueba, de nuevo, en una tercera validación del modelo, la coherencia del movimiento interpolado. La dinámica inversa calcula, para un movimiento definido -conocidas la posición, velocidad y la aceleración en cada instante de tiempo-, y conocidas las fuerzas externas que actúan (por ejemplo el peso); qué fuerzas hay que aplicar en los motores (donde hay control) para que se obtenga el citado movimiento. En la dinámica inversa, cada instante del tiempo es independiente de los demás y tiene una posición, una velocidad y una aceleración y unas fuerzas conocidas. En este caso concreto, se desean aplicar, de momento, sólo las fuerzas debidas al peso, aunque se podrían haber incorporado fuerzas de otra naturaleza si se hubiese deseado. Las posiciones, velocidades y aceleraciones, proceden del cálculo cinemático. El efecto inercial de las fuerzas tenidas en cuenta (el peso) es calculado. Como resultado final del análisis dinámico inverso, se obtienen los pares que han de ejercer los cuatro motores para replicar el movimiento prescrito con las fuerzas que estaban actuando. La cuarta validación del modelo consiste en confirmar que el movimiento obtenido por aplicar los pares obtenidos en la dinámica inversa, coinciden con el obtenido en el análisis cinemático (movimiento teórico). Para ello, es necesario acudir a la dinámica directa. La dinámica directa se encarga de calcular el movimiento del robot, resultante de aplicar unos pares en motores y unas fuerzas en el robot. Por lo tanto, el movimiento real resultante, al no haber cambiado ninguna condición de las obtenidas en la dinámica inversa (pares de motor y fuerzas inerciales debidas al peso de los eslabones) ha de ser el mismo al movimiento teórico. Siendo así, se considera que el robot está listo para trabajar. Si se introduce una fuerza exterior de mecanizado no contemplada en la dinámica inversa y se asigna en los motores los mismos pares resultantes de la resolución del problema dinámico inverso, el movimiento real obtenido no es igual al movimiento teórico. El control de lazo cerrado se basa en ir comparando el movimiento real con el deseado e introducir las correcciones necesarias para minimizar o anular las diferencias. Se aplican ganancias en forma de correcciones en posición y/o velocidad para eliminar esas diferencias. Se evalúa el error de posición como la diferencia, en cada punto, entre el movimiento teórico deseado en el análisis cinemático y el movimiento real obtenido para cada fuerza de mecanizado y una ganancia concreta. Finalmente, se mapea el error de posición obtenido para cada fuerza de mecanizado y las diferentes ganancias previstas, graficando la mejor precisión que puede dar el robot para cada operación que se le requiere, y en qué condiciones. -------------- This Master´s Thesis deals with a preliminary characterization of the behaviour for an industrial robot, configured with 4 elements and 4 degrees of freedoms, and subjected to machining forces at its end. Proposed working conditions are those typical from manufacturing plants with aluminium alloys for automotive industry. This type of components comes from a first casting process that produces rough parts. For medium and high volumes, high pressure die casting (HPDC) and low pressure die casting (LPC) are the most used technologies in this first phase. For high pressure die casting processes, most used aluminium alloys are, in simbolic designation according EN 1706 standard (between brackets, its numerical designation); EN AC AlSi9Cu3(Fe) (EN AC 46000) , EN AC AlSi9Cu3(Fe)(Zn) (EN AC 46500), y EN AC AlSi12Cu1(Fe) (EN AC 47100). For low pressure, EN AC AlSi7Mg0,3 (EN AC 42100). For the 3 first alloys, Si allowed limits can exceed 10% content. Fourth alloy has admisible limits under 10% Si. That means, from the point of view of machining, that components made of alloys with Si content above 10% can be considered as equivalent, and the fourth one must be studied separately. Geometrical and dimensional tolerances directly achievables from casting, gathered in standards such as ISO 8062 or DIN 1688-1, establish a limit for this process. Out from those limits, guarantees to achieve batches with objetive ppms currently accepted by market, force to go to subsequent machining process. Those geometries that functionally require a geometrical and/or dimensional tolerance defined according ISO 1101, not capable with initial moulding process, must be obtained afterwards in a machining phase with machining cells. In this case, tolerances achievables with cutting processes are gathered in standards such as ISO 2768. In general terms, machining cells contain several CNCs that they are interrelated and connected by robots that handle parts in process among them. Those robots have at their end a gripper in order to take/remove parts in machining fixtures, in interchange tables to modify position of part, in measurement and control tooling devices, or in entrance/exit conveyors. Repeatibility for robot is tight, even few hundredths of mm, defined according ISO 9283. Problem is like this; those repeatibilty ranks are only guaranteed when there are no stresses or they are not significant (f.e. due to only movement of parts). Although inertias due to moving parts at a high speed make that intermediate paths have little accuracy, at the beginning and at the end of trajectories (f.e, when picking part or leaving it) movement is made with very slow speeds that make lower the effect of inertias forces and allow to achieve repeatibility before mentioned. It does not happens the same if gripper is removed and it is exchanged by an spindle with a machining tool such as a drilling tool, a pcd boring tool, a face or a tangential milling cutter… Forces due to machining would create such big and variable torques in joints that control from the robot would not be able to react (or it is not prepared in principle) and would produce a deviation in working trajectory, made at a low speed, that would trigger a position error (see ISO 5458 standard) not assumable for requested function. Then it could be possible that tolerance achieved by a more exact expected process would turn out into a worst dimension than the one that could be achieved with casting process, in principle with a larger dimensional variability in process (and hence with a larger tolerance range reachable). As a matter of fact, accuracy is very tight in CNC, (its influence can be ignored in most cases) and it is not the responsible of, for example position tolerance when drilling a hole. Factors as, room and part temperature, manufacturing quality of machining fixtures, stiffness at clamping system, rotating error in 4th axis and part positioning error, if there are previous holes, if machining tool is properly balanced, if shank is suitable for that machining type… have more influence. It is interesting to know that, a non specific element as common, at a manufacturing plant in the enviroment above described, as a robot (not needed to be added, therefore with an additional minimum investment), can improve value chain decreasing manufacturing costs. And when it would be possible to combine that the robot dedicated to handling works could support CNCs´ works in its many waiting time while CNCs cut, and could take an spindle and help to cut; it would be double interesting. So according to all this, it would be interesting to be able to know its behaviour and try to explain what would be necessary to make this possible, reason of this work. Selected robot architecture is SCARA type. The search for a robot easy to be modeled and kinematically and dinamically analyzed, without significant limits in the multifunctionality of requested operations, has lead to this choice. Due to that, other very popular architectures in the industry, f.e. 6 DOFs anthropomorphic robots, have been discarded. This robot has 3 joints, 2 of them are revolute joints (1 DOF each one) and the third one is a cylindrical joint (2 DOFs). The first joint, a revolute one, is used to join floor (body 1) with body 2. The second one, a revolute joint too, joins body 2 with body 3. These 2 bodies can move horizontally in X-Y plane. Body 3 is linked to body 4 with a cylindrical joint. Movement that can be made is paralell to Z axis. The robt has 4 degrees of freedom (4 motors). Regarding potential works that this type of robot can make, its versatility covers either typical handling operations or cutting operations. One of the most common machinings is to drill. That is the reason why it has been chosen for the model and analysis. Within drilling, in order to enclose spectrum force, a typical solid drilling with 9 mm diameter. The robot is considered, at the moment, to have a behaviour as rigid body, as biggest expected influence is the one due to torques at joints. In order to modelize robot, it is used multibodies system method. There are under this heading different sorts of formulations (f.e. Denavit-Hartenberg). D-H creates a great amount of equations and unknown quantities. Those unknown quatities are of a difficult understanding and, for each position, one must stop to think about which meaning they have. The choice made is therefore one of formulation in natural coordinates. This system uses points and unit vectors to define position of each different elements, and allow to share, when it is possible and wished, to define kinematic torques and reduce number of variables at the same time. Unknown quantities are intuitive, constrain equations are easy and number of equations and variables are strongly reduced. However, “pure” natural coordinates suffer 2 problems. The first one is that 2 elements with an angle of 0° or 180°, give rise to singular positions that can create problems in constrain equations and therefore they must be avoided. The second problem is that they do not work directly over the definition or the origin of movements. Given that, it is highly recommended to complement this formulation with angles and distances (relative coordinates). This leads to mixed natural coordinates, and they are the final formulation chosen for this MTh. Mixed natural coordinates have not the problem of singular positions. And the most important advantage lies in their usefulness when applying driving forces, torques or evaluating errors. As they influence directly over origin variable (angles or distances), they control motors directly. The algorithm, simulation and obtaining of results has been programmed with Matlab. To design the model in mixed natural coordinates, it is necessary to model the robot to be studied in 2 steps. The first model is based in natural coordinates. To validate it, it is raised a defined trajectory and it is kinematically analyzed if robot fulfils requested movement, keeping its integrity as multibody system. The points (in this case starting and ending points) that configure the robot are quantified. As the elements are considered as rigid bodies, each of them is defined by its respectively starting and ending point (those points are the most interesting ones from the point of view of kinematics and dynamics) and by a non-colinear unit vector to those points. Unit vectors are placed where there is a rotating axis or when it is needed information of an angle. Unit vectors are not needed to measure distances. Neither DOFs must coincide with the number of unit vectors. Lengths of each arm are defined as geometrical constants. The constrains that define the nature of the robot and relationships among different elements and its enviroment are set. Path is generated by a cloud of continuous points, defined in independent coordinates. Each group of independent coordinates define, in an specific instant, a defined position and posture for the robot. In order to know it, it is needed to know which dependent coordinates there are in that instant, and they are obtained solving the constraint equations with Newton-Rhapson method according to independent coordinates. The reason to make it like this is because dependent coordinates must meet constraints, and this is not the case with independent coordinates. When suitability of model is checked (first approval), it is given next step to model 2. Model 2 adds to natural coordinates from model 1, the relative coordinates in the shape of angles in revoluting torques (3 angles; ϕ1, ϕ 2 and ϕ3) and distances in prismatic torques (1 distance; s). These relative coordinates become the new independent coordinates (replacing to cartesian independent coordinates from model 1, that they were natural coordinates). It is needed to review if unit vector system from model 1 is enough or not . For this specific case, it was necessary to add 1 additional unit vector to define perfectly angles with their related equations of dot and/or cross product. Constrains must be increased in, at least, 4 equations; one per each new variable. The approval of model 2 has two phases. The first one, same as made with model 1, through kinematic analysis of behaviour with a defined path. During this analysis, it could be obtained from model 2, velocities and accelerations, but they are not needed. They are only interesting movements and finite displacements. Once that the consistence of movements has been checked (second approval), it comes when the behaviour with interpolated trajectories must be kinematically analyzed. Kinematic analysis with interpolated trajectories work with a minimum number of 3 master points. In this case, 3 points have been chosen; starting point, middle point and ending point. The number of interpolations has been of 50 ones in each strecht (each 2 master points there is an strecht), turning into a total of 100 interpolations. The interpolation method used is the cubic splines one with condition of constant acceleration both at the starting and at the ending point. This method creates the independent coordinates of interpolated points of each strecht. The dependent coordinates are achieved solving the non-linear constrain equations with Newton-Rhapson method. The method of cubic splines is very continuous, therefore when it is needed to design a trajectory in which there are at least 2 movements clearly differents, it is required to make it in 2 steps and join them later. That would be the case when any of the motors would keep stopped during the first movement, and another different motor would remain stopped during the second movement (and so on). Once that movement is obtained, they are calculated, also with numerical differenciation formulas, the independent velocities and accelerations. This process is analogous to the one before explained, reminding condition that acceleration when t=0 and t=end are 0. Dependent velocities and accelerations are calculated solving related derivatives of constrain equations. In a third approval of the model it is checked, again, consistence of interpolated movement. Inverse dynamics calculates, for a defined movement –knowing position, velocity and acceleration in each instant of time-, and knowing external forces that act (f.e. weights); which forces must be applied in motors (where there is control) in order to obtain requested movement. In inverse dynamics, each instant of time is independent of the others and it has a position, a velocity, an acceleration and known forces. In this specific case, it is intended to apply, at the moment, only forces due to the weight, though forces of another nature could have been added if it would have been preferred. The positions, velocities and accelerations, come from kinematic calculation. The inertial effect of forces taken into account (weight) is calculated. As final result of the inverse dynamic analysis, the are obtained torques that the 4 motors must apply to repeat requested movement with the forces that were acting. The fourth approval of the model consists on confirming that the achieved movement due to the use of the torques obtained in the inverse dynamics, are in accordance with movements from kinematic analysis (theoretical movement). For this, it is necessary to work with direct dynamics. Direct dynamic is in charge of calculating the movements of robot that results from applying torques at motors and forces at the robot. Therefore, the resultant real movement, as there was no change in any condition of the ones obtained at the inverse dynamics (motor torques and inertial forces due to weight of elements) must be the same than theoretical movement. When these results are achieved, it is considered that robot is ready to work. When a machining external force is introduced and it was not taken into account before during the inverse dynamics, and torques at motors considered are the ones of the inverse dynamics, the real movement obtained is not the same than the theoretical movement. Closed loop control is based on comparing real movement with expected movement and introducing required corrrections to minimize or cancel differences. They are applied gains in the way of corrections for position and/or tolerance to remove those differences. Position error is evaluated as the difference, in each point, between theoretical movemment (calculated in the kinematic analysis) and the real movement achieved for each machining force and for an specific gain. Finally, the position error obtained for each machining force and gains are mapped, giving a chart with the best accuracy that the robot can give for each operation that has been requested and which conditions must be provided.

Biomass and essential oil yields of cornmint (Mentha arvensis L.) grown in the irrigation area of Río Dulce, Santiago del Estero, Argentina.

The aim of this study is to determine the yield and composition of the essential oil of cornmint (Mentha arvensis L.) grown in the irrigation area of Santiago del Estero, Argentina. Field tests were carried out under irrigation conditions, harvesting when 70% flowering was reached (in the summer and at the end of the winter seasons). Essential oil yields were 2% in the first cut and 1.6% in the second cut, respectively, the major constituents of the essential oil being menthol, menthone, isomenthone and menthofuran. In both cases, a high concentration of menthol was obtained, although during the winter the content decreased, increasing the concentration of menthofuran. It is concluded that during the summer a higher yield and better quality of essential oil are produced.

Comparison of linear and non-linear 2D+T registration methods for DE-MRI cardiac perfusion studies

A series of motion compensation algorithms is run on the challenge data including methods that optimize only a linear transformation, or a non-linear transformation, or both – first a linear and then a non-linear transformation. Methods that optimize a linear transformation run an initial segmentation of the area of interest around the left myocardium by means of an independent component analysis (ICA) (ICA-*). Methods that optimize non-linear transformations may run directly on the full images, or after linear registration. Non-linear motion compensation approaches applied include one method that only registers pairs of images in temporal succession (SERIAL), one method that registers all image to one common reference (AllToOne), one method that was designed to exploit quasi-periodicity in free breathing acquired image data and was adapted to also be usable to image data acquired with initial breath-hold (QUASI-P), a method that uses ICA to identify the motion and eliminate it (ICA-SP), and a method that relies on the estimation of a pseudo ground truth (PG) to guide the motion compensation.

A Novel Ground Fault Identification Method for 2 x 5 kV Railway Power Supply Systems

The location of ground faults in railway electric lines in 2 × 5 kV railway power supply systems is a difficult task. In both 1 × 25 kV and transmission power systems it is common practice to use distance protection relays to clear ground faults and localize their positions. However, in the particular case of this 2 × 25 kV system, due to the widespread use of autotransformers, the relation between the distance and the impedance seen by the distance protection relays is not linear and therefore the location is not accurate enough. This paper presents a simple and economical method to identify the subsection between autotransformers and the conductor (catenary or feeder) where the ground fault is happening. This method is based on the comparison of the angle between the current and the voltage of the positive terminal in each autotransformer. Consequently, after the identification of the subsection and the conductor with the ground defect, only the subsection where the ground fault is present will be quickly removed from service, with the minimum effect on rail traffic. This method has been validated through computer simulations and laboratory tests with positive results.

Simultaneous determination of multiclass emerging contaminants in aquatic plants by ultrasound assisted matrix solid phase dispersion and GC-MS

A multiresidue method was developed for the simultaneous determination of 31 emerging contaminants (pharmaceutical compounds, hormones, personal care products, biocides and flame retardants) in aquatic plants. Analytes were extracted by ultrasound assisted-matrix solid phase dispersion (UA-MSPD) and determined by gas chromatography-mass spectrometry after sylilation. The method was validated for different aquatic plants (Typha angustifolia, Arundo donax and Lemna minor) and a semiaquatic cultivated plant (Oryza sativa) with good recoveries at concentrations of 100 and 25 ng g-1 wet weight, ranging from 70 to 120 %, and low method detection limits (0.3 to 2.2 ng g-1 wet weight). A significant difference of the chromatographic response was observed for some compounds in neat solvent versus matrix extracts and therefore quantification was carried out using matrix-matched standards in order to overcome this matrix effect. Aquatic plants taken from rivers located at three Spanish regions were analyzed and the compounds detected were parabens, bisphenol A, benzophenone-3, cyfluthrin and cypermethrin. The levels found ranged from 6 to 25 ng g-1 wet weight except for cypermethrin that was detected at 235 ng g-1 wet weight in Oryza sativa samples.

A synthetic cryIC gene, encoding a Bacillus thuringiensis δ-endotoxin, confers Spodoptera resistance in alfalfa and tobacco

Spodoptera species, representing widespread polyphagous insect pests, are resistant to Bacillus thuringiensis δ-endotoxins used thus far as insecticides in transgenic plants. Here we describe the chemical synthesis of a cryIC gene by a novel template directed ligation–PCR method. This simple and economical method to construct large synthetic genes can be used when routine resynthesis of genes is required. Chemically phosphorylated adjacent oligonucleotides of the gene to be synthesized are assembled and ligated on a single-stranded, partially homologous template derived from a wild-type gene (cryIC in our case) by a thermostable Pfu DNA ligase using repeated cycles of melting, annealing, and ligation. The resulting synthetic DNA strands are selectively amplified by PCR with short specific flanking primers that are complementary only to the new synthetic DNA. Optimized expression of the synthetic cryIC gene in alfalfa and tobacco results in the production of 0.01–0.2% of total soluble proteins as CryIC toxin and provides protection against the Egyptian cotton leafworm (Spodoptera littoralis) and the beet armyworm (Spodoptera exigua). To facilitate selection and breeding of Spodoptera-resistant plants, the cryIC gene was linked to a pat gene, conferring resistance to the herbicide BASTA.

Assessment of clone identity and sequence fidelity for 1189 IMAGE cDNA clones

This report documents the error rate in a commercially distributed subset of the IMAGE Consortium mouse cDNA clone collection. After isolation of plasmid DNA from 1189 bacterial stock cultures, only 62.2% were uncontaminated and contained cDNA inserts that had significant sequence identity to published data for the ordered clones. An agarose gel electrophoresis pre-screening strategy identified 361 stock cultures that appeared to contain two or more plasmid species. Isolation of individual colonies from these stocks demonstrated that 7.1% of the original 1189 stocks contained both a correct and an incorrect plasmid. 5.9% of the original 1189 stocks contained multiple, distinct, incorrect plasmids, indicating the likelihood of multiple contaminating events. While only 739 of the stocks purchased contained the desired cDNA clone, agarose gel pre-screening, colony isolation and similarity searching of dbEST allowed for the identification of an additional 420 clones that would have otherwise been discarded. Considering the high error rate in this subset of the IMAGE cDNA clone set, the use of sequence verified clones for cDNA microarray construction is warranted. When this is not possible, pre-screening non-sequence verified clones with agarose gel electrophoresis provides an inexpensive and efficient method to eliminate contaminated clones from the probe set.

CDP/cut is the DNA-binding subunit of histone gene transcription factor HiNF-D: a mechanism for gene regulation at the G1/S phase cell cycle transition point independent of transcription factor E2F.

Transcription of the genes for the human histone proteins H4, H3, H2A, H2B, and H1 is activated at the G1/S phase transition of the cell cycle. We have previously shown that the promoter complex HiNF-D, which interacts with cell cycle control elements in multiple histone genes, contains the key cell cycle factors cyclin A, CDC2, and a retinoblastoma (pRB) protein-related protein. However, an intrinsic DNA-binding subunit for HiNF-D was not identified. Many genes that are up-regulated at the G1/S phase boundary are controlled by E2F, a transcription factor that associates with cyclin-, cyclin-dependent kinase-, and pRB-related proteins. Using gel-shift immunoassays, DNase I protection, and oligonucleotide competition analyses, we show that the homeodomain protein CDP/cut, not E2F, is the DNA-binding subunit of the HiNF-D complex. The HiNF-D (CDP/cut) complex with the H4 promoter is immunoreactive with antibodies against CDP/cut and pRB but not p107, whereas the CDP/cut complex with a nonhistone promoter (gp91-phox) reacts only with CDP and p107 antibodies. Thus, CDP/cut complexes at different gene promoters can associate with distinct pRB-related proteins. Transient coexpression assays show that CDP/cut modulates H4 promoter activity via the HiNF-D-binding site. Hence, DNA replication-dependent histone H4 genes are regulated by an E2F-independent mechanism involving a complex of CDP/cut with cyclin A/CDC2/ RB-related proteins.

Perspectives on archaeal diversity, thermophily and monophyly from environmental rRNA sequences.

Phylogenetic analysis of ribosomal RNA sequences obtained from uncultivated organisms of a hot spring in Yellowstone National Park reveals several novel groups of Archaea, many of which diverged from the crenarchaeal line of descent prior to previously characterized members of that kingdom. Universal phylogenetic trees constructed with the addition of these sequences indicate monophyly of Archaea, with modest bootstrap support. The data also show a specific relationship between low-temperature marine Archaea and some hot spring Archaea. Two of the environmental sequences are enigmatic: depending upon the data set and analytical method used, these sequences branch deeply within the Crenarchaeota, below the bifurcation between Crenarchaeota and Euryarchaeota, or even as the sister group to Eukaryotes. If additional data confirm either of the latter two placements, then the organisms represented by these ribosomal RNA sequences would merit recognition as a new kingdom, provisionally named "Korarchaeota."

Intermediate hosts of Toxoplasma gondii and food safety:epidemiology, genetics and parasite survival in meat-producing animals in Italy

Toxoplasma gondii is a coccidian parasite with a global distribution. The definitive host is the cat (and other felids). All warm-blooded animals can act as intermediate hosts, including humans. Sexual reproduction (gametogony) takes place in the final host and oocysts are released in the environment, where they then sporulate to become infective. In intermediate hosts the cycle is extra-intestinal and results in the formation of tachyzoites and bradyzoites. Tachyzoites represent the invasive and proliferative stage and on entering a cell it multiplies asexually by endodyogeny. Bradyzoites within tissue cysts are the latent form. T. gondii is a food-borne parasite causing toxoplasmosis, which can occur in both animals and humans. Infection in humans is asymptomatic in more than 80% of cases in Europe and North-America. In the remaining cases patients present fever, cervical lymphadenopathy and other non-specific clinical signs. Nevertheless, toxoplasmosis is life threatening if it occurs in immunocompromised subjects. The main organs involved are brain (toxoplasmic encephalitis), heart (myocarditis), lungs (pulmonary toxoplasmosis), eyes, pancreas and parasite can be isolated from these tissues. Another aspect is congenital toxoplasmosis that may occur in pregnant women and the severity of the consequences depends on the stage of pregnancy when maternal infection occurs. Acute toxoplasmosis in developing foetuses may result in blindness, deformation, mental retardation or even death. The European Food Safety Authority (EFSA), in recent reports on zoonoses, highlighted that an increasing numbers of animals resulted infected with T. gondii in EU (reported by the European Member States for pigs, sheep, goats, hunted wild boar and hunted deer, in 2011 and 2012). In addition, high prevalence values have been detected in cats, cattle and dogs, as well as several other animal species, indicating the wide distribution of the parasite among different animal and wildlife species. The main route of transmission is consumption of food and water contaminated with sporulated oocysts. However, infection through the ingestion of meat contaminated with tissue cysts is frequent. Finally, although less frequent, other food products contaminated with tachyzoites such as milk, may also pose a risk. The importance of this parasite as a risk for human health was recently highlighted by EFSA’s opinion on modernization of meat inspection, where Toxoplasma gondii was identified as a relevant hazard to be addressed in revised meat inspection systems for pigs, sheep, goats, farmed wild boar and farmed deer (Call for proposals -GP/EFSA/BIOHAZ/2013/01). The risk of infection is more highly associated to animals reared outside, also in free-range or organic farms, where biohazard measure are less strict than in large scale, industrial farms. Here, animals are kept under strict biosecurity measures, including barriers, which inhibit access by cats, thus making soil contamination by oocysts nearly impossible. A growing demand by the consumer for organic products, coming from free-range livestock, in respect of animal-welfare, and the desire for the best quality of derived products, have all led to an increase in the farming of free-range animals. The risk of Toxoplasma gondii infection increases when animals have access to environment and the absence of data in Italy, together with need for in depth study of both the prevalence and genotypes of Toxoplasma gondii present in our country were the main reasons for the development of this thesis project. A total of 152 animals have been analyzed, including 21 free-range pigs (Suino Nero race), 24 transhumant Cornigliese sheep, 77 free-range chickens and 21 wild animals. Serology (on meat juice) and identification of T. gondii DNA through PCR was performed on all samples, except for wild animals (no serology). An in-vitro test was also applied with the aim to find an alternative and valid method to bioassay, actually the gold standard. Meat samples were digested and seeded onto Vero cells, checked every day and a RT-PCR protocol was used to determine an eventual increase in the amount of DNA, demonstrating the viability of the parasite. Several samples were alos genetically characterized using a PCR-RFLP protocol to define the major genotypes diffused in the geographical area studied. Within the context of a project promoted by Istituto Zooprofilattico of Pavia and Brescia (Italy), experimentally infected pigs were also analyzed. One of the aims was to verify if the production process of cured “Prosciutto di Parma” is able to kill the parasite. Our contribution included the digestion and seeding of homogenates on Vero cells and applying the Elisa test on meat juice. This thesis project has highlighted widespread diffusion of T. gondii in the geographical area taken into account. Pigs, sheep, chickens and wild animals showed high prevalence of infection. The data obtained with serology were 95.2%, 70.8%, 36.4%, respectively, indicating the spread of the parasite among numerous animal species. For wild animals, the average value of parasite infection determined through PCR was 44.8%. Meat juice serology appears to be a very useful, rapid and sensitive method for screening carcasses at slaughterhouse and for marketing “Toxo-free” meat. The results obtained on fresh pork meat (derived from experimentally infected pigs) before (on serum) and after (on meat juice) slaughter showed a good concordance. The free-range farming put in evidence a marked risk for meat-producing animals and as a consequence also for the consumer. Genotyping revealed the diffusion of Type-II and in a lower percentage of Type-III. In pigs is predominant the Type-II profile, while in wildlife is more diffused a Type-III and mixed profiles (mainly Type-II/III). The mixed genotypes (Type-II/III) could be explained by the presence of mixed infections. Free-range farming and the contact with wildlife could facilitate the spread of the parasite and the generation of new and atypical strains, with unknown consequences on human health. The curing process employed in this study appears to produce hams that do not pose a serious concern to human health and therefore could be marketed and consumed without significant health risk. Little is known about the diffusion and genotypes of T. gondii in wild animals; further studies on the way in which new and mixed genotypes may be introduced into the domestic cycle should be very interesting, also with the use of NGS techniques, more rapid and sensitive than PCR-RFLP. Furthermore wildlife can become a valuable indicator of environmental contamination with T. gondii oocysts. Other future perspectives regarding pigs include the expansion of the number of free-range animals and farms and for Cornigliese sheep the evaluation of other food products as raw milk and cheeses. It should be interesting to proceed with the validation of an ELISA test for infection in chickens, using both serum and meat juice on a larger number of animals and the same should be done also for wildlife (at the moment no ELISA tests are available and MAT is the reference method for them). Results related to Parma ham do not suggest a concerning risk for consumers. However, further studies are needed to complete the risk assessment and the analysis of other products cured using technological processes other than those investigated in the present study. For example, it could be interesting to analyze products such as salami, produced with pig meat all over the Italian country, with very different recipes, also in domestic and rural contexts, characterized by a very short period of curing (1 to 6 months). Toxoplasma gondii is one of the most diffuse food-borne parasites globally. Public health safety, improved animal production and protection of endangered livestock species are all important goals of research into reliable diagnostic tools for this infection. Future studies into the epidemiology, parasite survival and genotypes of T. gondii in meat producing animals should continue to be a research priority.

Real time optimization in chemical process: evaluation of strategies, improvements and industrial application.

The increasing economic competition drives the industry to implement tools that improve their processes efficiencies. The process automation is one of these tools, and the Real Time Optimization (RTO) is an automation methodology that considers economic aspects to update the process control in accordance with market prices and disturbances. Basically, RTO uses a steady-state phenomenological model to predict the process behavior, and then, optimizes an economic objective function subject to this model. Although largely implemented in industry, there is not a general agreement about the benefits of implementing RTO due to some limitations discussed in the present work: structural plant/model mismatch, identifiability issues and low frequency of set points update. Some alternative RTO approaches have been proposed in literature to handle the problem of structural plant/model mismatch. However, there is not a sensible comparison evaluating the scope and limitations of these RTO approaches under different aspects. For this reason, the classical two-step method is compared to more recently derivative-based methods (Modifier Adaptation, Integrated System Optimization and Parameter estimation, and Sufficient Conditions of Feasibility and Optimality) using a Monte Carlo methodology. The results of this comparison show that the classical RTO method is consistent, providing a model flexible enough to represent the process topology, a parameter estimation method appropriate to handle measurement noise characteristics and a method to improve the sample information quality. At each iteration, the RTO methodology updates some key parameter of the model, where it is possible to observe identifiability issues caused by lack of measurements and measurement noise, resulting in bad prediction ability. Therefore, four different parameter estimation approaches (Rotational Discrimination, Automatic Selection and Parameter estimation, Reparametrization via Differential Geometry and classical nonlinear Least Square) are evaluated with respect to their prediction accuracy, robustness and speed. The results show that the Rotational Discrimination method is the most suitable to be implemented in a RTO framework, since it requires less a priori information, it is simple to be implemented and avoid the overfitting caused by the Least Square method. The third RTO drawback discussed in the present thesis is the low frequency of set points update, this problem increases the period in which the process operates at suboptimum conditions. An alternative to handle this problem is proposed in this thesis, by integrating the classic RTO and Self-Optimizing control (SOC) using a new Model Predictive Control strategy. The new approach demonstrates that it is possible to reduce the problem of low frequency of set points updates, improving the economic performance. Finally, the practical aspects of the RTO implementation are carried out in an industrial case study, a Vapor Recompression Distillation (VRD) process located in Paulínea refinery from Petrobras. The conclusions of this study suggest that the model parameters are successfully estimated by the Rotational Discrimination method; the RTO is able to improve the process profit in about 3%, equivalent to 2 million dollars per year; and the integration of SOC and RTO may be an interesting control alternative for the VRD process.

Combining visual features and Growing Neural Gas networks for robotic 3D SLAM

The use of 3D data in mobile robotics provides valuable information about the robot’s environment. Traditionally, stereo cameras have been used as a low-cost 3D sensor. However, the lack of precision and texture for some surfaces suggests that the use of other 3D sensors could be more suitable. In this work, we examine the use of two sensors: an infrared SR4000 and a Kinect camera. We use a combination of 3D data obtained by these cameras, along with features obtained from 2D images acquired from these cameras, using a Growing Neural Gas (GNG) network applied to the 3D data. The goal is to obtain a robust egomotion technique. The GNG network is used to reduce the camera error. To calculate the egomotion, we test two methods for 3D registration. One is based on an iterative closest points algorithm, and the other employs random sample consensus. Finally, a simultaneous localization and mapping method is applied to the complete sequence to reduce the global error. The error from each sensor and the mapping results from the proposed method are examined.

Indicators of success in the dietary management of overweight and obesity: weight, body fat loss and quality

Concepts: %WL: Percentage of weight loss; %FL: Percentage of fat loss. Objective: evaluate which unit of measurement for weight loss could determine the success or failure of dietary treatment for overweight and obesity. Method: 4,625 consultations carried out on 616 patients in the southeast of Spain from 2006 to 2012. All of the patients were over 25 years of age and suffered from overweight or obesity. The consultations were carried out every fortnight, using the Mediterranean or low-calorie diet. The patients were divided into four groups according to their %WL and %FL. Results: most of the sample consisted of: women; participants between 25-45 years of age; attended consultations for over a month and a half; obese. 80% of the patients obtained a %FL ≥ 5% (15.5 ± 12.8). The groups with a higher %FL obtained significant differences in weight loss (22.6 vs 11.2%, p = 0.000). The multinomial analysis shows significant differences between the groups with the highest %FL and the lowest %WL and %FL: sex (p = 0.006 vs p = 0.005), BMI (p = 0.010 vs p = 0.003) and attendance (p = 0.000 vs p = 0.000). Conclusion: the patients who lost < 5% of fat had higher initial parameters (percentage of weight and fat); most of the sample lost ≥ 5% of fat. This means that the method of personalised dietary treatment results in a high fat loss; fat is an indicator of the quality loss obtained. Recommendations: use the measurement of fat as a complementary unit of measurement to weight loss; establish a limit of 5% to evaluate such loss; and increase this type of research in any method of weight loss.

A simple method to predict elastic settlements in foundations resting on two soils of differing deformability

This paper shows the analysis results obtained from more than 200 finite element method (FEM) models used to calculate the settlement of a foundation resting on two soils of differing deformability. The analysis considers such different parameters as the foundation geometry, the percentage of each soil in contact with the foundation base and the ratio of the soils’ elastic moduli. From the described analysis, it is concluded that the maximum settlement of the foundation, calculated by assuming that the foundation is completely resting on the most deformable soil, can be correlated with the settlement calculated by FEM models through a correction coefficient named “settlement reduction factor” (α). As a consequence, a novel expression is proposed for calculating the real settlement of a foundation resting on two soils of different deformability with maximum errors lower than 1.57%, as demonstrated by the statistical analysis carried out. A guide for the application of the proposed simple method is also explained in the paper. Finally, the proposed methodology has been validated using settlement data from an instrumented foundation, indicating that this is a simple, reliable and quick method which allows the computation of the maximum elastic settlement of a raft foundation, evaluates its suitability and optimises its selection process.

Bullying Victimization and Perpetration Among Adolescent Sport Teammates

Purpose: Bullying is a specific pattern of repeated victimization explored with great frequency in school-based literature, but receiving little attention within sport. The current study explored the prevalence of bullying in sport, and examined whether bullying experiences were associated with perceptions about relationships with peers and coaches. Method: Adolescent sport team members (n = 359, 64% female) with an average age of 14.47 years (SD = 1.34) completed a pen-and-paper or online questionnaire assessing how frequently they perpetrated or were victimized by bullying during school and sport generally, as well as recent experiences with 16 bullying behaviors on their sport team. Participants also reported on relationships with their coach and teammates. Results: Bullying was less prevalent in sport compared with school, and occurred at a relatively low frequency overall. However, by identifying participants who reported experiencing one or more act of bullying on their team recently, results revealed that those victimized through bullying reported weaker connections with peers, whereas those perpetrating bullying only reported weaker coach relationships. Conclusion: With the underlying message that bullying may occur in adolescent sport through negative teammate interactions, sport researchers should build upon these findings to develop approaches to mitigate peer victimization in sport.