Mathematical Model and Design Optimization of Reduction Gear for Electric Agricultural Vehicle

Pandu Sandi Pratama,변재영,Eun-Suk Lee,Dimas Harris Sean Keefe,Ji-Ung Yang,정성원,최원식 한국산업융합학회 2019 한국산업융합학회 논문집 Vol.22 No.1

In electric agricultural machine the gearbox is used to increase torque and lower the output speed of the motor shaft. The gearbox consists of several shafts, helical gears and spur gears works in series. Optimization plays an important role in gear design as reducing the weight or volume of a gear set will increase its service life and improve the bearing capacity. In this paper the basic design parameters for gear like shaft diameter and face width are considered as the input variables. The bending stress and material volume is considered as the objective function. ANSYS was used to investigate the bending stress when the variable was changed. Artificial Neural Network (ANN) was used to obtain the mathematical model of the system based on the bending stress behaviour. The ANN was used since the output system is nonlinear. The Genetic Algorithm (GA) technique of optimization is used to obtain the optimized values of shaft diameter and face width on the pinion based on the ANN mathematical model and the results are compared as that obtained using the traditional method. The ANN and GA were performed using MATLAB. The simulation results were shown that the proposed algorithm was successfully calculated the value of shaft diameter and face width to obtain the minimal bending stress and material volume of the gearbox.

Mathematical Model and Design Optimization of Reduction Gear for Electric Agricultural Vehicle

Pratama, Pandu Sandi,Byun, Jae-Young,Lee, Eun-Suk,Keefe, Dimas Harris Sean,Yang, Ji-Ung,Chung, Song-Won,Choi, Won-Sik The Korean Society of Industry Convergence 2019 한국산업융합학회 논문집 Vol.22 No.1

In electric agricultural machine the gearbox is used to increase torque and lower the output speed of the motor shaft. The gearbox consists of several shafts, helical gears and spur gears works in series. Optimization plays an important role in gear design as reducing the weight or volume of a gear set will increase its service life and improve the bearing capacity. In this paper the basic design parameters for gear like shaft diameter and face width are considered as the input variables. The bending stress and material volume is considered as the objective function. ANSYS was used to investigate the bending stress when the variable was changed. Artificial Neural Network (ANN) was used to obtain the mathematical model of the system based on the bending stress behaviour. The ANN was used since the output system is nonlinear. The Genetic Algorithm (GA)　technique of optimization is used to obtain the optimized values of shaft diameter and face width on the pinion based on the ANN mathematical model and the results are compared as that obtained using the traditional method. The ANN and GA were performed using MATLAB. The simulation results were shown that the proposed algorithm was successfully calculated the value of shaft diameter and face width to obtain the minimal bending stress and material volume of the gearbox.

Thermal Analysis of Cooling System In Crusher Machine for Dry Soybean Powder Production

( Pandu Sandi Pratama ),( Supeno Destiani ),( Jaeyoung Byun ),( Wonsik Choi ) 한국농업기계학회 2018 한국농업기계학회 학술발표논문집 Vol.23 No.1

Soybean powder is finely grounded derived soybeans product. It is a rich source of proteins, as well as iron, B vitamins and calcium. Soybean powder was used as main ingredient of whole beans tofu, soy milk, and it is added to a variety of products such as cereals, pudding, yogurt, cottage cheese, shakes and casseroles to add a pleasant texture and flavor. To make a high quality soybean powder, soybeans was crushed into small size using crusher machine. During crusher operation, heat was generated through friction and contact between soybeans and cutting tooth. To prevent oil extracted from soybeans, the crusher temperature should be kept under 60°C. Therefore, cooling system is needed. The purpose of this research is to analyze the temperature variation occurred during crusher machine operation and to understand the effect of cooling system to the crusher machine. Moreover, the analysis was used to predict the temperature behavior and clarify the effectiveness of the proposed cooling system. The thermal analysis simulation was done using ANSYS Fluent 15. Firstly, 3D model of crusher housing was created. The model then simplified and the geometry model was obtained. In addition, the mesh of the model was generated. The materials properties were defined and the boundary condition was determined. Finally, problem was solved, visualized and the results was shown. The normal cumulative contact energy was obtained from cutting simulation based on discrete element method. This energy was dissipated as heat that increases the temperature of crusher machine. In this simulation, the initial temperature of inner side of housing is 70°C. The environment temperature is 28°C. The water cooler temperature was varied from 5°C to 20°C. The final temperature after 10 second was observed. The simulation result shows that the temperature on the middle of housing after 10 second using 5°C cooler is less than 30°C, using 10°C cooler is less than 40°C, using 15°C cooler is less than 50°C, and using 20 °C cooler is less than 60°C as a result. It was found that optimal temperature of water cooler is between 5 °C and 10°C. This work helps the soybeans crusher machine developer make a better product at the early design stage with lower cost and faster development time.

Path Planning Algorithm to Minimize an Overlapped Path and Turning Number for an Underwater Mining Robot

Pandu Sandi Pratama,Jin-Wook Kim,Hak-Kyeong Kim,Suk-Min Yoon,Tae-Kyeong Yeu,Sup Hong,Sea-June Oh,Sang-Bong Kim 제어로봇시스템학회 2015 제어로봇시스템학회 국제학술대회 논문집 Vol.2015 No.10

This paper considers the problem of minimizing an overlapped path and turning number to cover an uneven terrain ocean floor for an underwater mining robot. The purpose of this algorithm is to generate the shortest path to travel through the entire given bathymetric map with minimum overlapping path and minimum turning number based on binary map, cell decomposition, minimal sum of altitude method and depth-first search algorithm. To do this task, the following tasks are performed. Firstly, a binary map is obtained by applying threshold to the high slope regions of the ocean floor. Secondly, Morse cell decomposition method is applied to divide the whole area of work space into cells in the vertical and horizontal directions. To minimize the turning number, a minimal sum of altitude method is applied to the combination of vertical and horizontal cell decompositions. Finally, the coverage order is calculated by depth-first search algorithm. The simulation result shows that the proposed method generates the short coverage path with minimum overlapping, minimum turning number and fast coverage time compared to vertical and horizontal cell decomposition methods.

Modal and Stress Analysis of Spur Gear in DC Motor Gearhead using Finite Element Model

( Pandu Sandi Pratama ),( Destiani Supeno ),( Seongwon Jeong ),( Cunsook Park ),( Jihee Woo ),( Eunsook Lee ),( Woojin Yoon ),( Wonsik Choi ) 한국농업기계학회 2017 한국농업기계학회 학술발표논문집 Vol.22 No.1

In electric agricultural machine the gearhead is needed to convert the high speed low torque rotation motion generated by DC motor to lower speed high torque motion used by the vehicle. The gearhead consist of several spur gears works as reduction gears. Spur gear have straight tooth and are parallel to the axis of the wheel. Spur gears are the most easily visualized gears that transmit motion between two parallel shafts and easy to produce. The modeling and simulation of spur gears in DC motor gearhead is important to predict the actual motion behavior. A pair of spur gear tooth in action is generally subjected to two types of cyclic stress: contact stress and bending stress including bending fatigue. The stress may not attain their maximum values at the same point of contact fatigue. These types of failure can be minimized by analysis of the problem during the design stage and creating proper tooth surface profile with proper manufacturing methods. To improve its life expectation in this study modal and stress analysis of gearhead is simulated using ansys work bench software based on finite element method (FEM). The modal analysis was done to understand gearhead deformation behaviour when vibration occurs. FEM static stress analysis is also simulated on gearhead to simulate the gear teeth bending stress and contact stress behavior. This methodology serves as an approach for gearhead design evaluation, and the study of gear stress behavior in DC motor gearhead which is needed in the small workshop scale industries.

Trajectory Tracking and Fault Detection Algorithm for Automatic Guided Vehicle Based on Multiple Positioning Modules

Pandu Sandi Pratama,Amruta Vinod Gulakari,Yuhanes Dedy Setiawan,김대환,김학경,김상봉 제어·로봇·시스템학회 2016 International Journal of Control, Automation, and Vol.14 No.2

This paper presents an implementation and experimental validation of trajectory tracking and fault detectionalgorithm for sensors and actuators of Automatic Guided Vehicle (AGV) system based on multiple positioningmodules. Firstly, the system description and the mathematical modeling of the differential drive AGV system aredescribed. Secondly, a trajectory tracking controller based on the backstepping method is proposed to track thegiven trajectory. Thirdly, a fault detection algorithm based on the multiple positioning modules is proposed. TheAGV uses encoders, laser scanner, and laser navigation system to obtain the position information. To understandthe characteristics of each positioning module, their modeling are explained. The fault detection method uses two ormore positioning systems and compares them using Extended Kalman Filter (EKF) to detect an unexpected deviationeffected by fault. The pairwise differences between the estimated positions obtained from the sensors are calledas residue. When the faults occur, the residue value is greater than the threshold value. Fault isolation is obtainedby examining the biggest residue. Finally, to demonstrate the capability of the proposed algorithm, it is appliedto the differential drive AGV system. The simulation and experimental results show that the proposed algorithmsuccessfully detects the faults when the faults occur.

The Analysis of Frame Structure in Farm Vehicle

Pandu Sandi Pratama(프라타마 판두 산디),Destiani Supeno(수페노 데스티아니),Ji-Hee Woo(우지희),Eun-Sook Lee(이은숙),Cun-Sook Park(박춘숙),Woo-Jin Yoon(윤우진),Sung-Won Chung(정성원),Won-Sik Choi(최원식) 한국산업융합학회 2017 한국산업융합학회 논문집 Vol.20 No.1

An agriculture machines are subjected to different loads conditions. Due to this loads variations there will be certain deformations and stress which affect the performance of the electric vehicle in adverse manner. The purpose of this paper is to analyze the total deformation and stress of the electric farm vehicle middle frame based on the finite element method. The proposed electric farm vehicle has lifting and dumping capability. Therefore, in this research four operational condition such as normal condition, dumping condition, lifting condition, and lifting-dumping condition was analyzed. In this research, the design for whole frame structure is elaborated. According to the mechanical characteristics of the frame, materials are selected and manufacturability requirements are limited. Based on ANSYS 15 software, the finite element model of electric farm vehicle is established to carry out static analysis on full-loaded conditions. The simulation results shows that the proposed design meet the strength requirements and displacement requirements. The maximum deformation 0.53611 mm and maximum stress 30.163 MPa occurred at lifting-dumping condition.

Design Optimization of DC Motor Gearbox for Electric Agricultural Vehicle Based on Genetic Algorithm

( Pandu Sandi Pratama ),( Destiani Supeno ),( Cunsook Park ),( Jihee Woo ),( Eunsuk Lee ),( Wonsik Choi ) 한국농업기계학회 2017 한국농업기계학회 학술발표논문집 Vol.22 No.2

In electric agricultural machine the gearbox is used to increase torque and lower the output speed of the motor shaft. The gearbox consist of several shafts, helical gears and spur gears works in series. Optimization plays an important role in gear design as reducing the weight or volume of a gear set will increase its service life and improve the bearing capacity. In this paper the basic design parameters for gear like shaft diameter and face width are considered as the input variables. The bending stress and material volume is considered as the objective function. ANSYS was used to investigates the bending stress when the variable was changed. Artificial Neural Network (ANN) is used to obtained the mathematical model of the system based on the bending stress behaviour. The ANN was used since the output system is nonlinear. The Genetic Algorithm (GA) technique of optimization is used to obtain the optimized values of shaft diameter and face width on the pinion based on the ANN mathematical model and the results are compared as that obtained using the traditional method. The ANN and GA was perform using MATLAB. The simulation results was shown that the proposed algorithm was successfully calculate the value of shaft diameter and face width to obtain the minimal bending stress and material volume of the gearbox.

Positioning and Obstacle Avoidance of Automatic Guided Vehicle in Partially Known Environment

김상봉,Pandu Sandi Pratama,Trong-Hai Nguyen,김대환,김학경 제어·로봇·시스템학회 2016 International Journal of Control, Automation, and Vol.14 No.6

This paper presents positioning and obstacle avoidance of Automatic Guidance Vehicle (AGV) in partiallyknown environment. To do this task, the followings are done. Firstly, the system configuration of AGV isdescribed. Secondly, mathematical kinematic modeling of the AGV is presented to understand its characteristicsand behavior. Thirdly, the Simultaneous Localization and Mapping (SLAM) algorithm based on the laser measurementsystem and encoders is proposed. The encoders are used for detecting the motion state of the AGV. In aslippery environment and a high speed AGV condition, encoder positioning method generates big error. Therefore,Extended Kalman Filter (EKF) is used to get the best position estimation of AGV by combining the encoder positioningresult and landmark positions obtained from the laser scanner. Fourthly, to achieve the desired coordinate,D* Lite algorithm is used to generate a path from the start point to the goal point for AGV and to avoid unknownobstacles using information obtained from laser scanner. A backstepping controller based on Lyapunov stability isproposed for tracking the desired path generated by D* Lite algorithm. Finally, the effectiveness of the proposed algorithmsand controller are verified by using experiment. The experimental results show that the AGV successfullyreaches the goal point with an acceptable small error.

Tribology Characteristics of Hexagonal Shape Surface Textured Reduction Gear in Electric Agricultural Vehicle

최원식,Pandu Sandi Pratama,변재영,권순홍,권순구,박종민,김종순,정성원 한국산업융합학회 2019 한국산업융합학회 논문집 Vol.22 No.1

An experimental study was conducted on the wear and friction responses in sliding tests of a micro-textured surface on laser pattern (LP) steel as reduction gear material in electric guided vehicle. In this research, the friction characteristics of laser pattern steel under different micro texture density conditions were investigated. The friction tests were carried out at sliding speeds of 0.06 m/s to 0.34 m/s and at normal loads of 2 to 10 N. Photolithography method was used to create the dimples for surface texturing purpose. Four different specimens having different dimple densities of 10%, 12.5%, 15%, and 20% were observed respectively.In this research, friction conditions as shown in Stribeck curve were investigated. Furthermore, the microscopic surface was observed using scanning electron microscope. It was found that the dimple density had a significant role on the friction characteristics of laser pattern steel conditioned as reduction gear material in an agricultural vehicle. The duty number showed that the friction condition was hydrodynamic regime. The best performance was obtained from 12.5% dimple density with lowest friction coefficient achieved at 0.018771 under the velocity of 0.34 m/s and 10N load. An experimental study was conducted on the wear and friction responses in sliding tests of a micro-textured surface on laser pattern (LP) steel as reduction gear material in electric guided vehicle. In this research, the friction characteristics of laser pattern steel under different micro texture density conditions were investigated. The friction tests were carried out at sliding speeds of 0.06 m/s to 0.34 m/s and at normal loads of 2 to 10 N. Photolithography method was used to create the dimples for surface texturing purpose. Four different specimens having different dimple densities of 10%, 12.5%, 15%, and 20% were observed respectively.In this research, friction conditions as shown in Stribeck curve were investigated. Furthermore, the microscopic surface was observed using scanning electron microscope. It was found that the dimple density had a significant role on the friction characteristics of laser pattern steel conditioned as reduction gear material in an agricultural vehicle. The duty number showed that the friction condition was hydrodynamic regime. The best performance was obtained from 12.5% dimple density with lowest friction coefficient achieved at 0.018771 under the velocity of 0.34 m/s and 10N load.