Institute of Fundamental Technological Research

Hou J., Xu D., Jankowski Ł., Structural modal parameter identification with the Power-Exponential window function, MECHANICAL SYSTEMS AND SIGNAL PROCESSING, ISSN: 0888-3270, DOI: 10.1016/j.ymssp.2024.111771, Vol.222, pp.111771-1-111771-23, 2025

Abstract:
In view of the demand for accurate modal identification, and based on the characteristics of free vibration response, this paper introduces a new window function for Fourier Transform called the Power–Exponential window. The Power–Exponential window addresses the characteristics of free vibration response. It significantly enhances the accuracy of modal identification by improving the spectral properties of structural response. The proposed window function consists of exponential and power terms. This study focuses on the additional damping and frequency-domain differentiation introduced by the Power–Exponential window function. The exponential term weakens the boundary effect related to the time-domain truncation and suppresses the spectral leakage. Moreover, it can be interpreted in clear physical terms as providing additional damping to the signal. The power term in the window function corresponds to frequency domain differentiation, and it alleviates the spectral broadening that arises due to the additional damping. Furthermore, the analytical expression for the response spectrum confirms that the Power–Exponential window not only aligns the peak response frequency with the damped natural frequency but also establishes an explicit linear relationship between the actual structural damping ratio and the identification result from the half power bandwidth method. Both contribute to an improved accuracy and usability of certain frequency-domain modal identification methods. The influence of the Power–Exponential window parameters on modal parameter identification is analyzed, and the optimal selection principle and suggested parameter values are proposed. Finally, numerical simulations and an experimental frame model test are conducted to verify the accuracy and validity of modal parameter identification based on the Power–Exponential window.

Keywords:
Modal identification, Window function, Frequency domain, Spectrum leakage, Fourier Transform (FT)

Będkowski J., End to end navigation stack for nuclear power plant inspection with mobile robot, SoftwareX, ISSN: 2352-7110, DOI: 10.1016/j.softx.2024.101750, Vol.26, pp.101750-1-101750-11, 2024

Abstract:
This paper describes a novel approach for nuclear facility inspection with novel automated 3D mapping system as an open source end to end navigation stack available at https://github.com/JanuszBedkowski/msas_enrich_2023. Incidents such as Fukushima, Majak or Chernobyl as well as the decommissioning and dismantling of old nuclear facilities (e.g. Sellafield, Asse or Murmansk) are showing great importance of the robotic technology. Rapid inspection requires reliable, accurate, precise and repeatable simultaneous localization and mapping. Proposed SLAM approach uses only non repetitive scanning pattern Lidar (Livox Mid360) and integrated inertial measurement unit. The novelty is based on feature less single core SLAM implementation. It fuses Normal Distributions Transform and motion model for simultaneous map building and current pose estimation. Motion model bounds an optimization result, thus it is stable and reliable. It requires less than 10 ms for pose update, trajectory tracking and emergency behavior. This method is a candidate for real time application since a calculation time is bounded and it uses only one core of Intel Celeron CPU G1840 2.8 GHz. It was tested both (i) during EnRicH 2023 https://enrich.european-robotics.eu/ — the European robotics hackathon, (ii) in laboratory conditions. This open source project provides also software of base station, thus it is first end to end solution available in literature.

Keywords:
Navigation, Inspection, Mobile robot, SLAM, Localization

Tauzowski P., Błachowski B.D., Zawidzka E., Zawidzki M., MorphoGen: Topology optimization software for Extremely Modular Systems, SoftwareX, ISSN: 2352-7110, DOI: 10.1016/j.softx.2024.101797, Vol.27, pp.1-10, 2024

Abstract:
This paper introduces MorphoGen — an integrated reliability-based topology optimization and nonlinear finite element analysis system for 2D and 3D domains. The system’s key innovation is its seamless prototyping of scientific formulations for computational problems in topology optimization. Its layered and object-oriented architecture, based on the template method design pattern, facilitates effortless modifications of algorithms and the introduction of new types of finite elements, materials, and analyses. MorphoGen also offers flexible handling of objective functions and constraints during topological optimization, enhancing its adaptability. It empowers researchers and practitioners to explore a wide range of engineering challenges, fostering a deeper understanding of complex structural behaviors and efficient design solutions. There are many topology optimization software and open source codes, especially based on the classical SIMP method. Unlike these codes our package is freely distributed among users and since it is distributed on the MIT licence, which allows for its easy modification depending on the particular needs of the users. For this purpose, we use the topology optimization algorithm proposed for the first time in our previous paper (Blachowski et al., 2020). The algorithm is based on a fully stress design-based optimality criteria and can be applied for topology optimization of either linearly elastic and elastoplastic structures. Additionally, the novelty of the proposed system is related to its ability of solving optimal topology under various constraints such as displacement, stresses and fatigue in both deterministic and probabilistic cases. Another application are modular structures, which reduce design complexity and manufacturing costs as well as rapid reconfiguration. However, in the realm of structural optimization, modular systems are more challenging due to various: modes of operation of the modules and the stresses configurations. Moreover, this area of research is dramatically less explored. Thus the effectiveness of MorphoGen for structural engineering is demonstrated with examples of topological shape optimization of two Extremely Modular Systems: a planar robotic manipulator Arm-Z and spatial free-form ramp Truss-Z.

Keywords:
Stress Constrained Topology Optimizatio,Extremely Modular System,Object-oriented software architecture,MATLAB-based array programming,First Order Reliability Analysis

Orłowska-Gałęzia A. M., Graczykowski C., Pawłowski P. K., Ruta R., Rimasauskas M., Kuncius T., Majewska K., Mieloszyk M., Characterization of thermal expansion in additively manufactured continuous carbon fibre reinforced polymer composites using fibre Bragg grating sensors, MEASUREMENT, ISSN: 0263-2241, DOI: 10.1016/j.measurement.2024.114147, Vol.227, pp.114147-1-114147-15, 2024

Abstract:
This study investigates thermal strains in fibre reinforced polymeric samples manufactured using a modified Fused Deposition Modelling (FDM) method. The investigated material was a composition of polylactic acid (PLA) resin and continuous carbon fibres. Each test sample was equipped with two Bragg grating (FBG) sensors, one embedded inside and the other bonded to the surface. Both sensors monitored temperature-induced deformations
during the conditioning of the specimens in a thermal chamber. Multiscale, analytical and finite element method based models were implemented to quantify the temperature deformations. Research has revealed that in investigated samples, bending occurs due to thermal loading. This can result in an inaccurate estimation of the coefficient of thermal expansion when relying on surface deformation measurements. A proposed solution involves the use of one FBG sensor embedded inside the specimen or two FBG sensors placed symmetrically, capable of measuring axial thermal deformation and averaging the effects associated
with bending.

Keywords:
Continuous Carbon Fibre Reinforced Polymer Composites, Fibre Bragg gratings, Thermal expansion , Additive manufacturing, Multiscale modelling

Jankowski Ł., Pisarski D., Konowrocki R., Popławski B., Faraj R., Efficient real-time positioning using Bayesian analysis and magnetic anomaly field, MEASUREMENT, ISSN: 0263-2241, DOI: 10.1016/j.measurement.2024.114738, Vol.233, pp.114738-1-114738-13, 2024

Abstract:
Despite the prevalence of well-established and explored navigation systems, alternative localization methods are currently the focus of intensive research. This interest is driven by geopolitical challenges and increasingly sophisticated applications of mobile robots and uncrewed aerial vehicles. This study investigates the problem of real-time positioning in GPS-denied environments. Based on the mapped magnetic anomaly field and using Bayesian formalism for data fusion, the localization obtained from embedded sensors is corrected to reduce cumulative errors. The proposed method has minimal computational cost and a minimal number of tunable parameters. The paper introduces it and demonstrates its effectiveness in a laboratory study. Experimental tests, using a system equipped with an Inertial Measurement Unit, demonstrated a significant reduction in localization uncertainty. The improvement was especially notable in areas with large, smooth variations in the magnetic field. Finally, the accuracy of the method is analyzed, and its performance is compared to a particle filter.

Keywords:
Sensor fusion, Bayesian inference, Real-time positioning, Magnetic anomaly, Intelligent navigation system

Pisarski D., Jankowski Ł., Decentralized modular semi-active controller for suppression of vibrations and energy harvesting, JOURNAL OF SOUND AND VIBRATION, ISSN: 0022-460X, DOI: 10.1016/j.jsv.2024.118339, Vol.577, pp.118339-1-118339-20, 2024

Abstract:
The study investigates the problem of decentralized semi-active control of free vibration. The control scheme is designed for implementation in a modular controller architecture, where a collection of subcontrollers is employed, with each subcontroller being associated with a subsystem that represents a component of the vibrating structure. Each subcontroller uses state feedback from adjacent subsystem sensors to perform vibration suppression and energy harvesting using a switching control law. Furthermore, the assumption is made that neighbouring subcontrollers exchange information collaboratively to estimate the effects of coupling forces, achieving control efficiency comparable to that of a centralized approach. The effectiveness of the proposed approach is demonstrated on a modular suspension platform equipped with semi-active dampers and electromagnetic energy harvesters. The approach is evaluated under various free vibration scenarios, encompassing faulty measurement conditions, and is compared to passive and heuristic state-feedback control strategies. The results confirm that the proposed method attains a superior control performance, independent of the degree of decentralization in the adopted controller architecture, rendering it a viable solution for addressing large-scale semi-active control problems.

Keywords:
Vibration control,Energy harvesting,Adaptive control,Semi-active control,Decentralized controller

Tauzowski P., Błachowski B., Lógó J., Optimal topologies considering fatigue with reliability constraint, Advances in Engineering Software, ISSN: 0965-9978, DOI: 10.1016/j.advengsoft.2023.103590, Vol.189, pp.1-12, 2024

Abstract:
This paper addresses a challenging engineering problem that combines stress-limited topology optimization, reliability analysis, and plasticity-based low-cycle fatigue. Each of these issues represents a complex problem on its own, necessitating significant computational effort. In this study, we propose a novel approach that integrates safety assessment into the topology optimization process while considering the number of cycles for low-cycle fatigue. Our method employs a linear approximation of the performance function for safety control, incorporating the number of failure cycles within a complex, multi-level load program. The methodology is validated through real experiments, using a finite element model with cubic shape functions that yield nearly identical results between numerical and experimental outcomes in the case of fatigue-resistant design for a bi-axially tensioned structural joint.

Keywords:
Topology optimization, stress constraints, Reliability analysis, low-cycle fatigue, fatigueplasticity

Tauzowski P., Błachowski B., Lógó J., Computational framework for a family of methods based on stress-constrained topology optimization, COMPUTERS AND STRUCTURES, ISSN: 0045-7949, DOI: 10.1016/j.compstruc.2024.107493, Vol.303, pp.1-14, 2024

Abstract:
This study presents a general computational framework for topology optimization under constraints related to various engineering design problems, including: reliability analysis, low-cycle fatigue assessment, and stress limited analysis. Such a framework aims to facilitate comprehensive engineering design considerations by incorporating traditional constraints such as displacement and stress alongside probabilistic assessments of fatigue failure and the complex behaviors exhibited by structures made of elastoplastic material. The framework's amalgamation of diverse analytical components offers engineers a versatile toolkit to address intricate design challenges. Notably, the inclusion of reliability analysis introduces a probabilistic perspective, transforming conventional design constraints into random parameters, thereby enhancing the robustness of the design process.

Key to the framework's efficacy is its implementation using MATLAB mathematical computing software, leveraging the platform's efficient code execution and object-oriented programming paradigm. This choice ensures an intuitive and potent environment for designers and researchers, facilitating seamless adaptation across various engineering applications. Additionally, the proposed previously by the Authors algorithm for the topology optimization is extended by adaptive strategy allowing for efficient adjustment of an amount of material removed at individual optimization step.

The presented framework is offering a comprehensive and integrated approach to address multifaceted design challenges while enhancing design robustness and efficiency.

Keywords:
Topology optimization, Stress constraints, First order reliability analysis, Low-cycle fatigue, Plasticity

Kowalczyk-Gajewska K., Maj M., Bieniek K., Majewski M., Opiela K.C., Zieliński T.G., Cubic elasticity of porous materials produced by additive manufacturing: experimental analyses, numerical and mean-field modelling, ARCHIVES OF CIVIL AND MECHANICAL ENGINEERING, ISSN: 1644-9665, DOI: 10.1007/s43452-023-00843-z, Vol.24, pp.34-1-34-22, 2024

Abstract:
Although the elastic properties of porous materials depend mainly on the volume fraction of pores, the details of pore distribution within the material representative volume are also important and may be the subject of optimisation. To study their effect, experimental analyses were performed on samples made of a polymer material with a predefined distribution of spherical voids, but with various porosities due to different pore sizes. Three types of pore distribution with cubic symmetry were considered and the results of experimental analyses were confronted with mean-field estimates and numerical calculations. The mean-field ‘cluster’ model is used in which the mutual interactions between each of the two pores in the predefined volume are considered. As a result, the geometry of pore distribution is reflected in the anisotropic effective properties. The samples were produced using a 3D printing technique and tested in the regime of small strain to assess the elastic stiffness. The digital image correlation method was used to measure material response under compression. As a reference, the solid samples were also 3D printed and tested to evaluate the polymer matrix stiffness. The anisotropy of the elastic response of porous samples related to the arrangement of voids was assessed. Young’s moduli measured for the additively manufactured samples complied satisfactorily with modelling predictions for low and moderate pore sizes, while only qualitatively for larger porosities. Thus, the low-cost additive manufacturing techniques may be considered rather as preliminary tools to prototype porous materials and test mean-field approaches, while for the quantitative and detailed model validation, more accurate additive printing techniques should be considered. Research paves the way for using these computationally efficient models in optimising the microstructure of heterogeneous materials and composites.

Keywords:
Pore configuration, Anisotropy, Elasticity, Micro-mechanics, Additive manufacturing

Adamek A., Będkowski J., Kamiński P., Pasek R., Pełka M., Zawiślak J., Method for Underground Mining Shaft Sensor Data Collection, SENSORS, ISSN: 1424-8220, DOI: 10.3390/s24134119, Vol.24, No.13, pp.4119-1-4119-17, 2024

Abstract:
The motivation behind this research is the lack of an underground mining shaft data set in the literature in the form of open access. For this reason, our data set can be used for many research purposes such as shaft inspection, 3D measurements, simultaneous localization and mapping, artificial intelligence, etc. The data collection method incorporates rotated Velodyne VLP-16, Velodyne Ultra Puck VLP-32c, Livox Tele-15, IMU Xsens MTi-30 and Faro Focus 3D. The ground truth data were acquired with a geodetic survey including 15 ground control points and 6 Faro Focus 3D terrestrial laser scanner stations of a total 273,784,932 of 3D measurement points. This data set provides an end-user case study of realistic applications in mobile mapping technology. The goal of this research was to fill the gap in the underground mining data set domain. The result is the first open-access data set for an underground mining shaft (shaft depth −300 m).

Keywords:
LiDAR, IMU, underground shaft mapping, mine mapping

Zhang Q., Hou J., Chao L., Jankowski Ł., An X., Duan Z., Fast calculation of vehicle-road coupled response based on moving frequency response function, ADVANCES IN STRUCTURAL ENGINEERING, ISSN: 1369-4332, DOI: 10.1177/13694332241298016, pp.1-15, 2024

Abstract:
Vehicle–road coupled system is inherently time–varying, and its responses are traditionally calculated using time–domain methods which involves significant computational effort. Aiming to improve the efficiency of response calculation for the coupled system, this paper proposes a fast calculation method in frequency domain, based on the newly developed moving frequency response function (FRF). Firstly, considering the vibration characteristics of an infinitely long road, the road response is straightforwardly expressed using the road impulse response function (IRF). Subsequently, the concept of the road moving IRF is proposed and derived with respect to the moving observation points. The moving FRF is then obtained by applying Fourier transform, which allows the responses of the road moving observation points to be established in frequency domain for fast calculation under moving loads. Furthermore, by analyzing the vehicle–road coupled vibrations, based on the vehicle FRF and road moving FRF, a formula for the vehicle–road coupling force is derived in frequency domain, along with an expression for the responses at the vehicle–road contact points. Finally, the approach is illustrated in numerical simulations of vehicle–road coupled systems, and its computational efficiency and accuracy are verified through comparison with currently popular methods.

Keywords:
vehicle-road coupled vibration, frequency domain, frequency response function, impulse response function, numerical simulations

Zawidzka E., Szklarski J. T., Kobaka J., Zawidzki M., Przykłady Małej Architektury w oparciu o System Arm-Z, POMIARY - AUTOMATYKA - ROBOTYKA. PAR, ISSN: 1427-9126, DOI: 10.14313/PAR_252/73, Vol.2, pp.73-80, 2024

Abstract:
Arm-Z to koncepcja hiperredundantnego manipulatora robotycznego opartego na sekwencji szeregowo połączonych identycznych modułów. Każdy moduł ma tylko jeden stopień swobody (1-DOF) – skręt względem poprzedniego. Moduły systemu Arm-Z mogą być masowo produkowane i łatwo wymieniane w przypadku awarii. Sterowanie Arm-Z jest stosunkowo trudne, dlatego zwykle wymaga stosowania metod inteligencji obliczeniowej. W artykule przedstawiono kilka koncepcji kinetycznych obiektów małej architektury opartych na Arm-Z: spiralną kolumnę o regulowanej wysokości, system nadążania słonecznego, kinetyczną rzeźbę bioniczną i kinetyczny zraszacz/fontannę. Prezentowane koncepcje są zasadniczo nisko-technologiczne (“low-tech”). W każdym przypadku moduł bazowy jest przymocowany do podstawy (podłoża). Dla prostoty napęd jest przykładany bezpośrednio do pierwszego modułu, a następnie przenoszony za pomocą wewnętrznych przekładni na kolejne moduły. Każdy moduł jest wyposażony w zestaw cylindrycznych i stożkowych kół zębatych z zębami prostymi o profilu spiralnym (do połączeń miedzy modułami).

Keywords:
Arm-Z, hiperredundancja, manipulator, mała architektura, systemy modularne

Keigo Y., Ario I., Zawidzki M., Yuta H., Optimization Problem of the size-scale for a Foldable Chain Scissors Structure based on Stress Analysis, Journal of Physics: Conference Series, ISSN: 1742-6596, DOI: 10.1088/1742-6596/2647/4/042005, Vol.2647, pp.1-9, 2024

Abstract:
Emergency bridges are used to restore the lifeline of damaged bridges after disasters. However, the design specification of existing emergency bridges do not afford rapid bridging. Therefore, a trial deployable bridge (Scissors Bridge) using a scissors structure that folds compactly has been experimentally produced. But, the assembly process for the bridge has not been considered and there are no practical design examples or design methods for scissors bridges. In this paper, as for existing bridges, we established a design method of scissors bridges when considering the live load. In addition, a general-purpose member cross-sectional dimension optimization method, aimed at minimizing weight, was developed and proposed. Considering the problem of insufficient strength of the scissors bridge, the optimum reinforcing pattern and its cross-sectional dimensions were determined through two methods of reinforcement and optimization of the cross-sectional dimension of the member. Finally, a trial of practical design calculation was performed using the results of the study to determine whether a scissors bridge satisfying the standard of the Specifications for Highway Bridges can be designed.

Keywords:
scissors structure,deployable bridge,stress analysis