Kinga Stasik Lodz University of Technology, Department of Mechanics of Textile Machines ul. Żeromskiego 116, 90-924 Łódź, Poland E-mail: kinga.stasik@p.lodz.pl Method of Separating Fabric from a Stack – Part 2 Abstract A mathematical model of the gripper mechanism with an electric drive, characterised by an increased work surface is presented in the paper. Equations describing the kinematic and dynamic characteristics have been formulated for this model. The resulting equations have been solved numerically. The calculation results illustrating the rheological reaction of the material to the operation of the gripper have been shown in diagrams. Key words: gripper for textiles, computer control, mathematical model, garment production, robotisation. Introduction. Mathematical models of grippers for textiles Existing grippers very often use springs for compression [1 – 3]. Textiles are exposed to destruction because come into contact with the jaws in a very small area and they do not have the ability to control the compression force. Papers [4, 5] proposed an improvement associated with it, where the spring is replaced with a motor which is intended to prevent the crossing of the permissible pressures for the fabric so that there is no destruction. n Equations of motion Employing the principle of virtual works for moving parts of the gripper described in [6] in Figure 1 (see page 80), supplemented with moments of inertia of the guide rollers of the belt I2c, I3c, I4c, which move with velocity ϕ2r2c, the frictional forces between the belt and separating fabric layer T1 and T2 and the weight of the separating fabric mh and mv, we can write a dynamic equation of motion in the following form: d2 ϕ 3 d2 ϕ1 d2 ϕ 2 d dϕ1 − I2c dϕ 2 + − I3c d ϕ 3 − I4 c 2 2 d tdt d tdt d t 2 d t Despite the use of the motor dinstead of d2 ϕ 2 2 2 2 d ϕ ϕ1 ϕ ϕ d d 3 2 4 Mm dϕ1 −toI1ccontrol dϕ1the − I2c dϕ2 − I3c d ϕ 3 − I4 c dϕ 4 −+m tk (1)22 dϕ2r22c + the spring and the ability d t 2 d t 2 d tdt2 d tdt2 d t size of the pressure on thedmaterial, forc2 ϕ3 d2 ϕ1 d2 ϕ 2 d2 ϕ 4 d2 ϕ 2 − I3textiles Mm dϕ1 − I1c es acting dϕ1 − pointwise I2c dϕ2on d ϕ 3 − I4 c dϕ 4 − mtktk dϕ2r22c +− (T1 + T2 )dϕ 2 r2c = 0 c d t 2 d t 2 d t 2 may still d t 2 d tdt2 be too large. Reducing pressures necessary to maintain the fabric is possible by increasing the contact surface of the jaws. Therefore the solution to this problem proposed is agripper for textiles with parallel fingers [5]. The fingers are in contact with the separating fabric over a much larger area than grippers gripping the fabric in a “pinch” [4]. Mm dϕ1 − I1c The forces of friction between the belt and separation fabric layer equal, respectively, to: T1 = µp(Nv+mhg), T2 = µpNh (2) Equation 1, taking account of the friction forces T1 and T2 (2) and masses mh and mv (4a, 4b), as described in [6], after the transformation can be written as: I1c d2 ϕ3 r1cr2c d2ϕ1 d2ϕ2 r1c d2ϕ 4 r1c r2c + I2c + I3c + I4c + (m 2 2 22 d t d t Rc d t R cr3c d t 2 R c r4c dt dt dt d2 ϕas d2ϕ1 d2ϕ2 r1c serve d2ϕ 4 r1c r2c d2 ϕ r r 2 The grippersI discussed 3 r1c r2 c + I2c could + I3c + I4c + (m v + mh ) 22 1c 2c + (3) 1c 2 2 2 2 d t d t R d t R r d t R r d t Rc dt dt such for textiles, but they need to have c 3c c 4c c r r the fabric between their fingers. Effective + µ p (N v + Nh + m h g) 1c 2c − Mm = 0 Rc separation of the fabric requires a mechanism introducing the fabric between its Using the formulas defining the derivafingers. This paper describes a mecha- tive of a composite function: nism for introducing the fabric between 2 d2 ϕ 2 d2 ϕ1 dϕ 2 dϕ1 d2 ϕ 2 fingers using frictional forces, which can = + d t dϕ12 d tdt2 d tdt2 dϕ1 dt be realized by using an endless belt, pull2 2 2 ing the fabric by force of friction in the d ϕ 3 d ϕ1 d ϕ 3 d ϕ1 d 2 ϕ 3 = + (4) direction of the blockage place, where is tdt dϕ12 d tdt2 d t 22 dϕ1 d dt a fold formed entering between the belt 2 d2 ϕ4 d2 ϕ1 dϕ4 dϕ1 d2 ϕ4 = 22 + and foot. The further movement of the 22 d t d t dϕ1 d t dϕ12 dt dt dt belt will unfold the fabric between the elements involved in separating the fabric and substituting to expression (3) we oblayer [6]. tain a second order differential equation: Stasik K. Method of Separating Fabric from a Stack – Part 2. FIBRES & TEXTILES in Eastern Europe 2014, Vol. 22, No. 2(104): 79-83. 79 ϕ2r2c = ϕ3r3c, ϕ1 ϕ3 r r dϕ 3 r r = 1c 2c = 1c 2c , dϕ1 R c r3c ϕ1 R c r4c , (7) r r ϕ2r2c = ϕ4r4c, ϕ1 1c 2c = ϕ 4 r4c Rc r r r r ϕ4 dϕ 4 = 1c 2c = 1c 2c , ϕ1 R c r4c dϕ1 R c r4c After substituting Equations 6 and 7 into Equation 5, we then obtain a system of Equation 8 of the first order. Figure 1. Distribution and directions of moments in the gripper’s movable part system described in [6] in Figure 1; I1c, I2c, I3c, I4c, - moments of inertia of guide rollers of the belt, ϕ1,…,4 - angles of rotation of guide rollers of the belt, r1c, r2c, r3c, r4c, Rc - radii of rolls of the gripper, Mm – drive torque of the motor of rolls, T1 i T2 - boundary frictional forces between the belt and separating layers of the fabric, mh – mass of the fabric lying on the table (not picked up yet), mv – mass of the fabric between the foot and belt. For the purpose of numerical calculation of a simplified system of Equations 8, assuming that the guide roller belts are identical, and their moments of inertia I2c, I3c, I4c, radii r2c, r3c, r4c and angles of rotation ϕ2, ϕ3, ϕ4 are created equal. Using relationships (6) and (7) between the angles of rotation and radii of wheels, we can write that: dϕ 2 dϕ 3 dϕ 4 r1c = = = and dϕ1 dϕ1 dϕ1 R c d2 ϕ2 d2 ϕ3 d2 ϕ 4 = = =0 dϕ12 dϕ12 dϕ12 (9) After substituting Equation 9 into the system of Equations 8, the following is obtained: dϕ A = ϕB dt d t Figure 2. Step of pressing the textile package to the table (A) and a compression of separated layer between the foot and moving part of the gripper (C) described in [6], msv, msh - weight of the respective elements of the gripper. 2 Between dϕ3 r1c r2c dϕ2 r1c dϕ4 r1c r2c dϕ r r 2 dthe ϕ angles + I3c + I4c + (m v + mh ) 2 1c 2c 21 + I1c + I2c dϕ1 R c dϕ1 R c r3c dϕ1 R c r4c dϕ1 R c d t + I3c c r1c r2c = ϕ 3 r3c Rc of rotation ϕ1,…,4 and the radii of circles r1c, r2c, r3c, r4c, Rc dϕ3 r1c r2c dϕ4 r1c r2c d ϕ r r 2 d2 ϕ + I4c + (m v + mh ) 2 1c 2c 21 + dϕ1 R c r3c dϕ1 R c r4c dϕ1 R c d tdt can be formulated thus: 2 d2ϕ2 r1c d2ϕ3 r1c r2c d2ϕ4 r1c r2c d2ϕ2 r1c r22c dϕ1 + I2c + I3c + I4c + (m + (5) v + mh ) 2 dϕ12 R c r3c dϕ12 R c r4c dϕ12 R c d t dϕ1 R c ϕ2Rc = ϕ1r1c, 2 d ϕ3 r1c r2c d ϕ4 r1c r2c d ϕ r r dϕ1 + I4c + (m v + mh ) 22 + dϕ12 R c r3c dϕ12 R c r4c dϕ1 R c dt d t 2 2 2 2 1c 2 c + µp (Nv + Nh + mh g) r1c r2c − Mm = 0 Rc r ϕ2 = 1c ϕ1 R c , dϕ 2 r1c = dϕ1 R c ϕ2r2c = ϕ3r3c = ϕ4r4c ϕ 2 = ϕ1 (6) r1c Rc dϕ A = ϕB dt d t Mm − µp (Nv + Nh + mhg) + (m v + mh ) r1c r2c d2 ϕ2 r1c d2 ϕ3 r1c r2c d2 ϕ4 r1c r2c − I2c +I3c + I4c + 2 2 Rc dϕ A R c r3c dϕ2A R c r4c dϕ A R c d2ϕ2 r1c r22c dϕ A dt dϕ2A R c d t 2 dϕ BA = ϕB d t dt 2 2 2 2 r r r r r r r I1c + I2c 1c + I3c 1c 2c + I4c 1c 2c + (m v + mh ) 1c 2c R c r4c Rc Rc R c r3c Equation 8. 80 (8) dϕB = dt d t Mm − µp (Nv + Nh + mhg) r I1c + 3I2c 1c Rc 2 r1c r2c Rc (10) r r + (m v + mh ) 1c 2c Rc 2 While manipulating a package of fabrics, the gripper presses the fabric lying on the table in a stack (Figure 2.A) and a layer is separated from the stack between the foot and gripper’s movable part (Figure 2.C). The motion of the gripper along the vertical direction is initiated by an electric motor 9 with a driving torque Mmv and an angle of rotation of the main shaft φv by means of a screw 7 with a pitch hsv, which transforms the rotary motion of the motor into a vertical translatory one [6]. Analogously the motion of the gripper along the horizontal direction is performed by means of an electric motor 18 with a moment Mmh and angle of rotation of the main shaft φh and a screw 16 of pitch hsh [6]. FIBRES & TEXTILES in Eastern Europe 2014, Vol. 22, No. 2(104) Figures 3 and 4 present the distribution of accelerations and forces acting on the mass of the gripper msh along the horizontal and msv vertical direction. The mass msh consists of gripper elements, i.e. a plate 13 with three belt guide rollers 3, an electric motor 4 and a rubber belt 2 (Figure 2.C and 1 [6]), while the mass msv consists of a mass msh, a spring 15 and guides 19 for stabilisation of the gripper motion along the horizontal direction, an electric motor 18, and casing 14 (Figure 2.A and 1 [6]). a) b) Figure 3. Distribution of acceleration and forces acting on the mass of the gripper moving along the horizontal (a) and vertical (b) direction, driven by an electric motor 19 (a) and 9 (b)[6]. The dynamic equations of motion for the systems shown in Figure 3 can be presented using the principle of virtual works: Mmmh h − Nh d x d 2 x h dx d x h dx h − msh =0 sh dϕ h d tdt2 dϕ h Mmmv v − Nv d xdx v d2 x v d x v dx − msv =0 sv 2 dϕ v d ϕv d tdt (11) ϕv ϕh hsh hsv sv sh , x v = 2π 2π (12) where hsh and hsv mean the movement of the movable part of the gripper attributable to one rotation of the motor shaft. From the above equations, the following can be obtained: d x h h sh dx = sh dϕ h 2π 2 d xh b) Figure 4. Scheme of compression of the fabric layer with a force Nh (a) and Nv (b). The linear coordinates xh and xv and angular coordinates φh and φv define the position of the systems with masses msh and msv. Motion functions xh = xh(φh) and xv = xv(φv), which define geometrical relationships between the rotary motion of motors 9 and 18 and the horizontal and vertical motion of the gripper, are determined as: xh = a) Equations 15 are then written in the form of first-order equations for computer solution of the method of numerical integration: while the package of fabrics lying on the table (Figure 4.b) has been assumed in the following form: k v1 k v2 d u 3 Nv = uv + u v + c tv hsh sh L L Mmh m h − Nh gt nilv + gt t gt nilv + gt t dj d ϕhB dj dϕhB hA 2π hB LLtthh L th =j ϕhB = h B 2 dt d t dt d t hsh sh k v1 k v2 d u v msh du 3 sh u + u + ctvtv 2πv = N dt Lt v Lt v d t (16) g n + gt gt nilv + gt h sv sv t ilv L L L M − N th t h t h mv m v v dϕhA dj dj dϕhA vA 2π vB =j ϕhA = vB 2 dt dt d t d t for uv > 0 and Lh > 0.001 (18) hsv sv msvsv 2π k k d u du v 3 Nv = v1 u v + v 2 u v + c tvtv In paper [7] a model of fabric in the form gt nilv gt nilv d tdt of serially connected elements - springs and silencers has been described. For the purposes of this study nonlinear deformation (third degree) of the compression material has been selected. Assumed values of the elasticity constants of the fabric kh1, kh2, kv1 and kv2 describing e the deformation of the third degree for the sample selected, were determined on the basis of the results given in [8]. The relationships between compressive forces Nh and deformations uh in the fabric layer between the foot and gripper’s movable part (Figure 4.a) have been assumed in the following form: for uv > 0 and Lh ≤ 0.001 Nv = 0 for uv ≤ 0 where Nh denotes the force that compresses the fabric between the foot and (13) the gripper’s movable part, Nv the force d2 x v dx d x v hsvsv = , dϕ 2 = 0 that compresses the package of fabrics dϕ v 2π v lying on the table, (kh1, kh2, kv1, kv2) elasticity constants, cth, ctv damping coeffiEmploying the formula that defines a decients, uh, uv compression, gt thickness rivative of the complex function: of one layer of fabric, nilh = 0, 1 or 2 [6] 2 dx d2 x v d2 ϕ v d x v dϕ v d 2 x v the number of layers of the compressing = + (14) d t dϕ 2v d tdt2 d tdt2 dϕ v dt fabric between the foot and gripper belt, n ilv the number of layers in the stack, Lt which after taking into account relations the total length of the fabric lying on the k h1 k h2 d u h (13) and after substituting to equations 3 uh + cLthth the Nh = uh + table, length of fabric lying on the L L (11), we obtain the second order differd t gtnilh + gt t gt nilh + gt t table calculated by the formula (5a [6]), ential equations: Ltvtv L tv Ltv length of the compression fabric lok k d u du 3 h 1 h 2 h 2 2 N uh + uh + c th = cated between the foot and belt (5b [6]). h sh h h sh sh sh d ϕ h Lt L d t dt = Mmh msh m h − Nh sh 2π d gtnilh + gt t 2 2π gtnilh + gt L (17) tdt LLtvtv uh = nilhgt - rdh, tv (15) 2 2 hsv h ssv uv = uv1 + uv2 + ... + uvn (19) for uh > 0 sv v d ϕv = Mmv − Nv msvsv m v Nh = 0 for uh ≤ 0 uv = nilvgt - rdv 2π tdt2 2π d , dϕ h2 =0 FIBRES & TEXTILES in Eastern Europe 2014, Vol. 22, No. 2(104) 81 In the sample the normal forces Nh and Nv compress for rdh < gt, rdv < gt, where gt stands for the thickness of one layer of the fabric. If rdh ≥ gt and rdv ≥ gt then the forces Nh = 0 and Nv = 0. In Figure 6 uv1 = uv2 = ... = uvn denotes compressions of subsequent fabric layers, whose thicknesses are equal to gt1 = gt2 = ... =gtn; rdh is the distance between the foot and the gripper’s movable part, calculated with relationship (20); rdv is the distance of the gripper from the table, calculated with relationship (20), where x0h and x0v mean distances rdh and rdv at the initial time instants. The logic feedbacks controlling the gripper’s operation and stating that if the compressive forces are lower than the assigned forces Nh < Nset and Nv < Nset, then the values of the supply voltage increases by Δeh (eh := eh + Δeh) and Δev (ev := ev + Δev), have been introduced into the computer program. On the other hand, if Nh > Nset and Nv > Nset, then eh := eh - Δeh and ev := ev - Δev. Nset denotes the force with which the gripper should act on the fabric. Simultaneously the current intensity cannot exceed the admissible value. The increment values of the electromotive forces Δeh and Δev in the following steps are expressed as products of current electromotive forces eh and ev, increases in forces ΔNh and ΔNv relative to the setpoint force (ΔNh = Nh - Nset and ΔNv = Nv - Nset), integration step Δt and numbers εh and εv, agreed in order to reach a converging solution: Δev=ev·ΔNv·Δt·εv Δeh=eh·ΔNh·Δt·εh -2 x10 (24) where Tm denotes the motor time constant, cm - motor rigidity, Ωm - motor angular velocity at which the moment is equal to zero, im - current intensity, Lm inductance, Rm - resistance, em - supply voltage, Kbm, Ktm - motor constants, and φ1 - angle of rotation of the motor. Assumptions for the calculation and results The computer program simulates the work of the gripper, extended by equation (4 - 8), as described in [6] and (1 - 24). Appropriate parameters for the gripper, motors and textiles have been selected as follows: ndimensions: r1c = 0.0062 m, r2c = 0.0138 m, Rc = 0.0116 m, x0v = 0.008 m, x0h = 0.008 m, n mass moment of inertia of the guide roller belt: I2c = 55·10-7 kgm², n masses of relevant parts of the gripper: msh = 0.18 kg, msv = 0.25 kg, n pitch of the screw h = 0.002 m, n gear ratio j = 4, n weight of one layer of the fabric mtk = 0.02 kg, length of one layer of the fabric Lt = 0.4 m, coefficient of friction of the belt to the fabric μp = 0.3, the number of layers of fabric in the stack nilv = 4, thickness of compression fabric: gt = 0.002 m, n elasticity constants of textile: kv1 = kh1 := 1·105 N/m; kv2 = kh2 := 1·1011 N/m3, n damping coefficients cv = ch = 0.01 Ns/m; nnumber εv = εh = 18.48, integration step Δt = 4.51·10-5. 7.22 MMmm,[Nm] Nm (21) Tm = 5.42 d M m 1 dϕ dM = c m Ωm − 1 − Mm (23) d t Tm d t dt dt 0.09 t [s] t, s The motor has been assumed as follows: n An electric motor for driving the rollers which lead the belt (item 4, Figure 1 in [6]) characterised by: constant voltage Kb = 0.038 V/(rad·s), constant torque Kt = 13.2 Nm/A, resistance R = 343 Ω, inductance L = 53·10-3 H, supply voltage e = 25 V and mass moment of inertia of the rotor I1c = 5·10-8 kgm². n The electric motor initiating the vertical movement of the gripper (item 9, Figure 1 in [6]) is characterised by: constant voltage Kbv = 0.038 V/(rad·s), constant torque Ktv = 0.33 Nm/A, resistance Rv = 343 Ω, inductance Lv = 53·10-3 H, supply voltage ev = 10 V. n The electric motor initiating the horizontal movement of the gripper (item 18, Figure 1 in [6]) is characterised by: constant voltage Kbh = 0.038 V/(rad·s), constant torque Kth = 0.33 Nm/A, resistance Rh = 343 Ω, inductance x10 1.22 1.18 0.86 1.10 0.98 0.86 0.54 0.22 0.05 Figure 5. Time history of the motor torque Mm [Nm] used for driving the rollers leading the belt. 1.50 The equations of moments of the motors: driving the rollers which lead belt 4, initiate the vertical motion of gripper 9, and initiate the horizontal motion of the gripper 18, as shown in Figure 1 in [6], are expressed by the formulas: 0.01 -3 -3 x10 (22) 6.62 6.02 Mmv, [Nm] Nm d rdrdh hsh dϕ h du h du = − dh = sh , d t d t 2π dt d t dt dt d rdr h dϕ v du v du = − dvdv = svsv d t d t 2π dt d t dt dt 82 Kbmbm K tm Lm tm ·⋅ K , cm = R , Rm m M e Ωm = m , im = m K Kbm tm tm b m ϕh ϕv hsvsv (20) hsh v = x0v − sh , rddv 2π 2π MMmh , Nm mh[Nm] rdh dh = x 0h − 0.01 0.05 t [s] t, s 0.09 0.74 0.59 1.49 t [s] t, s -2 x10 Figure 6. Time history of the motor torque Mmh and Mmv in Nm used for initiating the horizontal and vertical movement of the gripper. FIBRES & TEXTILES in Eastern Europe 2014, Vol. 22, No. 2(104) -4 x10 1.80 uuvv,[m] m u huh[m] ,m 3.01 2.01 1.20 0.60 1.01 0.01 Reducing pressures necessary to maintain the fabric is achieved by increasing the contact surface of the respective elements of the gripper. -6 x10 4.01 0.01 0.05 t [s] t, s 0 0.09 0.59 1.49 t [s] t, s x10 -2 Figure 7. Time history of the compression of the material uh and uv in m. Computer programs describing the work of grippers for textiles allow analysis of the behavior of the system, which shortens the design process of the device. Modelling studies showed that there is a possibility to choose relevant parameters of these mechanisms. 20.68 N Nhh, m [m] Nvv, m[m] N 17.47 14.68 11.47 8.68 2.68 The model of the gripper developed, which is characterized by an increased working surface, was granted a patent as an invention on 31.01.2008 [9]. 5.47 0.01 0.05 t [s] t, s 0.09 0.47 0.59 1.49 t t,[s]s -2 x10 Figure 8. Time history of the compressing force on the fabric layer located between the gripper and foot Nh in N and of the stack of the fabric Nv in N. Lh = 53·10-3 H, supply voltage eh = 10 V. Simulation calculations were carried out for various parameters and the results obtained are shown in the graphs (Figures 5 - 8). Graphs (Figure 8) show that compressive forces Nh & Nv achieve a maximum value, then decrease and stabilise with time until reaching a constant setpoint value Nset. It has been observed that the stabilisation of parameters up to the value of the force assigned Nset takes place sooner for the vertical direction than for the horizontal one, whereas the values of the compressive forces Nv and Nh that cause the deflection of the fabric are close. These plots illustrate the rhelogical reaction of the fabric to the gripper operation. Under the influence of the forces the fabric is compressed in the stack uv between the gripper and foot uh (Figure 7), the values of which, as for forces Nh & Nv stabilise in time and cause compression in the range of 0.05%. FIBRES & TEXTILES in Eastern Europe 2014, Vol. 22, No. 2(104) Entering the edge of the fabric between the respective elements of the gripper was realised by using the endless belt and then pulling the fabric by the force of friction in the direction of the blockage place where the fold entering between the belt and foot is formed. nConclusions A mathematical model of the gripper separating fabric from a stack has been developed and the phenomena of separation actions of the layer examined. The assumptions made have been confirmed. Thanks to the motors, whose torques are controlled as a function of the size of the pressure, the gripper exerts a sufficient force on the separating fabric to prevent the slipping out of fabric while not exceeding the limit values which may cause damage to the fabric. A force value Nzad was established that the gripper would exert on the separating fabric to prevent it from slipping out while not exceeding the limit force. This is achieved by replacing the clamping spring in appropriate elements of the gripper and having an electric motor whose torque is controlled as a function of the size of the pressure. The feedback adjusts the value of electromotive forces eh and ev, and consequently the values of the current intensity ih and iv and driving torques motors Mmh and Mmv are obtained. References 1. Fort J. Darnieulles, France: Gripper for Textile Cloth or The Like; Patent Number: 4,526,363; Date of Patent: Jul. 2, 1985. 2. Keeton JH. Cloth Pickup and Folding Head; Patent Number: 4,444,384; Date of Patent: Apr. 24, 1984. 3. Fort J. Darnieulles, France: Gripper for Textile Layer or The Like; Patent Number: 4,697,837; Date of Patent: Oct. 6, 1987. 4. Stasik K. Mathematical Model of a Mechatronic Pinch-Type Gripper for Textiles. Fibres & Textiles in Eastern Europe 2005; 13, 1, 49: 67-70. 5. Stasik K. Mathematical Model of a Mechatronic Parallel Finger Gripper for Textiles. Fibres & Textiles in Eastern Europe 2005; 13, 2, 50: 73-75. 6. Stasik K. Method of Separating Fabric from a Stack – Part 1. Fibres & Textiles in Eastern Europe 2014; 22, 1, 103: 103107. 7. Zajączkowski J. Modelling of Dynamical Properties of Textiles Under Compression. Fibres & Textiles in Eastern Europe 2000; 8, 1, 28: 57-58. 8. Robak D.: Dynamics of Transport Fabric in the Process of Sewing (in Polish), Ph. D. Thesis, Technical University of Łódź, Department of Mechanics of Textile Machines, 2003. 9. Zajączkowski J, Stasik K. Device for Gripping a Single Layer from the Material Stack (in Polish), Patent PL 197 340, 31.01.2008. Received 23.05.2012 Reviewed 04.07.2013 83