It is very important for developing an intelligent hobbing machine design that the hob wear, cutting forces and hobbed gear accuracy are estimated in advance. Using the numerical analysis of hobbing mechanism, a new analytical technique is developed to calculate the volume cut with every hob tooth, cutting forces and feed mark patterns. This paper introduces some qualitative estimation by adapting the new analytical method; (1) Hob wears vs. calculated cutting volume (2) Feed marks remaining on the tooth surfaces of hobbed gears vs. the hobbed gear accuracy. Finish hobbing is superior in productivity, such as high-speed cutting, large amount of cutting stock and so on. This method has a merit of omission of shaving and/or grinding process, if the gears can be finished satisfactorily concerning their condition of accuracy and surface roughness. The ability required to finish hobs is to obtain smooth surface and accurate tooth profile of the finished gears demanded from the performance of gears concerned. This paper also introduces the cermet-and the CBN-tipped finishing hobs for medium hardness gears and high hardness ones (case-hardened gears), respectively, which are different from skiving hobs.

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In the present invited paper, the activities of my recent research in the fields of micro systems, i. e., miniature mechanisms, micro mechanisms, and nano-meter-order manufacturing are reported, especially, concerning (1) Micro bonding system, (2) Micro mechanism and its element manufactured by Reactance Ion Etching (RIE), (3) Palmtop surface mount system for micro devices, (4) Positioning-and-orientation miniature mechanism with large-deflective hinges, (5) Fast Atom Beam (FAB) process and its applications, etc.

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In order to enhance reality of a virtual object and handling skill of a robot, tactile sensation provides essential information used by a human being and a robot. Key parts for the human being and the robot are a tactile sensor and a tactile display, respectively. Firstly, optical tactile sensors are demonstrated to explain sensor design. Second, the tactile display is described to show that human sensation mechanism should be considered for the display specification. Finally, several applications for the tactile sensor and display are exemplified to discus effectiveness of the tactile sensor and display.

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The author has stayed at Uppsala University for 4 months as a visiting scholar supported by the Japanese Ministry of Education. A brief review is made on the state of research on Tribology in Sweden.

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This paper presents a study on residual stresses and hardened layers of gears due to dual frequency induction hardening (using both high-and low-frequency heat sources). Temperatures during a single frequency induction heating process of the gear were calculated by FEM electromagnetic field analysis and heat conduction analysis methods, considering changes of the magnetic permeability and the resistivity with the temperature, and were measured using thermocouples. An electromagnetic field analysis, a heat conduction analysis and an elastic-plastic stress analysis, considering changes of the magnetic permeability, the resistivity, the thermal expansion coefficient and the yield stress with the temperature, during the single frequency and the dual frequency induction hardening process of the gear were carried out by the three-dimensional finite-element method (3D-FEM), and then residual stresses and hardened layers were obtained. The effects of the electric power and the frequency on the temperature and the stress change during the induction hardening process, the residual stress and the hardened layer were determined.

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For the purpose of the development of case-carburized gears for the high load carrying capacity, the relation between tooth surface-finishing method and surface durability of gear was studied. First, the surface qualities of ground roller, shot peened roller and shot peeded and ground roller made of the hypoxia vacuum melting case-carburized alloy steel were examined by means of a scanning electron microscope and a penetrometer, etc. As the result, the effect of the shot peening processes on surface shape, surface roughness and surface hardness of the case-carburized alloy steel are clarified. Secondly, the surface durability of three kinds of roller was investigated by using a 2-roller-type contact fatigue testing machine. The following results are obtained : The influence of shot peening processes on damage, roughness and hardness of the rolling-sliding contact surface is clear. The increase in surface hardness with shot peening processes does not always have an advantageous effect on surface durability.

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Focusing on the hardness, residual stress and inclusions, a simulation method is proposed to compute the fatigue strength of carburized gears. The simulation is based on the comparison of bending stress at every position of defects with material's strength. For the purpose of putting inclusions in the imaginary material for the computation, the distribution of the inclusions size is applied in the weibull distribution, based on the microscope observation. As a result of simulation, the fatigue strength distribution follows a normal distribution and have good correlation with the bending fatigue test result. Density of the large size inclusions influences fatigue strengths.

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When the finite element method is applied to the stress analysis of meshing tooth pair, a large difference between dimensions of tooth flank modification and finite elements should be one of the main issues. In the present study, as a solution to the issue, a new element for representing boundary condition at contact area, a tooth flank film element, is proposed. This new element can include particular information on a tooth flank; e. g., tooth modification, geometrical overlap, and radius of curvature, with general information included in a finite element; e. g., coordinate, and displacement. The tooth flank film element enables the boundary condition at contact area to be given as distributed load. Meanwhile, Global Local Finite Element Method, in which a classical analytical solution is combined with finite element solutions on the basis of energy principle, is also applied to the stress analysis of meshing tooth pair. Using the proposed analytical method, the contact problem of semi-infinite body and sphere is analyzed. As a result, validity of the method can be confirmed. Furthermore, the application of the proposed method can also induce reasonable results in the stress analysis of meshing spur gear pair.

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A thin-webbed gear is likely used for light-weigh characteristics of a transmission and its natural mode of vibration tend to excite exterior vibration and noise. Present paper deals with the experimental investigation of modal behavior using several helix angle gears at various torques and speeds. At first, it is clarified that the modal vibration having one diametral nodal line cannot be observed, and the second mode with two nodal lines is always markedly observed even it does not excited by mesh frequency. Also, third and fourth modes are observed only when it meets an excitation by mesh frequency. In addition, these modes are proven fixed to the spatial coordinate if the torque is applied to a certain amount. Secondly, the resonant frequency increases according to the increase in torque. Finally, position of nodal lines on driving and driven side are made clear, that are directed to near the mesh region but not in line.

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For the purpose of a detailed description of rotational vibration response of a helical gear pair having tooth surface deviation during light load transmission, we have already developed the numerical calculation method for gear vibration which can take any type of deviation into account. But there can be seen the tendency that the accuracy become worse when transmitting load is too low. Especially, gear pair's resonant frequency is too much influenced with transmitting torque comparing with the experimental results. To improve the accuracy of proposed simulation, we examine two types of tooth elastic deformation, tooth bending deformation and compressive deformation of tooth surfaces, precisely with vibration measurement and observation of contact pattern of meshing teeth.

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The spiral bevel gears, which have little noise, are suitable for high speed running. These gears are widely used for automobiles, helicopters, etc. Recently, as the precision of this gear required become more and more high standard, the process of three-dimensional tooth surface correction by an NC lapping machine is carried out after heat treatment. On the other hands, gear noise is evaluated by various measuring method, and generally the value at mesh frequency is paid attention. However, recently the sideband wave of the mesh frequency have been beginning to be evaluated to confirm an accuracy dispersion of each tooth in a gear. But there are few papers dealing with the sideband wave. Then, we pay attention to the side bands of mesh frequency, such as the Oerlikon-type which has been considered the high of the cutting efficiency. Then, the mechanism of side bands was clarified by supposing that was generated amplitude modulation and frequency modulation. On the other hands, a simplified measurement method of pitch errors was proposed. And relation sideband wave of rotational vibration of gear and pitch error of gear was also investigated.

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This paper describes the power loss of bevel gear drives. We measured the friction loss and the churning loss of straight bevel gear and spiral bevel gear using a power circulating-type bevel gear testing machine, by the oil immersion formula, whose method is based on the oil temperature rise due to the power loss in the gear drives. It was found that the friction loss of the straight bevel gear is larger than that of the spiral bevel gear, and the gear friction loss ratio of the bevel gears decreases with the increase in the gear torque. Furthermore, we calculated the gear friction loss and the churning loss of the bevel gear drives. The calculated value agreed approximately with the experimental data.

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For the purpose of improving the efficiency of automotive transmission, there is a greater need to modify even the gear dimensions and tooth surface for reducing gear mesh loss. In this paper the effects of gear dimensions and tooth surface modification on reducing gear mesh loss were experimentally investigated. It was confirmed that fine pitch gear is effective for reducing mesh loss and that the mesh efficiency is improved by increasing the amount of tooth profile crowning. In order to verify these results we developed a prediction program of gear mesh efficiency that can estimate the influence of gear dimensions and the tooth surface modification on the mesh efficiency.

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Tooth Bearing Inspection is one of the most common inspections for hypoid gear pairs. Usually, in the inspection, hypoid gear pairs are qualitatively evaluated by OK/NG. However, in order to conduct a follow-up survey on bad quality of products, quantitative evaluation of tooth bearing could be effective. Change in machine setting parameters for lapping process enables many kinds of tooth bearing to be purposely given on hypoid gear pairs. Using this method, a certain evaluation value could be given to each tooth bearing. Considering such evaluation values, experienced technicians for the inspection could evaluate each result of the tooth bearing inspection. The present paper describes a computer evaluation system for tooth bearing of hypoid gear pair which can evaluate the results of the inspections instead of the experienced technician. The evaluation performance of the developed system was discussed, and quality of normative tooth bearings which are used for training the developed system greatly affects the performance. The comparison of system evaluations with the technician's ones reveals that correct answer ratio of the developed system within evaluation allowance reached 90% in the best case.

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A practical method to analyze tooth contact of involute gears with arbitrarily modified tooth surface in consideration of tooth deflection and axis displacement was developed. In this paper, the outline of developed system is introduced and the calculation examples on the transmission error and exciting force of gear pairs are shown to investigate the effects of profile modification, tooth trace crowning, alignment error and bias modification.

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Theory and production method of Hourglass worm gear of small size with a high performance are proposed. Wheel tooth is involute helical gear of this worm gear and pinion cutter generates worm tooth. This worm gear set is produced and contact mark is coinciding well with the theory.

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Tooth Contact Analysis of hourglass worm gearing of this study is reported in this report. Contact lines and radius of relative curvatures of mating teeth surface are obtained by T. C. A. The displacement of tooth contact mark caused by axial errors is represented by 3D contours.

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Theory and calculating method of axial section of Hourglass worm are introduced. Axial section of worm tooth is measured by 3 dimensional measuring machine. Profile errors of worm tooth are determined by comparing theoretical values and measured values of tooth profile.

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Conventional method of laser interferometry is useful to know how a tooth flank has form deviation. But its method has a defect that it takes much time to process data of brightness intensity on CCD image sensor and the method can't be introduced in production line for the sake of optical instability of the measuring system. Therefore to detect a form deviation of a cylindrical involute gear tooth, a new measuring system is introduced. Possibility of rapid detection method of a tooth form by using laser holography is investigated.

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A new type of a mechanical variable speed transmission, which consists of a 2K-H type differential gear and a HST unit, is devised. The pattern of this transmission is replaced with a combined planetary gear train system. Through a theoretical analysis of the system, it is confirmed that the power circulation is occurring in the system. And it is made possible to realize a new highly efficient transmission only by controlling the quantity of power flow.

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The crossed axle traction drive developed by authors has been applied to the new mechanism of CVT. The input and output shafts attaching conical disks are parallel and a idler shaft having conical roller at the end is placed across the input/output shafts. The relation between the movements of each axis to change a ratio is analyzed geometrically. This report deals with the development of prototype and evaluation of efficiency of the transmission. From the result of experiments, the efficiency is 77% in case of the constant loading force.

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Dry hybrid belt is used for continuously variable transmission (CVT) of the automobile. It is a combination belt composed of tension members and many blocks. In this study, the mechanism of fatigue failure in the tension member was investigated to obtain a high performance CVT-belt. Especially, failure observation after fatigue test and bending deformation measurement of the tension member were carried out, and the mechanism of the fatigue in the tension member was discussed.

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Fatigue failure mechanism of synchronous belts has been investigated focussing on the bending fatigue failure in helical cords. The fatigue damage is initiated as a de-bonding between strands in the cords. The de-bonding is initiated by a shearing stress along the strands. The author has proposed a geometrical parameter S, which is useful to estimate the extent of the shearing stress. In this study, the effect of strand radius and the cord construction on the parameter S is discussed. The shearing stress is low in the cords in which the strand radius is small. Moreover, the extent of the shearing stress is compared between the helical cords and a plaited cord.

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Fatigue failure initiation site in synchronous belts depends on the belt tension and the torque conditions, namely fluctuating torque or constant torque conditions. For example, the tooth root cracking is observed at the tight side under a constant torque, while the tooth root cracking is initiated at the slack side under a fluctuating torque. However, the effects of those mechanical conditions on the failure initiation site have not sufficiently been understood. In this study, the effects of belt tension and tooth load on the failure initiation site were investigated using a FEM analysis. The maximum shearing stress is initiated at the slack side tooth root under low tooth load conditions and at the tight side under high tooth load conditions. It is considered that the former simulates the fluctuating torque conditions and the latter simulates the constant torque conditions.

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Synchronous belt drives are often used in bidirectional applications such as printing machines, high-performance machine tools and industrial robotics, and are required to provide high transmission and positioning accuracy. Helical synchronous belt drives, in comparison to conventional synchronous belt drives, are effective for reducing noise and transmission error over single pitches of the pulley. In the present study, the transmission error of a helical synchronous belt drive under installation tension was investigated both theoretically and experimentally for the case when the drive reverses direction. The computed transmission error agrees with the experimental results, confirming the applicability of the proposed theoretical analysis for transmission error. It is found that transmission error in this case is generated by a change in the contact state between the belt tooth flank and the pulley tooth flank, and axial displacement of the belt between the driving pulley and the driven pulley. By setting the installation tension as high as possible, the transmission error can be reduced and stabilized more quickly. In addition, when the outside diameters of both the driving and driven pulleys are equal, transmission error does not occur.

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In this paper, the jumping characteristics of the driving and the driven pulleys of synchronous belt drives of 2 pulley systems with the same tooth numbers are experimentally and analytically discussed. The jumping phenomena on both pulleys have been observed by a high speed video camera and they have been simulated by the finite element method. The jumping of synchronous belts occurs when the elongation at the free span of the belt is more than a certain value. The following parameters are considered in the expression stiffness of the belt cord, height of belt tooth, ratio of tight side and slack side tension, belt installation tension, wrapping angle of belt, diameter of pulley pitch circle and the bending stiffness of machine. Jumping usually occurs at the driven pulley, jumping occurs when the wrapping angle of the belt on the driving pulley is less than 90 degrees.

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In this paper, as a basic study on sandwich-belts conveyor, the belt tension distribution and belt slip of a simple four pulleys and two belts layout are discussed analytically. Also, a FEM analysis is carried out for verifying the theoretical analysis. It is found that belt tensions obtained with both of theoretical analysis and FEM agree well, but the belt slips do not.

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Studies on optical switches have been researched and developed for optical information networks for a highly developed information technology society. In reality, however, a manipulator cannot apply for multi input and output due to a rather small output displacement at mirror parts of actuators. Therefore, in order to develop optical switches capable of switching multi input and output, we suggest an electrostatic driving-type micro-manipulator that is capable of large angular output displacement by low applied voltage. The actuator is driven by the method of suction between the beam supporting a mirror and the fixed plate with a insulating membrane on it.

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Diamond is a high-performance material in many ways : e.g., mechanically, it has the highest hardness; thermally, the highest thermal conductivity; chemically, high stability in various atmospheres at ordinary temperatures; and electrically, high insulation. The goal of this study is to fabricate a maintenance-free micromachine system, equipped with diamond elements, that can function under severe conditions, in the human body for example, for a long period. As the first step of this study, the authors fabricated a micromanipulator having a diamond end-effector that can handle microelements, as small as several to several tens of micrometers, made of CVD diamond film. And next, reversal mechanism was added at this end-effector in order to attempt efficiency improvement of the work. The result was good, when the micro manipulation work was carried out using this system.

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The air film thickness between a foil and a drum is studied experimentally using a measuring system under conditions where the Air film thickness is effected by the bending stiffness of the foil. For comparatively flexible foil cases, the experimental results coincide fairly well with theoretical ones obtained by applying the separation boundary condition. For cases with stiffer foil the tangency pint condition as well as the infinity point condition for the film pressure generation point. The theoretical tool of Finite Element Method is used to analyze film thickness and pressure distribution in a foil bearing for various values of foil stiffness, The calculated results agree with the experimental data, and it is concluded that the shallow shells model is useful and accurrate.

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The purpose of this paper is to develop a control method of the spherical ultrasonic motor with a magnetized rotor using the phase control method. This paper proposes a new measurement method to detect the orientation of the rotor. The orientation of the magnetized rotor is detected by three-hall devices embedded at the center of each stator. This paper will describe the magnetization method of the rotor, the mechanism and method for detecting the orientation of the magnetized rotor as well as the result of the experiment.

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This study proposes a trajectory generation of maipulators by heuristic method to suppress dynamic input torques and consumed kinetic energy which are caused by inertial force. The proposed method uses polynomials to reveal trajectories which are correspond to positions of output points, velocities and acceleration. Furthermore, the coefficients of each polynomial dimensions are decided by a heuristic method. The study uses the heuristic algorithms SHA proposed by S.Lin et al. This study confirmed that the proposed method will easily generate trajectories which can suppress dynamic torques and consumed kinetic energy.

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Dynamic stresses acting on a link depend upon the area of the section of a link and the forces acting on the section, and the inertia forces and the inertia torque depend upon the distributions of masses of a link and the shape of a link. Therefore, it is important for improving the distribution of the stresses of links to design the shape of section of a link for reducing the weight, the shaking force and the shaking moment of the mechanism. This paper presents a design method of the uniform strength links in a planar four-bar link mechanism. The design examples are also given. Both the numerical calculating results and the experimental results show that the method is efficient for reducing the weight of the mechanism.

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This paper describes compensation methods for joint displacements caused by external forces, joint runouts, thermal deformations of links of the parallel mechanism, and flame deformation caused by heat and the external forces. In these methods, the runout and the deformation of the joints are measured and compensated by displacement sensors built in the joints or by linear scale units built in the prismatic joints of the parallel mechanism. Moreover, the thermal expansion of the links is mechanically compensated by Super-Invar rod connected to the joints and the linear scale units. Finally, nine displacement sensors with nine Super-Invar rods measure the deformation of the flame supporting the mechanism.

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A DBB (Double-Ball-Bar) based ki nematic calibration method for in -parallel actuated mechanisms using Fourier series and an algorithm for determining an optimal set of paths using these indices have been presented. For determining an set of measurement with adequate measurement pa ths and highest pose accuracy after calibration, relationship between measurement error and number of measurement path is considered and an index for evaluating error of identified value without test is proposed. Investigation of identified kinematic parameters has been carried out throu gh the experimental.

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This paper describes a kinematic analysis of a spatial parallel manipulator with three degrees-of-freedom. The output platform of the manipulator is supported with three link chains with two revolute pairs and a spherical pair. Both of direct and inverse kinematics of the manipulator were formulated and solved with Newton-Raphson method. A prototype of the manipulator was built with a rapid prototyping and was experimentally examined.

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Recently, Y.Otsubo et al., reported that a kind of dielectric fluids such as dibutyl decanedioate produced jet-flow by applying high voltage electrostatic field. The fluids are called Electro-conjugate Fluid (ECF), which are considered as smart fluids. In this study, we propose a novel micro actuator, whose new principle is application of pressure due to ECF jet flows with needle-type electrode and ring-type electrode (ECF jet flows with needle-type electrodes). In this paper, firstly, characteristics of ECF jet flows with needle-type electrodes are experimentally exermined. Consequently, it is confirmed that the pressure due to the ECF jet flows with needle-type electrodes are raised by miniaturization of electrodes, such as tip angle and base diameter of needle-type electrode, and diameter, width and height of ring-type electrode. The characteristics are suitable for microactuator. Secondly, a novel micro actuator is proposed, which is driven by pressure due to ECF jet flows with needle-type electrodes. Mathematical model of the actuator is proposed. Furthermore large model are fabricated, and then, experimentally exermined. As the result, it is confirmed that the large model is driven by new principle, and mathematical model is adequacy. Future works are fabrication and experimental exermination of the micro actuator.

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This paper deals with the constructions and their characteristics of the linear actuators, which a new functional fluid so-called ECF is applied to. ECF is an electric fluid having dibuty decanedioate as its main ingredient, and a strong flow (jet-flow) is generated from the anode to cathode when an electric field is applied to ECF. Two types of the linear actuators are developed and their characteristics such as driving speed to applied voltage and driving force to driving speed are evaluated.

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As an advanced control component for practical micromachines using fluid power in millimeter size, the authors have proposed and developed a microvalve using homogeneous electro-rheological (ER) fluid called micro ER valve. By using the homogeneous ER fluid whose viscosity is controlled by the applied electric field strength, a simple-structural control valve composed of fixed electrodes can be realized. In this paper, to mount on in-pipe working micromachines, a compact ER valve-integrated microactuator is proposed and fabricated. First, miniaturization characteristics of the micro ER valve fabricated by micromachining are examined experimentally. Second, a polyimide-diaphragm fluid microactuator is proposed, fabricated and tested. Finally, an ER valve-integrated microactuator is constructed by using above devices with 8mm width, 10mm length and 1.4mm height and the static characteristics are investigated experimentally. Also, as an application, a micro gripper driven by the actuator is demonstrated.

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In this paper, to realize micro fluid power sources applicable to microfactory or micromachines using fluid power, a resonantly-driven piezoelectric micropump with newly devised check valve unit is developed and the pumping characteristics are experimentally investigated. Furthermore, a practical application to micro press is attempted. First, micro sheet valve having the floating valve-body to increase valve-opening and to decrease pressure loss is proposed and fabricated by micromachining such as etching and micro-EDM (electrical discharge machining). The validity is verified through experiments on static characteristics between flow rates across the check valve and applied pressures. Second, frequency characteristics of the micropump that employs two micro sheet valves for inlet/outlet are experimentally investigated. Finally, a micro press equipped with the developed micropump is fabricated with he effective size of 20×20×28(mm)^3. Blanking of a hole with 0.3mm diameter to aluminum sheet with 0.01mm thickness is realized.

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A new type of pneumatic stepping motor, named pneumatic nutation motor was developed. Pneumatic nutation motor consists of some pneumatic cylinders, an input bevel gear and an output bevel gear. Injecting air into each cylinder causes nutation of the input bevel gear, which makes the output bevel gear to rotate. In this report, first, the driving principle and design of this motor are presented. Next, its characteristics are analyzed theoretically. The prototype of pneumatic nutation motor is fabricated and tested. Experimental results are very promising. The features of pneumatic nutation motor are (1) big torque, (2) simple structure , and (3) heat-, water- and dust-proof.

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Low-pressure water hydraulic is an attractive technology having the low price level of pneumatics, good controllability and stiffness of oil hydraulics as well as safety to environment. This paper deals with the dynamic characteristics of the low-pressure water hydraulic drive system consisting of a vortex pump, a flexible tube with a length of 10m, an electro-magnetic on-off valve and a single rod cylinder with some inertia loads. The step responses of pressure and piston displacement in the water hydraulic ststem under the operation condition of a low pressure are experimentally obtained. And the computer simulation of the system under the above experimental conditions was done by simulation software of OHC-Sim. On the basis of the simulation results the efficiency of water hydraulic system is also discussed.

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In this study, a precision stage constructed of the electromagnetic actuator using the rubber film has been developed. We have proposed the hybrid rubber-electromagnetic actuator (RE actuator), and have the following features. (1) Viscous damping is essentially obtained by rubber. (2) The actuator functions also as flexible joint. (3) Since there is no sliding guide, precise positioning can be performed. As an application of this actuator, the XYZ precision stage has been made. The feature of this stage is that it can be driven in the XYZ direction in spite of monolithic structure. And it is also one of the features that residual vibration does not occur after positioning. Fundamental properties of the stage are investigated, and experimental data demonstrate 20 nanometer positioning and illustrate tracking a spiral orbit.

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Two methods are proposed for grasping object with unknown weight and the friction coefficient by robot hands in recent years. First method is to detect partial incipient slip region at the contact surface. Another one is to detect the friction coefficient between robot hands and object. The latter method have demerit that needs entire slippage of an object. In the present study, new method is proposed for detecting a friction coefficient between an object and a curved surface elastic finger only by indenting the finger into the object. First, a contact condition between a plate and a elastic finger having curbed surface is calculated using finite element analysis. The deformation of the elastic finger, and strain distribution inside the elastic finger are calculated for different friction coefficients between finger and plate. Results show that strain distribution inside the finger differs when the friction coefficient differs. Experimental results show similar tendency to calculation. From these results, the method is confined that friction coefficient can be measured by elastic finger having curved surface.

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