A non-linear multi-rigid-body system dynamic modelling is developed for the automated clutch system in power transmission during clutch engagements, especially at sharp vehicle start-up, sudden engine flame-out, low driving speed and clutch plate overwearing. In order to guarantee an ideal dynamic performance of the clutch engagement, an adaptive optimal controller is designed by considering throttle angle, engine speed, gear ratio, vehicle acceleration and road condition. A non-linear model reference adaptive controller is utilized to prevent the engine from flame-out or fly-off effectively and the minimum value principle is also introduced to achieve an optimal dynamic performance of the non-linear system compromised in friction plate wear and vehicle drive quality. The optimal trajectory of the clutch engagement can be described in the form of explicit and analytical expressions and characterized by a deterministic and accurate control strategy instead of indeterministic and soft control techniques which need thousands of experiments. For validation of the controller, test work is carried out for the automated clutch engagements in a commercial car with a traditional mechanical transmission, a hydraulic actuator, a group of sensors and a portable computer system. It is shown through experiments that dynamic behaviours of the clutch engagement operated by the adaptive optimal control are more effective and efficient than those by a fuzzy PID control.

This paper proposes a novel dual-input/single-output actuator unit, called a redundant and fault-tolerant actuator (RFTA), designed for heavy-load parallel manipulators. After the definitions of redundant and fault tolerance are given, the principle of the proposed RFTA is described using its two working processes. According to the derived kinematics, 12 fault modes caused by two different input velocities are developed and classified, and the physical meanings are represented correspondingly. Mechanical transmitting properties of the proposed RFTA are analysed respectively. On the other hand, RFTA, as a dual-module hot spare architecture to achieve high reliability and safety, with its complete redundant structure can be called Multiple Births Structure (MBS) and is different form the traditional partial redundant structures – Siamesed Births Structure (SBS). The reliability models show that RFTA is more reliable than SBS. Three guidelines – the select guideline, the design guideline, and the operation guideline – are suggested. Those design guidelines are useful to designers and users. A prototype of RFTA and its control system are developed and the relevant experiments are carried out. The experimental results demonstrate that RFTA is able to not only supply double driving force but also tolerate some local faults caused by out-of-syncs. RFTA provides heavy-duty equipment, especially large-scale parallel manipulators, with a new probability in changing their drive mode, from the hydraulic power supply to the motor drive. Furthermore, this paper also demonstrates that RFTA has some potential applicable prospects under heavy-duty environments, such as a large-scale parallel earthquake simulator and an electric press with heavy duty cycles.

In this article, an orthogonal 6-degree-of-freedom (DOF) parallel robot with redundant actuation is studied as an earthquake motion simulator. Taking the practical simulation of earthquake waves into consideration, the general characteristics of natural earthquakes are analysed and complexity and variety of seismic waves, three-dimensional and multi-DOF movement, and strong devastating force are regarded as the three obvious features in this article. Based on the characteristics of this orthogonal 6-DOF parallel robot with redundant actuation and the features of earthquakes, the feasibility of using this parallel robot as an earthquake motion simulator is analysed from three aspects: orthogonal 6-DOF structure, decoupling feature, and redundant actuation module. In order to simulate an earthquake motion using this parallel robot, its inverse kinematics and dynamics models are derived. The control system of this earthquake simulator is developed based on the PXIbus development platform. The computed-torque control algorithm based on the inverse dynamics is used in the controller of this equipment. A typical three-directional earthquake motion, the El Centro earthquake, is simulated on the end-effector of this parallel robot by means of its mathematical models and control system. Three main motion parameters of simulated seismic waves, displacements, velocities, and accelerations, are measured, respectively, by laser tracker and acceleration sensors. The experimental results show this equipment is appropriate to be used as an earthquake simulator.