Development and Validation of An Automated Crank Press System Integrating the Stephenson II Six-Bar Linkage and Model Predictive Control
Kuatova M. Tuleshov A. Baurzhan A. Jomartov A. Tuleshov Y. Sayakov O.
December 2025Engineered Science Publisher
ES Materials and Manufacturing
2025#30
Crank presses play a critical role in industrial manufacturing, yet traditional designs often face inefficiencies, inconsistent product quality, and safety concerns. This study introduces and validates a fully automated crank press system that combines a Stephenson II six-bar linkage with real-time sensor data and Model Predictive Control (MPC)—a predictive control method frequently associated with advanced automation. The system utilizes Linear Variable Differential Transformers (LVDTs), strain gauge load cells, and Resistance Temperature Detectors (RTDs) to monitor position, force, and temperature with high precision. Through SimulationX modeling and experimental trials, the press demonstrated a close match between simulated and empirical data, confirming its reliability and operational efficiency. By uniting the Stephenson II linkage with MPC, the system optimizes force distribution, ensures accurate ram positioning, and achieves consistent product quality while reducing mechanical wear. This integrated approach offers a safe, efficient, and precise solution for high-load industrial environments and underscores the potential for further innovation in mechanism design and predictive control.
Accepted: 03 October 2025 , Crank press , High-load precision , LVDT , Manufacturing efficiency , Mechanical automation , Model predictive control (MPC) , Real-time sensor integration , Revised: 09 October 2025 , Simulationx. Received: 25 August 2025
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Laboratory of Intelligent Robotic Systems, Joldasbekov Institute of Mechanics and Engineering, 28 Shevchenko street, Almaty, 050010, Kazakhstan
Department of Robotics and Technical Means of Automation, Satbayev University, 22 Satbaev street, Almaty, 050013, Kazakhstan
Mechanical and Aerospace Engineering Department, School of Engineering and Digital Sciences, Nazarbayev University, 53 Kabanbay Batyr, Akmola, Astana, 010000, Kazakhstan
Laboratory of Intelligent Robotic Systems
Department of Robotics and Technical Means of Automation
Mechanical and Aerospace Engineering Department
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