2012 Vol.25(1)
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2012, 26(1).
Abstract:
Magnetic drive pump has gotten great achievement and has been widely used in some special fields. Currently, the researches on magnetic drive pump have focused on hydraulic design, bearing, axial force in China, and a new magnetic drive pump with low flow and high head have been developed overseas. However, low efficiency and large size are the common disadvantages for the magnetic drive pump. In order to study the performance of high-speed magnetic drive pump, FLUENT was used to simulate the inner flow field of magnetic drive pumps with different rotate speeds, and get velocity and pressure distributions of inner flow field. According to analysis the changes of velocity and pressure to ensure the stable operation of pump and avoid cavitation. Based on the analysis of velocity and pressure, this paper presents the pump efficiency of magnetic drive pumps with different rotated speeds by calculating the power loss in impeller and volute, hydraulic loss, volumetric loss, mechanical loss and discussing the different reasons of power loss between the magnetic drive pumps with different rotated speeds. In addition, the magnetic drive pumps were tested in a closed testing system. Pressure sensors were set in inlet and outlet of magnetic drive pumps to get the pressure and the head, while the pump efficiency could be got by calculating the power loss between the input power and the outlet power. The results of simulation and test were similar, which shows that the method of simulation is feasible. The proposed research provides the instruction to design high-speed magnetic drive pump.
Magnetic drive pump has gotten great achievement and has been widely used in some special fields. Currently, the researches on magnetic drive pump have focused on hydraulic design, bearing, axial force in China, and a new magnetic drive pump with low flow and high head have been developed overseas. However, low efficiency and large size are the common disadvantages for the magnetic drive pump. In order to study the performance of high-speed magnetic drive pump, FLUENT was used to simulate the inner flow field of magnetic drive pumps with different rotate speeds, and get velocity and pressure distributions of inner flow field. According to analysis the changes of velocity and pressure to ensure the stable operation of pump and avoid cavitation. Based on the analysis of velocity and pressure, this paper presents the pump efficiency of magnetic drive pumps with different rotated speeds by calculating the power loss in impeller and volute, hydraulic loss, volumetric loss, mechanical loss and discussing the different reasons of power loss between the magnetic drive pumps with different rotated speeds. In addition, the magnetic drive pumps were tested in a closed testing system. Pressure sensors were set in inlet and outlet of magnetic drive pumps to get the pressure and the head, while the pump efficiency could be got by calculating the power loss between the input power and the outlet power. The results of simulation and test were similar, which shows that the method of simulation is feasible. The proposed research provides the instruction to design high-speed magnetic drive pump.
2012, 26(1).
Abstract:
Heat exchangers are widely used in the process engineering such as the chemical industries, the petroleum industries, and the HVAC applications etc. An optimally designed heat exchanger cannot only help the optimization of the equipment size but also the reduction of the power consumption. In this paper, a new optimization approach called algorithms of changes (AOC) is proposed for design and optimization of the shell-tube heat exchanger. This new optimization technique is developed based on the concept of the book of changes (I Ching) which is one of the oldest Chinese classic texts. In AOC, the hexagram operations in I Ching are generalized to binary string case and an iterative process, which imitates the I Ching inference, is defined. Before applying the AOC to the heat exchanger design problem, the new optimization method is examined by the benchmark optimization problems such as the global optimization test functions and the travelling salesman problem (TSP). Based on the TSP results, the AOC is shown to be superior to the genetic algorithms (GA). The AOC is then used in the optimal design of heat exchanger. The shell inside diameter, tube outside diameter, and baffles spacing are treated as the design (or optimized) variables. The cost of the heat exchanger is arranged as the objective function. For the heat exchanger design problem, the results show that the AOC is comparable to the GA method. Both methods can find the optimal solution in a short period of time.
Heat exchangers are widely used in the process engineering such as the chemical industries, the petroleum industries, and the HVAC applications etc. An optimally designed heat exchanger cannot only help the optimization of the equipment size but also the reduction of the power consumption. In this paper, a new optimization approach called algorithms of changes (AOC) is proposed for design and optimization of the shell-tube heat exchanger. This new optimization technique is developed based on the concept of the book of changes (I Ching) which is one of the oldest Chinese classic texts. In AOC, the hexagram operations in I Ching are generalized to binary string case and an iterative process, which imitates the I Ching inference, is defined. Before applying the AOC to the heat exchanger design problem, the new optimization method is examined by the benchmark optimization problems such as the global optimization test functions and the travelling salesman problem (TSP). Based on the TSP results, the AOC is shown to be superior to the genetic algorithms (GA). The AOC is then used in the optimal design of heat exchanger. The shell inside diameter, tube outside diameter, and baffles spacing are treated as the design (or optimized) variables. The cost of the heat exchanger is arranged as the objective function. For the heat exchanger design problem, the results show that the AOC is comparable to the GA method. Both methods can find the optimal solution in a short period of time.
2012, 26(1).
Abstract:
Though the lengthened shrink-fit holder (LSFH) is widely applied in high speed milling of the parts characterized by deep cavities at present, its design and selection mainly depends on the experience and lacks a correct theoretical guidance. In this paper, attention is focus on the radial grip rigidity of the matching of LSFH and cutter in high speed milling. Based on the experiment modal analysis (EMA) technique, an accurate finite element model of the matching of LSFH and cutter is established firstly. Subsequently, the influence of different interference, grip length and spindle speed on the grip rigidity of LSFH are analyzed. The analysis results show that there is a reasonable interference and grip length between the LSFH and cutter so that to have a steepless grip and have a good radial grip rigidity and at the same time to avoid the strength of LSFH to exceed it’s yield limit which will reduce the precision and service life of LSFH, besides when spindle speed reach a extension the weakening influence of the centrifugal force on the radial grip rigidity of the matching of LSFH and cutter should been taken into account. Finally, the finite element analysis results are verified based on the construction of measurement method of the grip rigidity and the results fit very well. The studies provide a theoretical basis for the design, selection and the serialization and standardization of the matching of LSFH and cutter.
Though the lengthened shrink-fit holder (LSFH) is widely applied in high speed milling of the parts characterized by deep cavities at present, its design and selection mainly depends on the experience and lacks a correct theoretical guidance. In this paper, attention is focus on the radial grip rigidity of the matching of LSFH and cutter in high speed milling. Based on the experiment modal analysis (EMA) technique, an accurate finite element model of the matching of LSFH and cutter is established firstly. Subsequently, the influence of different interference, grip length and spindle speed on the grip rigidity of LSFH are analyzed. The analysis results show that there is a reasonable interference and grip length between the LSFH and cutter so that to have a steepless grip and have a good radial grip rigidity and at the same time to avoid the strength of LSFH to exceed it’s yield limit which will reduce the precision and service life of LSFH, besides when spindle speed reach a extension the weakening influence of the centrifugal force on the radial grip rigidity of the matching of LSFH and cutter should been taken into account. Finally, the finite element analysis results are verified based on the construction of measurement method of the grip rigidity and the results fit very well. The studies provide a theoretical basis for the design, selection and the serialization and standardization of the matching of LSFH and cutter.
2012, 26(1).
Abstract:
A new biped robot with a triangle configuration is presented and it is a planar closed chain mechanism. The scalability of three sides of the triangle is realized by three actuated prismatic joints. The three vertexes of the triangle are centers of three passive revolute joints coincidently. The biped mechanism for straight walking is proposed and its walking principle and mobility are explained. The static stability and the height and span of one step are analyzed. Kinematic analysis is performed to plan the gaits of walking on an even floor and going upstairs. A prototype is developed and experiments are carried out to validate the straight walking gait. Two additional revolute joints are added to form a modified biped robot which can follow the instruction of turning around. The turning ability is verified by experiments. As a new member of biped robots, its triangle configuration is used to impart geometry knowledge. Because of its high stiffness, some potential applications are on the way.
A new biped robot with a triangle configuration is presented and it is a planar closed chain mechanism. The scalability of three sides of the triangle is realized by three actuated prismatic joints. The three vertexes of the triangle are centers of three passive revolute joints coincidently. The biped mechanism for straight walking is proposed and its walking principle and mobility are explained. The static stability and the height and span of one step are analyzed. Kinematic analysis is performed to plan the gaits of walking on an even floor and going upstairs. A prototype is developed and experiments are carried out to validate the straight walking gait. Two additional revolute joints are added to form a modified biped robot which can follow the instruction of turning around. The turning ability is verified by experiments. As a new member of biped robots, its triangle configuration is used to impart geometry knowledge. Because of its high stiffness, some potential applications are on the way.
Quasi-static Analysis of Thrust-loaded Angular Contact Ball Bearings Part I: Theoretical Formulation
2012, 26(1).
Abstract:
Ball bearings play an important role in various rotating machineries, but the complicated kinematic and tribological features of ball bearings make many aspects of their operating behaviors still inconclusive. Most theoretical analyses of ball bearings up to date are based on either the hypothesis of race control or other empirical models to determine the ball motion of ball bearings, but none of these strategies can reveal and consequently employ the intrinsic coupling mechanism between the spin and the tangential traction of contacting bodies rolling upon one another. To remedy the deficiency of current analytical models for ball bearing analysis, the rolling contact theory is employed to establish an explicit link between motions and interactions within ball bearings. A differential slip model is established to precisely define the slip component due to the significant curvature of the common contact patches between the ball and inner/outer raceways. The creepage and the spin ratio are formulated to accurately define the relative rigid motion between the ball and the inner/outer raceway. Then a quasi-static analytical model is established that can accurately determine the motions of the balls and races of the ball bearing. It can also give a vivid description of the slip and traction distributions within the contact area. The analytical model can be effectively used to analyze the operational conditions and tribological features of solid-lubricated ball bearings. It can also be used optimize the construction of ball bearings for specific applications.
Ball bearings play an important role in various rotating machineries, but the complicated kinematic and tribological features of ball bearings make many aspects of their operating behaviors still inconclusive. Most theoretical analyses of ball bearings up to date are based on either the hypothesis of race control or other empirical models to determine the ball motion of ball bearings, but none of these strategies can reveal and consequently employ the intrinsic coupling mechanism between the spin and the tangential traction of contacting bodies rolling upon one another. To remedy the deficiency of current analytical models for ball bearing analysis, the rolling contact theory is employed to establish an explicit link between motions and interactions within ball bearings. A differential slip model is established to precisely define the slip component due to the significant curvature of the common contact patches between the ball and inner/outer raceways. The creepage and the spin ratio are formulated to accurately define the relative rigid motion between the ball and the inner/outer raceway. Then a quasi-static analytical model is established that can accurately determine the motions of the balls and races of the ball bearing. It can also give a vivid description of the slip and traction distributions within the contact area. The analytical model can be effectively used to analyze the operational conditions and tribological features of solid-lubricated ball bearings. It can also be used optimize the construction of ball bearings for specific applications.
2012, 26(1).
Abstract:
To solve the precision and reliability problem of various machinery equipments and military vehicles, some military organisations, the industrial sector and the academia at home and abroad begin to pay attention to the statistical distribution of machining dimensions, material properties and service loads, and the system reliability optimization design with constraints and reliability optimization design of various mechanical parts is studied in this way. However, the above researches focus on solving the strength and the life problem, and no studies have been done on the discrete degree and discrete pattern of other performance indicators. The concept of using a random vector to describe the mechanical parts performance indicators is presented; characteristics between the value of the vector variance matrix determinant and the sum of the diagonal covariance matrix in describing the performance indicators of vector dispersion are studied and compared. A clutch diaphragm spring is set as an example, the geometric dimension indicator is described with random vector, and the applicability of using variance matrix determinant and variance matrix trace of geometric dimension vector to describe discrete degree of random vector is studied by using Monte-Carlo simulation method and component discrete degree perturbation method. Also, the effects of different components of diaphragm spring geometric dimension vector on the value of covariance matrix determinant and the sum of covariance matrix diagonal of diaphragm spring performance indicators vector are analyzed. The present study shows that the impacts of the dispersion of diaphragm spring cone angle on every performance dispersion are all ranked first, and far exceed that of other dimension dispersion. So it must be strictly controlled in the production process. The result of the research work provides a reference for the design of diaphragm spring, and also it presents a proper method for researching the performance of other mechanical parts.
To solve the precision and reliability problem of various machinery equipments and military vehicles, some military organisations, the industrial sector and the academia at home and abroad begin to pay attention to the statistical distribution of machining dimensions, material properties and service loads, and the system reliability optimization design with constraints and reliability optimization design of various mechanical parts is studied in this way. However, the above researches focus on solving the strength and the life problem, and no studies have been done on the discrete degree and discrete pattern of other performance indicators. The concept of using a random vector to describe the mechanical parts performance indicators is presented; characteristics between the value of the vector variance matrix determinant and the sum of the diagonal covariance matrix in describing the performance indicators of vector dispersion are studied and compared. A clutch diaphragm spring is set as an example, the geometric dimension indicator is described with random vector, and the applicability of using variance matrix determinant and variance matrix trace of geometric dimension vector to describe discrete degree of random vector is studied by using Monte-Carlo simulation method and component discrete degree perturbation method. Also, the effects of different components of diaphragm spring geometric dimension vector on the value of covariance matrix determinant and the sum of covariance matrix diagonal of diaphragm spring performance indicators vector are analyzed. The present study shows that the impacts of the dispersion of diaphragm spring cone angle on every performance dispersion are all ranked first, and far exceed that of other dimension dispersion. So it must be strictly controlled in the production process. The result of the research work provides a reference for the design of diaphragm spring, and also it presents a proper method for researching the performance of other mechanical parts.
Quasi-static Analysis of Thrust-loaded Angular Contact Ball Bearings Part II: Results and Discussion
2012, 26(1).
Abstract:
Ball bearings are widely employed mechanical components characterized by high precision and quality, and usually play important roles in various rotary machines and mechanisms. Many advanced applications require a deep understanding of their various kinematic and tribological characteristics that are essential to predict the fatigue endurance, relieve the vibration and minimize the power dissipation of ball bearings in particular applications. An angular contact ball bearing under a specified operating condition is simulated with the quasi-static/creepage analytical model proposed in the preceding article. The results demonstrate that the ball bearing is a statically determinate system. That the balls spin on both inner and outer races means the ball is controlled by neither the inner nor the outer raceway. The friction between the ball and raceway renders the inner and outer contact angles unequal. The larger the coefficient of friction is, the larger the angle deviation. The tangential traction perpendicular to the rolling direction due to the spin induces a gyro-like rotation of the ball with respect to the raceway even if no inertial effects are considered. The tangential elastic compliance of contacting surfaces gives rise to locked areas within the contact patch and transforms the sliding lines from circles into spirals. The differential slip due to the close conformity of the ball and raceway makes the sliding and traction distributions asymmetric, which will influence the location of the spinning center of the ball with respect to the raceway. The quasi-static/creepage model can be used to reveal the operating behaviors of ball bearings running under steady conditions and to optimize the design of ball bearings for specific applications.
Ball bearings are widely employed mechanical components characterized by high precision and quality, and usually play important roles in various rotary machines and mechanisms. Many advanced applications require a deep understanding of their various kinematic and tribological characteristics that are essential to predict the fatigue endurance, relieve the vibration and minimize the power dissipation of ball bearings in particular applications. An angular contact ball bearing under a specified operating condition is simulated with the quasi-static/creepage analytical model proposed in the preceding article. The results demonstrate that the ball bearing is a statically determinate system. That the balls spin on both inner and outer races means the ball is controlled by neither the inner nor the outer raceway. The friction between the ball and raceway renders the inner and outer contact angles unequal. The larger the coefficient of friction is, the larger the angle deviation. The tangential traction perpendicular to the rolling direction due to the spin induces a gyro-like rotation of the ball with respect to the raceway even if no inertial effects are considered. The tangential elastic compliance of contacting surfaces gives rise to locked areas within the contact patch and transforms the sliding lines from circles into spirals. The differential slip due to the close conformity of the ball and raceway makes the sliding and traction distributions asymmetric, which will influence the location of the spinning center of the ball with respect to the raceway. The quasi-static/creepage model can be used to reveal the operating behaviors of ball bearings running under steady conditions and to optimize the design of ball bearings for specific applications.
2012, 26(1).
Abstract:
In the high precision image measurement system, the verticality error between the axis of the shooting system and the measured object can bring error of the measurement result. The high demand of the system’s vertical degree is raised by measure system due to the demands of high precision and disposable full field imaging in the micro-parts imaging measurement. The existing method of optical axis verticality detection cannot meet the demand all. In order to achieve the high-precision adjustment of the system optical axis, the algorithm of detecting verticality based on regional image definition is proposed. First, the objected standard image is divided into fixed area. Then, the object plane is moved from the downside to the upside of the focus plane, meanwhile, recording the definition function values of each standard image region at each step, and fitting out the clearest positions of the regions. Finally, according to the inter-regional relations between the locations and the height difference of the each regional clearest position, the small angle between the optical axis and the measured surface can be calculated. The experiment is based on the given image of lithography template with the scale of 10 μm as move unit, and the results show that this method effective reduced the small angle between the system optical axis and the measured body in high-precision image measuring system, the evaluation accuracy is less than 0.1°, meeting the requirements in high-precision measurement. The proposed method of detecting verticality based on regional image definition can evaluate the verticality error between the axis of the shooting system and the measured object accurately, effectively and conveniently.
In the high precision image measurement system, the verticality error between the axis of the shooting system and the measured object can bring error of the measurement result. The high demand of the system’s vertical degree is raised by measure system due to the demands of high precision and disposable full field imaging in the micro-parts imaging measurement. The existing method of optical axis verticality detection cannot meet the demand all. In order to achieve the high-precision adjustment of the system optical axis, the algorithm of detecting verticality based on regional image definition is proposed. First, the objected standard image is divided into fixed area. Then, the object plane is moved from the downside to the upside of the focus plane, meanwhile, recording the definition function values of each standard image region at each step, and fitting out the clearest positions of the regions. Finally, according to the inter-regional relations between the locations and the height difference of the each regional clearest position, the small angle between the optical axis and the measured surface can be calculated. The experiment is based on the given image of lithography template with the scale of 10 μm as move unit, and the results show that this method effective reduced the small angle between the system optical axis and the measured body in high-precision image measuring system, the evaluation accuracy is less than 0.1°, meeting the requirements in high-precision measurement. The proposed method of detecting verticality based on regional image definition can evaluate the verticality error between the axis of the shooting system and the measured object accurately, effectively and conveniently.
2012, 26(1).
Abstract:
Now the researches concerning integral bus mainly focused on design and analysis of overall mechanical property of bus body, and paid little attention to characteristic of local structures, such as joint, plug welding hole, and bolt connection point, etc. So there is much blindness on the design of local connecting structure. Since integral bus body structure cancels large section longitudinal beam, and uses framework made by welding small section bars together as principal part to bear the whole load when the vehicle works, there are many joints receiving high load in the body structure, and local stress concentration can not be avoided. Under such circumstances, by adopting beam-shell mixed model based on super element technique, and selecting a joint commonly used by bus sidewall, the rule of the effect of bar joints welding seam spacing on joints local mechanical property is investigated in this paper, and the investigating results show that joints have minimum stress concentration with welding seam spacing of 8 mm. To learn whether the above rule is affected by relative bar wall thickness, many groups of bars with different relative bar wall thicknesses are studied experimentally, and the experimental results show that the joints local stress levels vary with different relative bar wall thicknesses, but the rule of the effect of bar joints welding seam spacing on joints local stress level remains the same. The research is significant for local structure design of bus joint in the future.
Now the researches concerning integral bus mainly focused on design and analysis of overall mechanical property of bus body, and paid little attention to characteristic of local structures, such as joint, plug welding hole, and bolt connection point, etc. So there is much blindness on the design of local connecting structure. Since integral bus body structure cancels large section longitudinal beam, and uses framework made by welding small section bars together as principal part to bear the whole load when the vehicle works, there are many joints receiving high load in the body structure, and local stress concentration can not be avoided. Under such circumstances, by adopting beam-shell mixed model based on super element technique, and selecting a joint commonly used by bus sidewall, the rule of the effect of bar joints welding seam spacing on joints local mechanical property is investigated in this paper, and the investigating results show that joints have minimum stress concentration with welding seam spacing of 8 mm. To learn whether the above rule is affected by relative bar wall thickness, many groups of bars with different relative bar wall thicknesses are studied experimentally, and the experimental results show that the joints local stress levels vary with different relative bar wall thicknesses, but the rule of the effect of bar joints welding seam spacing on joints local stress level remains the same. The research is significant for local structure design of bus joint in the future.
2012, 26(1).
Abstract:
In the traditional flow-resistance-differential (FRD) type valve-less piezoelectric pump, the generated outflow and pressure are discontinuous because of the inherent periodicity and fluctuation of the pump. To overcome these drawbacks, utilizing the bending vibration of piezoelectric bimorph to drive fluid was conducted. However, our investigation on the current status of this piezoelectric bimorph pump shows that larger driving force and vibration amplitude are required for fluid pumping; the pumping can be realized through the centrifugal force; and the mechanism of fluid pumping is no longer further studied. Based on these cases, the paper designed a piezoelectric-stack pump with variable-cross-section oscillating (VCSO) vibrator by imitating the swing of the caudal-fin of tuna, and the pump is neither the rotating type nor the volumetric type according to the taxonomy. The interaction between the oscillating vibrator and the fluid parcel is firstly analyzed from the viewpoint of momentum conservation, and the analytical expression of pump flow rate is obtained. Then the modal and harmonic response analyses on the vibrator immerged in water are carried out. From the analyses the first two orders resonance frequencies are 832 Hz and 1 939 Hz, respectively, and the peak value of the tip amplitude is 0.6 mm. Laser Doppler vibrometer is used to measure both the frequency and vibration amplitude, and the determined first two orders resonance frequencies are 617 Hz and 1 356 Hz, respectively. The measured tip amplitude reaches to the peak value of 0.3 mm. At last, experimental measurement for the flow rates with different driving frequencies is conducted. The results show that the flow rate can reach 560 mLmin at 1 370 Hz when the pump runs under the backpressure of 30 mm water column. And the flow rate is as much as 560% of that of experiment results carried out by researchers from Brazil. The proposed pump innovates in both theory and taxonomy; in addition, the pump overcomes the drawbacks such as large flow fluctuation and low flow rate in the traditional FRD type pumps, which will help to broaden the application of the valve-less piezoelectric pump.
In the traditional flow-resistance-differential (FRD) type valve-less piezoelectric pump, the generated outflow and pressure are discontinuous because of the inherent periodicity and fluctuation of the pump. To overcome these drawbacks, utilizing the bending vibration of piezoelectric bimorph to drive fluid was conducted. However, our investigation on the current status of this piezoelectric bimorph pump shows that larger driving force and vibration amplitude are required for fluid pumping; the pumping can be realized through the centrifugal force; and the mechanism of fluid pumping is no longer further studied. Based on these cases, the paper designed a piezoelectric-stack pump with variable-cross-section oscillating (VCSO) vibrator by imitating the swing of the caudal-fin of tuna, and the pump is neither the rotating type nor the volumetric type according to the taxonomy. The interaction between the oscillating vibrator and the fluid parcel is firstly analyzed from the viewpoint of momentum conservation, and the analytical expression of pump flow rate is obtained. Then the modal and harmonic response analyses on the vibrator immerged in water are carried out. From the analyses the first two orders resonance frequencies are 832 Hz and 1 939 Hz, respectively, and the peak value of the tip amplitude is 0.6 mm. Laser Doppler vibrometer is used to measure both the frequency and vibration amplitude, and the determined first two orders resonance frequencies are 617 Hz and 1 356 Hz, respectively. The measured tip amplitude reaches to the peak value of 0.3 mm. At last, experimental measurement for the flow rates with different driving frequencies is conducted. The results show that the flow rate can reach 560 mLmin at 1 370 Hz when the pump runs under the backpressure of 30 mm water column. And the flow rate is as much as 560% of that of experiment results carried out by researchers from Brazil. The proposed pump innovates in both theory and taxonomy; in addition, the pump overcomes the drawbacks such as large flow fluctuation and low flow rate in the traditional FRD type pumps, which will help to broaden the application of the valve-less piezoelectric pump.
2012, 26(1).
Abstract:
Improvements in hybrid electric vehicle (HEV) fuel economy and emissions heavily depend on an efficient energy management strategy (EMS). However, the uncertainty of future driving conditions generally cannot be easily tackled in EMS design. Most existing EMSs act upon fixed parameters and cannot adapt to varying driving conditions. Therefore, they usually fail to fully explore the potential of these advanced vehicles. In this paper, a novel EMS design procedure based on neural dynamic programming (NDP) is proposed. The NDP is a generic online learning algorithm, which combines stochastic dynamic programming (SDP) and the temporal difference (TD) method. Instead of computing the utility function and optimal control actions through Bellman equations, the NDP algorithm uses two neural networks to approximate them. The weights of these neural networks are updated online by the TD method. It avoids the high computational cost that SDP suffers from and is suitable for real-time implementation. The main advantages of NDP EMS is that it does not rely on prior information related to future driving conditions, and can self-tune with a wide variance in operating conditions. The NDP EMS has been applied to “Qianghua-I”, a prototype of a parallel HEV, using a revolving drum test bench for verification. Experiment results illustrate the potential of the proposed EMS in terms of fuel economy and in keeping state of charge (SOC) deviations at a low level. The proposed research ensures the optimality of NDP EMS, as well as real-time applicability.
Improvements in hybrid electric vehicle (HEV) fuel economy and emissions heavily depend on an efficient energy management strategy (EMS). However, the uncertainty of future driving conditions generally cannot be easily tackled in EMS design. Most existing EMSs act upon fixed parameters and cannot adapt to varying driving conditions. Therefore, they usually fail to fully explore the potential of these advanced vehicles. In this paper, a novel EMS design procedure based on neural dynamic programming (NDP) is proposed. The NDP is a generic online learning algorithm, which combines stochastic dynamic programming (SDP) and the temporal difference (TD) method. Instead of computing the utility function and optimal control actions through Bellman equations, the NDP algorithm uses two neural networks to approximate them. The weights of these neural networks are updated online by the TD method. It avoids the high computational cost that SDP suffers from and is suitable for real-time implementation. The main advantages of NDP EMS is that it does not rely on prior information related to future driving conditions, and can self-tune with a wide variance in operating conditions. The NDP EMS has been applied to “Qianghua-I”, a prototype of a parallel HEV, using a revolving drum test bench for verification. Experiment results illustrate the potential of the proposed EMS in terms of fuel economy and in keeping state of charge (SOC) deviations at a low level. The proposed research ensures the optimality of NDP EMS, as well as real-time applicability.
2012, 26(1).
Abstract:
Contact problems are one of the most challenging fields in virtual assembly. Information of contact states could be utilized to realize compliant motion of work pieces, to analyze the contact stress, to assist positioning parts and so on. Some methods have already been proposed to estimate contact states between objects and in most of these methods contact states between objects are simplified in order to realize real-time visual reality animation. While in virtual assembly contact states between parts are required to analyze contact stress, deformation and quality. Besides the contact state estimation method for virtual assembly should be able to handle a number of complex parts in real time. There are rarely known methods which could meet this requirement till now. In this study a contact state estimation algorithm based on surface-matching for virtual assembly is proposed. Contacts between parts are categorized into six basic types according to contact region of surfaces. Based on continuous collision detection of polyhedral models a novel contact state identification algorithm which is based on surface matching is proposed. Then contact evolution algorithm, which utilizes the extern force and contact information, is implemented to handle evolution of contact state. Finally a prototype system is developed to verify the above technologies. Experiment results reveal that contact state between parts could be estimated correctly in real time virtual assembly. The proposed contact state estimation algorithm provides a complete solution to obtain the contact state between parts in virtual assembly. Information of contact state between parts could be utilized to realize contact dynamic, contact stress analysis, assembly quality analysis, and so on.
Contact problems are one of the most challenging fields in virtual assembly. Information of contact states could be utilized to realize compliant motion of work pieces, to analyze the contact stress, to assist positioning parts and so on. Some methods have already been proposed to estimate contact states between objects and in most of these methods contact states between objects are simplified in order to realize real-time visual reality animation. While in virtual assembly contact states between parts are required to analyze contact stress, deformation and quality. Besides the contact state estimation method for virtual assembly should be able to handle a number of complex parts in real time. There are rarely known methods which could meet this requirement till now. In this study a contact state estimation algorithm based on surface-matching for virtual assembly is proposed. Contacts between parts are categorized into six basic types according to contact region of surfaces. Based on continuous collision detection of polyhedral models a novel contact state identification algorithm which is based on surface matching is proposed. Then contact evolution algorithm, which utilizes the extern force and contact information, is implemented to handle evolution of contact state. Finally a prototype system is developed to verify the above technologies. Experiment results reveal that contact state between parts could be estimated correctly in real time virtual assembly. The proposed contact state estimation algorithm provides a complete solution to obtain the contact state between parts in virtual assembly. Information of contact state between parts could be utilized to realize contact dynamic, contact stress analysis, assembly quality analysis, and so on.
2012, 26(1).
Abstract:
The reliability-based maintenance optimization model has been focused by the engineers and scholars but it has never been solved effectively to formulate the effect of a maintenance action on the optimization model. In existing works, the system reliability was assumed to be increased to 1 after a predictive maintenance. However, it is very difficult in the most practical systems. Therefore, a new reliability-based maintenance optimization model under imperfect predictive maintenance (PM) is proposed in this paper. In the model, the system reliability is only restored to Ri (0Ri 1, iN, N is natural number set) after the ith PM. The system uptimes and the corresponding probability in two cases whether there is an unexpected fault in one cycle are derived respectively and the system expected uptime model is given. To formulate the system expected downtime, the probability of each imperfect PM number in one cycle is calculated. Then, the system expected total time model is obtained. The total expected long-term operation cost is composed of the expected maintenance cost, the expected loss due to the downtime and the expected additional cost due to the occurrence of an unexpected failure. They are modeled respectively in this work. Jointing the system expected total time and long-term operation cost in one cycle, the expected long-term operation cost per time could be computed. Then, the proposed maintenance optimization model is formulated where the objective function is to minimize the expected long-term operation cost per time. The results of numerical example show that the proposed model could scheme the optimal maintenance actions for the considered system when the required parameters are given and the optimal solution of the proposed model is sensitive to the parameters of effective age model and insensitive to other parameters. The proposed model effectively solves the problem of evaluating the effect of an imperfect PM on the system reliability and presents a more practical optimization method for the reliability-based maintenance strategy than the existing works.
The reliability-based maintenance optimization model has been focused by the engineers and scholars but it has never been solved effectively to formulate the effect of a maintenance action on the optimization model. In existing works, the system reliability was assumed to be increased to 1 after a predictive maintenance. However, it is very difficult in the most practical systems. Therefore, a new reliability-based maintenance optimization model under imperfect predictive maintenance (PM) is proposed in this paper. In the model, the system reliability is only restored to Ri (0Ri 1, iN, N is natural number set) after the ith PM. The system uptimes and the corresponding probability in two cases whether there is an unexpected fault in one cycle are derived respectively and the system expected uptime model is given. To formulate the system expected downtime, the probability of each imperfect PM number in one cycle is calculated. Then, the system expected total time model is obtained. The total expected long-term operation cost is composed of the expected maintenance cost, the expected loss due to the downtime and the expected additional cost due to the occurrence of an unexpected failure. They are modeled respectively in this work. Jointing the system expected total time and long-term operation cost in one cycle, the expected long-term operation cost per time could be computed. Then, the proposed maintenance optimization model is formulated where the objective function is to minimize the expected long-term operation cost per time. The results of numerical example show that the proposed model could scheme the optimal maintenance actions for the considered system when the required parameters are given and the optimal solution of the proposed model is sensitive to the parameters of effective age model and insensitive to other parameters. The proposed model effectively solves the problem of evaluating the effect of an imperfect PM on the system reliability and presents a more practical optimization method for the reliability-based maintenance strategy than the existing works.
2012, 26(1).
Abstract:
The mechanical balance process is the key process to eliminate the quadrature error and improve the performance of the cupped wave gyro. The conventional mechanical balance method for cupped wave gyro based on cup-wall trimming requires high control accuracy of trimming quantity, which increases the production cost and decreases the fabrication efficiency in large extent. However, it is hard to reach the high balance accuracy with the natural frequency split of mHz grade by using the conventional method. In this paper, the lumped mass dynamic model of the cupped wave gyro is built by discretization method, and the effects of different position trimming on the natural frequency are analyzed. It is pointed out that trimming off a tiny quantity of material from cup-wall causes large variation of the natural frequency is the main reason for the low accuracy of the conventional mechanical balance method. Then, a precision balance method for cupped wave gyro based on cup-bottom trimming is presented and the entire procedures of this method are given. The static balance process and dynamic balance process of the precision balance method are simulated by the finite element software. The simulation result shows that the precision balance method based on cup-bottom trimming brings less additional natural frequency split in the static balance process, minimizes the natural frequency split to mHz grade and rectify the angle of mode offset to 0.1° grade in the dynamic balance process, furthermore, the method decreases the requirement for control accuracy of trimming quantity evidently. The research work provides references for structure optimization design and balance process plan of the cupped wave gyro.
The mechanical balance process is the key process to eliminate the quadrature error and improve the performance of the cupped wave gyro. The conventional mechanical balance method for cupped wave gyro based on cup-wall trimming requires high control accuracy of trimming quantity, which increases the production cost and decreases the fabrication efficiency in large extent. However, it is hard to reach the high balance accuracy with the natural frequency split of mHz grade by using the conventional method. In this paper, the lumped mass dynamic model of the cupped wave gyro is built by discretization method, and the effects of different position trimming on the natural frequency are analyzed. It is pointed out that trimming off a tiny quantity of material from cup-wall causes large variation of the natural frequency is the main reason for the low accuracy of the conventional mechanical balance method. Then, a precision balance method for cupped wave gyro based on cup-bottom trimming is presented and the entire procedures of this method are given. The static balance process and dynamic balance process of the precision balance method are simulated by the finite element software. The simulation result shows that the precision balance method based on cup-bottom trimming brings less additional natural frequency split in the static balance process, minimizes the natural frequency split to mHz grade and rectify the angle of mode offset to 0.1° grade in the dynamic balance process, furthermore, the method decreases the requirement for control accuracy of trimming quantity evidently. The research work provides references for structure optimization design and balance process plan of the cupped wave gyro.
2012, 26(1).
Abstract:
China’s High-speed steel cutting tools hold a considerable share in the global market. However, the overproduction of low-end HSS tools causes serious resource waste and low efficiency, which has become one of the major problems in the tool industry in China. So a new Surface Modification technology is developed, which can make the low-end HSS tools into the high-end ones. On the analysis of the mechanism of cryogenic and quenching-polish-quenching(QPQ), the cryogenic and QPQ compound treatment are studied by using 8 HSS(M2) drills. The nitriding layer and the base of the drill bit are Studied and analyzed, and the mechanism of compound treatment is discussed by the technological parameters adjustment and the combination test of cryogenic, nitrogen, tempering procedures, and several analysis methods such as the optics metallographic microscope, the scanning electronic microscope (SEM), X-ray diffraction and micro hardness. The cutting test is done on the drills by cryogenic treatment, QPQ treatment and cryogenic and QPQ compound treatment separately. The results indicates that the cutting life of HSS (M2) drill can be increased dramatically by cryogenic and QPQ compound treatment.
China’s High-speed steel cutting tools hold a considerable share in the global market. However, the overproduction of low-end HSS tools causes serious resource waste and low efficiency, which has become one of the major problems in the tool industry in China. So a new Surface Modification technology is developed, which can make the low-end HSS tools into the high-end ones. On the analysis of the mechanism of cryogenic and quenching-polish-quenching(QPQ), the cryogenic and QPQ compound treatment are studied by using 8 HSS(M2) drills. The nitriding layer and the base of the drill bit are Studied and analyzed, and the mechanism of compound treatment is discussed by the technological parameters adjustment and the combination test of cryogenic, nitrogen, tempering procedures, and several analysis methods such as the optics metallographic microscope, the scanning electronic microscope (SEM), X-ray diffraction and micro hardness. The cutting test is done on the drills by cryogenic treatment, QPQ treatment and cryogenic and QPQ compound treatment separately. The results indicates that the cutting life of HSS (M2) drill can be increased dramatically by cryogenic and QPQ compound treatment.
2012, 26(1).
Abstract:
The velocity, pressure and temperature distributions of the flow in the gap between hydro-viscous drive friction disks are the key parameters in the design of hydro-viscous drive and angular velocity controller. In the previous works dealing with the flow in the gap between disks in hydro-viscous drive, few authors considered the effect of Coriolis force on the flow. The object of this work is to investigate the flow with consideration of the effects of centrifugal force, Coriolis force and variable viscosity. A simplified mathematical model based on steady and laminar flow is presented. An approximate solution to the simplified mathematical model is obtained by using the iteration method assuming that the fluid viscosity remains constant. Then the model considering the effect of variable viscosity is solved by means of computational fluid dynamics code FLUENT. Numerical results of the flow are obtained. It is found that radial velocity profile diverges from the ideal parabolic curve due to inertial forces and tangential velocity profile is nonlinear due to Coriolis force, and pressure has two possible solution branches. In addition, it is found that variable viscosity plays an important role on pressure profiles which are significantly different from those of fluid with constant viscosity. The experimental device designed for this work consists of two disks, and one of them is fixed. Experimental pressure and temperature of the flow within test rig are obtained. It is shown that the trend of numerical results is in agreement with that of experimental ones. The research provides a theoretical foundation for hydro-viscous drive design.
The velocity, pressure and temperature distributions of the flow in the gap between hydro-viscous drive friction disks are the key parameters in the design of hydro-viscous drive and angular velocity controller. In the previous works dealing with the flow in the gap between disks in hydro-viscous drive, few authors considered the effect of Coriolis force on the flow. The object of this work is to investigate the flow with consideration of the effects of centrifugal force, Coriolis force and variable viscosity. A simplified mathematical model based on steady and laminar flow is presented. An approximate solution to the simplified mathematical model is obtained by using the iteration method assuming that the fluid viscosity remains constant. Then the model considering the effect of variable viscosity is solved by means of computational fluid dynamics code FLUENT. Numerical results of the flow are obtained. It is found that radial velocity profile diverges from the ideal parabolic curve due to inertial forces and tangential velocity profile is nonlinear due to Coriolis force, and pressure has two possible solution branches. In addition, it is found that variable viscosity plays an important role on pressure profiles which are significantly different from those of fluid with constant viscosity. The experimental device designed for this work consists of two disks, and one of them is fixed. Experimental pressure and temperature of the flow within test rig are obtained. It is shown that the trend of numerical results is in agreement with that of experimental ones. The research provides a theoretical foundation for hydro-viscous drive design.
2012, 26(1).
Abstract:
Many years experience of the operation of high stress (72% specified minimum yield strength, SMYS) gas pipelines and statistical analysis results of pipeline incidents showed that the operating pipelines at stress levels over 72% SMYS have not presented problems in USA and Canada, and design factor does not control incidents or the safety of pipelines. Enhancing pipeline safety management level is most important for decreasing incident rate. The application history of higher design factors in the U.S and Canada was reviewed. And the effect of higher factors to the critical flaw size, puncture resistance, change of reliability with time, risk level and the arrest toughness requirements of pipeline were analyzed here. The comparison of pipeline failure rates and risk levels between two design factors (0.72 and 0.8) has shown that a change in design factor from 0.72 to 0.8 would bring little effect on failure rates and risk levels. On the basis of the analysis result, the application feasibility of design factor of 0.8 in China was discussed and the related suggestions were proposed. When an operator wishes to apply design factor 0.8 to gas pipeline, the following process is recommended: stress level of line pipe hydro test should be up to 100% SMYS, reliability and risk assessment at the design feasibility or conceptual stage should be conducted, Charpy impact energy should meet the need of pipeline crack arrest; and establish and execute risk based integrity management plan. The technology of pipeline steel metallurgy, line pipe fabrication and pipeline construction, and line pipe quality control level in China achieved tremendous progresses, and line pipe product standards and property indexes have come up to international advanced level. Furthermore, pipeline safety management has improved greatly in China. Consequently, the research for the feasibility of application of design factor of 0.8 in China has fundamental basis.
Many years experience of the operation of high stress (72% specified minimum yield strength, SMYS) gas pipelines and statistical analysis results of pipeline incidents showed that the operating pipelines at stress levels over 72% SMYS have not presented problems in USA and Canada, and design factor does not control incidents or the safety of pipelines. Enhancing pipeline safety management level is most important for decreasing incident rate. The application history of higher design factors in the U.S and Canada was reviewed. And the effect of higher factors to the critical flaw size, puncture resistance, change of reliability with time, risk level and the arrest toughness requirements of pipeline were analyzed here. The comparison of pipeline failure rates and risk levels between two design factors (0.72 and 0.8) has shown that a change in design factor from 0.72 to 0.8 would bring little effect on failure rates and risk levels. On the basis of the analysis result, the application feasibility of design factor of 0.8 in China was discussed and the related suggestions were proposed. When an operator wishes to apply design factor 0.8 to gas pipeline, the following process is recommended: stress level of line pipe hydro test should be up to 100% SMYS, reliability and risk assessment at the design feasibility or conceptual stage should be conducted, Charpy impact energy should meet the need of pipeline crack arrest; and establish and execute risk based integrity management plan. The technology of pipeline steel metallurgy, line pipe fabrication and pipeline construction, and line pipe quality control level in China achieved tremendous progresses, and line pipe product standards and property indexes have come up to international advanced level. Furthermore, pipeline safety management has improved greatly in China. Consequently, the research for the feasibility of application of design factor of 0.8 in China has fundamental basis.
2012, 26(1).
Abstract:
The existing research of the flatness control for strip cold rolling mainly focuses on the calculation of the optimum adjustment of individual flatness actuator in accordance with the flatness deviation, which can be used for general flatness control. However, it does not work for some special rolling processes, such as the elimination of ultra single side edge-waves and the prevention of strip break due to tilting roll control overshooting. For the purpose of solving these problems, the influences of non-symmetrical work roll bending and intermediate roll bending on flatness control were analyzed by studying efficiencies of them. Moreover, impacts of two kinds of non-symmetrical roll bending control on the pressure distribution between rolls were studied theoretically. A non-symmetrical work roll bending model was developed by theoretical analysis in accordance with practical conditions. The model was applied to the revamp of a 1250 6-H reversible universal crown mill (UCM) cold mill. Theoretical study and practical applications show that the coordination utilization of the non-symmetrical work roll bending control and tilting roll control was effective in flatness control when there appeared bad strip single side edge waves, especially when the incoming strip was with a wedge shape. In addition, the risk of strip break due to tilting control overshooting could be reduced. Furthermore, the non-symmetrical roll bending control can reduce the extent of uneven distribution of pressure between rolls caused by intermediate roll shifting in flatness control and slow down roll wear. The non-symmetrical roll bending control technology has important theoretical and practical significance to better flatness control.
The existing research of the flatness control for strip cold rolling mainly focuses on the calculation of the optimum adjustment of individual flatness actuator in accordance with the flatness deviation, which can be used for general flatness control. However, it does not work for some special rolling processes, such as the elimination of ultra single side edge-waves and the prevention of strip break due to tilting roll control overshooting. For the purpose of solving these problems, the influences of non-symmetrical work roll bending and intermediate roll bending on flatness control were analyzed by studying efficiencies of them. Moreover, impacts of two kinds of non-symmetrical roll bending control on the pressure distribution between rolls were studied theoretically. A non-symmetrical work roll bending model was developed by theoretical analysis in accordance with practical conditions. The model was applied to the revamp of a 1250 6-H reversible universal crown mill (UCM) cold mill. Theoretical study and practical applications show that the coordination utilization of the non-symmetrical work roll bending control and tilting roll control was effective in flatness control when there appeared bad strip single side edge waves, especially when the incoming strip was with a wedge shape. In addition, the risk of strip break due to tilting control overshooting could be reduced. Furthermore, the non-symmetrical roll bending control can reduce the extent of uneven distribution of pressure between rolls caused by intermediate roll shifting in flatness control and slow down roll wear. The non-symmetrical roll bending control technology has important theoretical and practical significance to better flatness control.
2012, 26(1).
Abstract:
In nature, to realize the smooth motion for different speeds, the continuous gait transition is usually required for the quadrupeds. Thus, the gait simulation of quadrupeds is a requisite step to obtain the stable and energy-efficient gait for the walking machines. In this paper, the definitions of the two gait parameters, phasic difference and duty factor are presented, which can determine the gait of the quadrupeds. Then, several typical gaits of the quadrupeds are analyzed such that the seven standard gaits and corresponding parameters are summarized. Additionally, the variance law of the two parameters, which determine the relationship of gait transition, is analyzed. Furthermore, the quadruped gait derivative spectrum (QGDS) is proposed and the gait definition of the quadrupeds is presented. To minimize the power consumption, the choice criterion of gait, the optimal gait in terms of the motion speed, duty factory, and power consumption for the walking machines, is developed. Last, the continuous variance of the gait is implemented by the simulation of the gait transition from walk to trot, which evaluate the choice criterion and transition of gait.
In nature, to realize the smooth motion for different speeds, the continuous gait transition is usually required for the quadrupeds. Thus, the gait simulation of quadrupeds is a requisite step to obtain the stable and energy-efficient gait for the walking machines. In this paper, the definitions of the two gait parameters, phasic difference and duty factor are presented, which can determine the gait of the quadrupeds. Then, several typical gaits of the quadrupeds are analyzed such that the seven standard gaits and corresponding parameters are summarized. Additionally, the variance law of the two parameters, which determine the relationship of gait transition, is analyzed. Furthermore, the quadruped gait derivative spectrum (QGDS) is proposed and the gait definition of the quadrupeds is presented. To minimize the power consumption, the choice criterion of gait, the optimal gait in terms of the motion speed, duty factory, and power consumption for the walking machines, is developed. Last, the continuous variance of the gait is implemented by the simulation of the gait transition from walk to trot, which evaluate the choice criterion and transition of gait.
2012, 26(1).
Abstract:
Spanwise flexibility is a key factor influencing propulsion performance of pectoral foils. Performances of bionic fish with oscillating pectoral foils can be enhanced by properly selecting the spanwise flexibility. The influence law of spanwise flexibility on thrust generation and propulsion efficiency of a rectangular hydro-foil is discussed. Series foils constructed by the two-component silicon rubber are developed. NACA0015 shape of chordwise cross-section is employed. The foils are strengthened by fin rays of different rigidity to realize variant spanwise rigidity and almost the same chordwise flexibility. Experiments on a towing platform developed are carried out at low Reynolds numbers of 10 000, 15 000, and 20 000 and Strouhal numbers from 0.1 to 1. The following experimental results are achieved: (1) The average forward thrust increases with the St number increased; (2) Certain degree of spanwise flexibility is beneficial to the forward thrust generation, but the thrust gap is not large for the fins of different spanwise rigidity; (3) The fin of the maximal spanwise flexibility owns the highest propulsion efficiency; (4) Effect of the Reynolds number on the propulsion efficiency is significant. The experimental results can be utilized as a reference in deciding the spanwise flexibility of bionic pectoral fins in designing of robotic fish prototype propelled by flapping-wing.
Spanwise flexibility is a key factor influencing propulsion performance of pectoral foils. Performances of bionic fish with oscillating pectoral foils can be enhanced by properly selecting the spanwise flexibility. The influence law of spanwise flexibility on thrust generation and propulsion efficiency of a rectangular hydro-foil is discussed. Series foils constructed by the two-component silicon rubber are developed. NACA0015 shape of chordwise cross-section is employed. The foils are strengthened by fin rays of different rigidity to realize variant spanwise rigidity and almost the same chordwise flexibility. Experiments on a towing platform developed are carried out at low Reynolds numbers of 10 000, 15 000, and 20 000 and Strouhal numbers from 0.1 to 1. The following experimental results are achieved: (1) The average forward thrust increases with the St number increased; (2) Certain degree of spanwise flexibility is beneficial to the forward thrust generation, but the thrust gap is not large for the fins of different spanwise rigidity; (3) The fin of the maximal spanwise flexibility owns the highest propulsion efficiency; (4) Effect of the Reynolds number on the propulsion efficiency is significant. The experimental results can be utilized as a reference in deciding the spanwise flexibility of bionic pectoral fins in designing of robotic fish prototype propelled by flapping-wing.
2012, 26(1).
Abstract:
Planetary gear set is the critical component in helicopter transmission train, and an important problem in condition monitoring and health management of planetary gear set is quantitative damage detection. In order to resolve this problem, an approach based on physical models is presented to detect damage quantitatively in planetary gear set. A particular emphasis is put on a feature generation and selection method, which is used for sun gear tooth breakage damage detection quantitatively in planetary gear box of helicopter transmission system. In this feature generation procedure, the pure torsional dynamical models of 2K-H planetary gear set is established for healthy case and sun gear tooth-breakage case. Then, a feature based on the spectrum of simulation signals of the dynamical models is generated. Aiming at selecting the best feature suitable for quantitative damage detection, a two-sample Z-test procedure is used to analyze the performance of features on damage evolution tracing. A feature named SR, which had better performance in tracking damage, is proposed to detect damage in planetary gear set. Meanwhile, the sun gear tooth-chipped seeded experiments with different severity are designed to validate the method above, and then the test vibration signal is picked up and used for damage detection. With the results of several experiments for quantitative damage detection, the feasibility and the effect of this approach are verified. The proposed method can supply an effective tool for degradation state identification in condition monitoring and health management of helicopter transmission system.
Planetary gear set is the critical component in helicopter transmission train, and an important problem in condition monitoring and health management of planetary gear set is quantitative damage detection. In order to resolve this problem, an approach based on physical models is presented to detect damage quantitatively in planetary gear set. A particular emphasis is put on a feature generation and selection method, which is used for sun gear tooth breakage damage detection quantitatively in planetary gear box of helicopter transmission system. In this feature generation procedure, the pure torsional dynamical models of 2K-H planetary gear set is established for healthy case and sun gear tooth-breakage case. Then, a feature based on the spectrum of simulation signals of the dynamical models is generated. Aiming at selecting the best feature suitable for quantitative damage detection, a two-sample Z-test procedure is used to analyze the performance of features on damage evolution tracing. A feature named SR, which had better performance in tracking damage, is proposed to detect damage in planetary gear set. Meanwhile, the sun gear tooth-chipped seeded experiments with different severity are designed to validate the method above, and then the test vibration signal is picked up and used for damage detection. With the results of several experiments for quantitative damage detection, the feasibility and the effect of this approach are verified. The proposed method can supply an effective tool for degradation state identification in condition monitoring and health management of helicopter transmission system.
2012, 26(1).
Abstract:
Servo scanning 3D micro electrical discharge machining (3D SSMEDM) is a novel and effective method in fabricating complex 3D micro structures with high aspect ratio on conducting materials. In 3D SSMEDM process, the axial wear of tool electrode can be compensated automatically by servo-keeping discharge gap, instead of the traditional methods that depend on experiential models or intermittent compensation. However, the effects of process parameters on 3D SSMEDM have not been reported up until now. In this study, the emphasis is laid on the effects of pulse duration, peak current, machining polarity, track style, track overlap, and scanning velocity on the 3D SSMEDM performances of machining efficiency, processing status, and surface accuracy. A series of experiments were carried out by machining a micro-rectangle cavity (900 μm600 μm) on doped silicon. The experimental results were obtained as follows. Peak current plays a main role in machining efficiency and surface accuracy. Pulse duration affects obviously the stability of discharge state. The material removal rate of cathode processing is about 3/5 of that of anode processing. Compared with direction-parallel path, contour-parallel path is better in counteracting the lateral wear of tool electrode end. Scanning velocity should be selected moderately to avoid electric arc and short. Track overlap should be slightly less than the radius of tool electrode. In addition, a typical 3D micro structure of eye shape was machined based on the optimized process parameters. These results are beneficial to improve machining stability, accuracy, and efficiency in 3D SSMEDM.
Servo scanning 3D micro electrical discharge machining (3D SSMEDM) is a novel and effective method in fabricating complex 3D micro structures with high aspect ratio on conducting materials. In 3D SSMEDM process, the axial wear of tool electrode can be compensated automatically by servo-keeping discharge gap, instead of the traditional methods that depend on experiential models or intermittent compensation. However, the effects of process parameters on 3D SSMEDM have not been reported up until now. In this study, the emphasis is laid on the effects of pulse duration, peak current, machining polarity, track style, track overlap, and scanning velocity on the 3D SSMEDM performances of machining efficiency, processing status, and surface accuracy. A series of experiments were carried out by machining a micro-rectangle cavity (900 μm600 μm) on doped silicon. The experimental results were obtained as follows. Peak current plays a main role in machining efficiency and surface accuracy. Pulse duration affects obviously the stability of discharge state. The material removal rate of cathode processing is about 3/5 of that of anode processing. Compared with direction-parallel path, contour-parallel path is better in counteracting the lateral wear of tool electrode end. Scanning velocity should be selected moderately to avoid electric arc and short. Track overlap should be slightly less than the radius of tool electrode. In addition, a typical 3D micro structure of eye shape was machined based on the optimized process parameters. These results are beneficial to improve machining stability, accuracy, and efficiency in 3D SSMEDM.
2012, 26(1).
Abstract:
Virtual simulation technology is of great importance for the teleoperation of lunar rovers during the exploration phase, as well as the design of locomotion systems, performance evaluation, and control strategy verification during the R&D phase. The currently used simulation methods for lunar rovers have several disadvantages such as poor fidelity for wheel-soil interaction mechanics, difficulty in simulating rough terrains, and high complexity making it difficult to realize mobility control in simulation systems. This paper presents an approach for the construction of a virtual simulation system that integrates the features of 3D modeling, wheel-soil interaction mechanics, dynamics analysis, mobility control, and visualization for lunar rovers. Wheel-soil interaction experiments are carried out to test the forces and moments acted on a lunar rover’s wheel by the soil with a vertical load of 80 N and slip ratios of 0, 0.03, 0.05, 0.1, 0.2, 0.3, 0.4, and 0.6. The experimental results are referenced in order to set the parameters’ values for the PAC2002 tire model of the ADAMSTire module. In addition, the rough lunar terrain is simulated with 3DS Max software after analyzing its characteristics, and a data-transfer program is developed with Matlab to simulate the 3D reappearance of a lunar environment in ADAMS. The 3D model of a lunar rover is developed by using ProE software and is then imported into ADAMS. Finally, a virtual simulation system for lunar rovers is developed. A path-following control strategy based on slip compensation for a six-wheeled lunar rover prototype is researched. The controller is implemented by using MatlabSimulink to carry out joint simulations with ADAMS. The designed virtual lunar rover could follow the planned path on a rough terrain. This paper can also provide a reference scheme for virtual simulation and performance analysis of rovers moving on rough lunar terrains.
Virtual simulation technology is of great importance for the teleoperation of lunar rovers during the exploration phase, as well as the design of locomotion systems, performance evaluation, and control strategy verification during the R&D phase. The currently used simulation methods for lunar rovers have several disadvantages such as poor fidelity for wheel-soil interaction mechanics, difficulty in simulating rough terrains, and high complexity making it difficult to realize mobility control in simulation systems. This paper presents an approach for the construction of a virtual simulation system that integrates the features of 3D modeling, wheel-soil interaction mechanics, dynamics analysis, mobility control, and visualization for lunar rovers. Wheel-soil interaction experiments are carried out to test the forces and moments acted on a lunar rover’s wheel by the soil with a vertical load of 80 N and slip ratios of 0, 0.03, 0.05, 0.1, 0.2, 0.3, 0.4, and 0.6. The experimental results are referenced in order to set the parameters’ values for the PAC2002 tire model of the ADAMSTire module. In addition, the rough lunar terrain is simulated with 3DS Max software after analyzing its characteristics, and a data-transfer program is developed with Matlab to simulate the 3D reappearance of a lunar environment in ADAMS. The 3D model of a lunar rover is developed by using ProE software and is then imported into ADAMS. Finally, a virtual simulation system for lunar rovers is developed. A path-following control strategy based on slip compensation for a six-wheeled lunar rover prototype is researched. The controller is implemented by using MatlabSimulink to carry out joint simulations with ADAMS. The designed virtual lunar rover could follow the planned path on a rough terrain. This paper can also provide a reference scheme for virtual simulation and performance analysis of rovers moving on rough lunar terrains.
2012, 26(1).
Abstract:
Rollover and jack-knifing of tractor semi-trailer are serious threats for vehicle safety, and accordingly active safety technologies have been widely used to reduce or prevent the occurrence of such accidents. However, currently tractor semi-trailer stability control is generally only a single hazardous condition (rollover or jack-knifing) control, it is difficult to ensure the vehicle comprehensive stability of various dangerous conditions. The main objective of this study is to introduce a multi-objective stability control algorithm which can improve the vehicle stability of a tractor semi-trailer by using differential braking. A vehicle controller is designed to minimize the likelihood of rollover and jack-knifing. First a linear vehicle model of tractor semi-trailer is constructed. Then an optimal yaw control for tractor using differential braking is applied to minimize the yaw rate and lateral acceleration deviation of tractor, as well as the hitch articulation angle of tractor semi-trailer, so as to improve the vehicle stability. Second a braking scheme and variable structure control with sliding mode control are introduced in order to achieve the best braking effect. Last Fishhook maneuver is introduced to the active safety simulation and the active control system effect verification. The simulation results show that multi-objective stability control algorithm of semi-trailer could improve the vehicle stability significantly during the transient maneuvers. The proposed multi-objective stability control algorithm is effective to prevent the vehicle rollover and jackknifing.
Rollover and jack-knifing of tractor semi-trailer are serious threats for vehicle safety, and accordingly active safety technologies have been widely used to reduce or prevent the occurrence of such accidents. However, currently tractor semi-trailer stability control is generally only a single hazardous condition (rollover or jack-knifing) control, it is difficult to ensure the vehicle comprehensive stability of various dangerous conditions. The main objective of this study is to introduce a multi-objective stability control algorithm which can improve the vehicle stability of a tractor semi-trailer by using differential braking. A vehicle controller is designed to minimize the likelihood of rollover and jack-knifing. First a linear vehicle model of tractor semi-trailer is constructed. Then an optimal yaw control for tractor using differential braking is applied to minimize the yaw rate and lateral acceleration deviation of tractor, as well as the hitch articulation angle of tractor semi-trailer, so as to improve the vehicle stability. Second a braking scheme and variable structure control with sliding mode control are introduced in order to achieve the best braking effect. Last Fishhook maneuver is introduced to the active safety simulation and the active control system effect verification. The simulation results show that multi-objective stability control algorithm of semi-trailer could improve the vehicle stability significantly during the transient maneuvers. The proposed multi-objective stability control algorithm is effective to prevent the vehicle rollover and jackknifing.
2012, 26(1).
Abstract:
The body temperature of pilots wearing anti-G garments becomes uncomfortably or even dangerously high in moderate to hot environments. To reduce the body heat stress, thermal characteristics and thermal protection performance of anti-G garments should be studied systematically, but up to now there is no related research to simulate the anti-G garment thermal protection performance. First, a human thermoregulation model is established which can analyze blood convective heat exchange and the central blood temperature fluctuation, according to this model the heat and mass transfer processes of a thermal system are simulated which consists of human body, an anti-G garment, and the surrounding environment, then on the base of this thermal system simulation influences of clothing permeability, thermal resistance and bladder coverage on anti-G garments are analyzed. Calculation of the human thermoregulation model is carried out by using finite element method. Experiments are conducted in 35 ℃ and 40 ℃ climate chambers, and model built above is well validated by these experiments. Model simulation reveals that low thermal resistance and high permeability of anti-G garments reduce body heat stress in moderate environments. In hot environments, however, anti-G garments with lower thermal resistance increase body heat stress. The body heat stress rises significantly as the bladder coverage area of anti-G garments increases. Anti-G garments thermal parameters can be appropriately designed by using the model built in this paper to ensure body physiological requirements.
The body temperature of pilots wearing anti-G garments becomes uncomfortably or even dangerously high in moderate to hot environments. To reduce the body heat stress, thermal characteristics and thermal protection performance of anti-G garments should be studied systematically, but up to now there is no related research to simulate the anti-G garment thermal protection performance. First, a human thermoregulation model is established which can analyze blood convective heat exchange and the central blood temperature fluctuation, according to this model the heat and mass transfer processes of a thermal system are simulated which consists of human body, an anti-G garment, and the surrounding environment, then on the base of this thermal system simulation influences of clothing permeability, thermal resistance and bladder coverage on anti-G garments are analyzed. Calculation of the human thermoregulation model is carried out by using finite element method. Experiments are conducted in 35 ℃ and 40 ℃ climate chambers, and model built above is well validated by these experiments. Model simulation reveals that low thermal resistance and high permeability of anti-G garments reduce body heat stress in moderate environments. In hot environments, however, anti-G garments with lower thermal resistance increase body heat stress. The body heat stress rises significantly as the bladder coverage area of anti-G garments increases. Anti-G garments thermal parameters can be appropriately designed by using the model built in this paper to ensure body physiological requirements.
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