2012 Vol.25(6)
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2012, 26(6).
Abstract:
Frequent shifts of output and operating mode require a pump turbine with excellent stability. Current researches show that large partial flow conditions in pump mode experience positive-slope phenomena with a large head drop. The pressure fluctuation at the positive slope is crucial to the pump turbine unit safety. The operating instabilities at large partial flow conditions for a pump turbine are analyzed. The hydraulic performance of a model pump turbine is tested with the pressure fluctuations measured at unstable operating points near a positive slope in the performance curve. The hydraulic performance tests show that there are two separated positive-slope regions for the pump turbine, with the flow discharge for the first positive slope from 0.85 to 0.91 times that at the maximum efficiency point. The amplitudes of the pressure fluctuations at these unstable large partial flow conditions near the first positive slope are much larger than those at stable operating condtions. A dominant frequency is measured at 0.2 times the impeller rotational frequency in the flow passage near the impeller exit, which is believed to be induced by the rotating stall in the flow passage of the wicket gates. The test results also show hysteresis with pressure fluctuations when the pump turbine is operated near the first positive slope. The hysteresis creates different pressure fluctuations for those operation points even though their flow rates and heads are similar respectively. The pressure fluctuation characteristics at large partial flow conditions obtained by the present study will be helpful for the safe operation of pumped storage units.
Frequent shifts of output and operating mode require a pump turbine with excellent stability. Current researches show that large partial flow conditions in pump mode experience positive-slope phenomena with a large head drop. The pressure fluctuation at the positive slope is crucial to the pump turbine unit safety. The operating instabilities at large partial flow conditions for a pump turbine are analyzed. The hydraulic performance of a model pump turbine is tested with the pressure fluctuations measured at unstable operating points near a positive slope in the performance curve. The hydraulic performance tests show that there are two separated positive-slope regions for the pump turbine, with the flow discharge for the first positive slope from 0.85 to 0.91 times that at the maximum efficiency point. The amplitudes of the pressure fluctuations at these unstable large partial flow conditions near the first positive slope are much larger than those at stable operating condtions. A dominant frequency is measured at 0.2 times the impeller rotational frequency in the flow passage near the impeller exit, which is believed to be induced by the rotating stall in the flow passage of the wicket gates. The test results also show hysteresis with pressure fluctuations when the pump turbine is operated near the first positive slope. The hysteresis creates different pressure fluctuations for those operation points even though their flow rates and heads are similar respectively. The pressure fluctuation characteristics at large partial flow conditions obtained by the present study will be helpful for the safe operation of pumped storage units.
2012, 26(6).
Abstract:
Crimping is used in production of large diameter submerged-arc welding pipes. Many researches are focused on crimping in certain manufacturing mode of welding pipe. The application scopes of research achievements become limited due to lack of uniformity in theoretical analysis. In order to propose a crimping prediction method in order to control forming quality, the theory model of crimping based on elastic-plastic mechanics is established. The main technical parameters are determined by theoretical analysis, including length of crimping, base radius of punch, terminal angle of punch, base radius of die, terminal angle of die and horizontal distance between punch and die. In addition, a method used to evaluate the forming quality is presented, which investigates the bending angle after springback, forming force, straight edge length and equivalent radius of curvature. In order to investigate the effects of technical parameters on forming quality, a two-dimensional finite element model is established by finite element software ABAQUS. The finite element model is verified in that its shapes error is less than 5% by comparable experiments, which shows that their geometric precision meets demand. The crimping characteristics is obtained, such as the distribution of stress and strain and the changes of forming force, and the relation curves of technical parameters on forming quality are given by simulation analysis. The sensitivity analysis indicates that the effects of length of crimping, technical parameters of punch on forming quality are significant. In particular, the data from simulation analysis are regressed by response surface method (RSM) to establish prediction model. The feasible technical parameters are obtained from the prediction model. This method presented provides a new thought used to design technical parameters of crimping forming and makes a basis for improving crimping forming quality.
Crimping is used in production of large diameter submerged-arc welding pipes. Many researches are focused on crimping in certain manufacturing mode of welding pipe. The application scopes of research achievements become limited due to lack of uniformity in theoretical analysis. In order to propose a crimping prediction method in order to control forming quality, the theory model of crimping based on elastic-plastic mechanics is established. The main technical parameters are determined by theoretical analysis, including length of crimping, base radius of punch, terminal angle of punch, base radius of die, terminal angle of die and horizontal distance between punch and die. In addition, a method used to evaluate the forming quality is presented, which investigates the bending angle after springback, forming force, straight edge length and equivalent radius of curvature. In order to investigate the effects of technical parameters on forming quality, a two-dimensional finite element model is established by finite element software ABAQUS. The finite element model is verified in that its shapes error is less than 5% by comparable experiments, which shows that their geometric precision meets demand. The crimping characteristics is obtained, such as the distribution of stress and strain and the changes of forming force, and the relation curves of technical parameters on forming quality are given by simulation analysis. The sensitivity analysis indicates that the effects of length of crimping, technical parameters of punch on forming quality are significant. In particular, the data from simulation analysis are regressed by response surface method (RSM) to establish prediction model. The feasible technical parameters are obtained from the prediction model. This method presented provides a new thought used to design technical parameters of crimping forming and makes a basis for improving crimping forming quality.
2012, 26(6).
Abstract:
A key design issue related to the turbopump of the rocket engine is that cavitation occurs in cryogenic fluids when the fluid pressure is lower than the vapor pressure at a local thermodynamic state. Cavitation in cryogenic fluids generates substantial thermal effects and strong variations in fluid properties, which in turn alter the cavity characteristics. To date, fewer investigate the thermal effect on cavitation in cryogenic fluids clearly by the numerical methods due to the difficulty of the heat transfer in the phase change process. In order to study the thermal effect on cavitation in cryogenic fluid, computations are conducted around a 2D quarter caliber hydrofoil in liquid nitrogen and hydrogen respectively by implementing modified Merkle cavitation model, which accounts for the energy balance and variable thermodynamic properties of the fluid. The numerical results show that with the thermal effect, the vapour content in constant location decreases, the cavity becomes more porous and the interface becomes less distinct which shows increased spreading while getting shorter in length. In the cavity region, the temperature around the cavity depresses due to absorb the evaporation latent heat and the saturation pressure drops. When the vapour volume fraction is higher, the temperature depression and pressure depression becomes larger. It is also observed that a slight temperature rise is found above the reference fluid temperature at the cavity rear end attributed to the release of latent heat during the condensation process. When the fluid is operating close to its critical temperature, thermal effects on cavitation are more obviously in both the liquid nitrogen and hydrogen. The thermal effect on cavitation in liquid hydrogen is more distinctly compared with that in liquid nitrogen due to the density ratio, vapour pressure and other variable properties of the fluid. The investigation provides aid for the design of the cryogenic pump of the liquid rocket.
A key design issue related to the turbopump of the rocket engine is that cavitation occurs in cryogenic fluids when the fluid pressure is lower than the vapor pressure at a local thermodynamic state. Cavitation in cryogenic fluids generates substantial thermal effects and strong variations in fluid properties, which in turn alter the cavity characteristics. To date, fewer investigate the thermal effect on cavitation in cryogenic fluids clearly by the numerical methods due to the difficulty of the heat transfer in the phase change process. In order to study the thermal effect on cavitation in cryogenic fluid, computations are conducted around a 2D quarter caliber hydrofoil in liquid nitrogen and hydrogen respectively by implementing modified Merkle cavitation model, which accounts for the energy balance and variable thermodynamic properties of the fluid. The numerical results show that with the thermal effect, the vapour content in constant location decreases, the cavity becomes more porous and the interface becomes less distinct which shows increased spreading while getting shorter in length. In the cavity region, the temperature around the cavity depresses due to absorb the evaporation latent heat and the saturation pressure drops. When the vapour volume fraction is higher, the temperature depression and pressure depression becomes larger. It is also observed that a slight temperature rise is found above the reference fluid temperature at the cavity rear end attributed to the release of latent heat during the condensation process. When the fluid is operating close to its critical temperature, thermal effects on cavitation are more obviously in both the liquid nitrogen and hydrogen. The thermal effect on cavitation in liquid hydrogen is more distinctly compared with that in liquid nitrogen due to the density ratio, vapour pressure and other variable properties of the fluid. The investigation provides aid for the design of the cryogenic pump of the liquid rocket.
2012, 26(6).
Abstract:
For optimal design of constant stress accelerated life test(CSALT) with two-stress, if the stresses could not reach the highest levels simultaneously, the test region becomes non-rectangular. For optimal CSALT design on non-rectangle test region, the present method is only focused on non-rectangle test region with simple boundary, and the optimization algorithm is based on experience which can not ensure to obtain the optimal plan. In this paper, considering the linear-extreme value model and the optimization goal to minimize the variance of lifetime estimate under normal stress, the optimal design method of two-stress type-І censored CSALT plan on general non-rectangular test region is proposed. First, two properties of optimal test plans are proved and the relationship of all the optimal test plans is determined analytically. Then, on the basis of the two properties, the optimal problem is simplified and the optimal design method of two-stress CSALT plan on general non-rectangular test region is proposed. Finally, a numerical example is used to illustrate the feasibility and effectiveness of the method. The result shows that the proposed method could obtain the optimal test plan on non-rectangular test regions with arbitrary boundaries. This research provides the theory and method for two-stress optimal CSALT planning on non-rectangular test regions.
For optimal design of constant stress accelerated life test(CSALT) with two-stress, if the stresses could not reach the highest levels simultaneously, the test region becomes non-rectangular. For optimal CSALT design on non-rectangle test region, the present method is only focused on non-rectangle test region with simple boundary, and the optimization algorithm is based on experience which can not ensure to obtain the optimal plan. In this paper, considering the linear-extreme value model and the optimization goal to minimize the variance of lifetime estimate under normal stress, the optimal design method of two-stress type-І censored CSALT plan on general non-rectangular test region is proposed. First, two properties of optimal test plans are proved and the relationship of all the optimal test plans is determined analytically. Then, on the basis of the two properties, the optimal problem is simplified and the optimal design method of two-stress CSALT plan on general non-rectangular test region is proposed. Finally, a numerical example is used to illustrate the feasibility and effectiveness of the method. The result shows that the proposed method could obtain the optimal test plan on non-rectangular test regions with arbitrary boundaries. This research provides the theory and method for two-stress optimal CSALT planning on non-rectangular test regions.
2012, 26(6).
Abstract:
The collapse of thin-walled micro-grooved heat pipes is a common phenomenon in the tube flattening process, which seriously influences the heat transfer performance and appearance of heat pipe. At present, there is no other better method to solve this problem. A new method by heating the heat pipe is proposed to eliminate the collapse during the flattening process. The effectiveness of the proposed method is investigated through a theoretical model, a finite element(FE) analysis, and experimental method. Firstly, A theoretical model based on a deformation model of six plastic hinges and the Antoine equation of the working fluid is established to analyze the collapse of thin walls at different temperatures. Then, the FE simulation and experiments of flattening process at different temperatures are carried out and compared with theoretical model. Finally, the FE model is followed to study the loads of the plates at different temperatures and heights of flattened heat pipes. The results of the theoretical model conform to those of the FE simulation and experiments in the flattened zone. The collapse occurs at room temperature. As the temperature increases, the collapse decreases and finally disappears at approximately 130 ℃ for various heights of flattened heat pipes. The loads of the moving plate increase as the temperature increases. Thus, the reasonable temperature for eliminating the collapse and reducing the load is approximately 130 ℃. The advantage of the proposed method is that the collapse is reduced or eliminated by means of the thermal deformation characteristic of heat pipe itself instead of by external support. As a result, the heat transfer efficiency of heat pipe is raised.
The collapse of thin-walled micro-grooved heat pipes is a common phenomenon in the tube flattening process, which seriously influences the heat transfer performance and appearance of heat pipe. At present, there is no other better method to solve this problem. A new method by heating the heat pipe is proposed to eliminate the collapse during the flattening process. The effectiveness of the proposed method is investigated through a theoretical model, a finite element(FE) analysis, and experimental method. Firstly, A theoretical model based on a deformation model of six plastic hinges and the Antoine equation of the working fluid is established to analyze the collapse of thin walls at different temperatures. Then, the FE simulation and experiments of flattening process at different temperatures are carried out and compared with theoretical model. Finally, the FE model is followed to study the loads of the plates at different temperatures and heights of flattened heat pipes. The results of the theoretical model conform to those of the FE simulation and experiments in the flattened zone. The collapse occurs at room temperature. As the temperature increases, the collapse decreases and finally disappears at approximately 130 ℃ for various heights of flattened heat pipes. The loads of the moving plate increase as the temperature increases. Thus, the reasonable temperature for eliminating the collapse and reducing the load is approximately 130 ℃. The advantage of the proposed method is that the collapse is reduced or eliminated by means of the thermal deformation characteristic of heat pipe itself instead of by external support. As a result, the heat transfer efficiency of heat pipe is raised.
2012, 26(6).
Abstract:
When relative motion occurs between a liquid and a solid, the two phases carry electric charge with opposite signs. The created charge easily accumulates in the liquid, and the amount of the charge carried in an insulated liquid refers to many factors, such as contact area with the solid surface, the contact time, and so forth. However, current theories agree that the amount of charge created during flow electrification is proportional to the contact surface. In this paper, the classical wall current theory is applied to establish an interfacial electrical double-layer model of flow electrification phenomena when an insulated liquid passes over metal pipe surface. Meanwhile, in conjunction with charge relaxation function, the relation between the charge density and flow velocity, the contact time and the contact area is obtained during the liquid flowing process. The experimental result demonstrates that the flowing charge carried in the insulated liquid is not simply proportional to the contact area, but has a non-linear dependence on the contact area and the contact time. Moreover, down flow experimental equipment pipes of different length and diameter, and dielectric hydraulic oil VG46 are used in an experimental study of laminar flow, in order to understand electrification phenomena in dielectric liquid flowing over metal pipes of different length and aperture. If they both increase linearly, charge relaxation will increase exponentially. As a result, the test result verifies related theoretical analysis, and the method given provides a theoretical basis to analyze interfacial electrical phenomena.
When relative motion occurs between a liquid and a solid, the two phases carry electric charge with opposite signs. The created charge easily accumulates in the liquid, and the amount of the charge carried in an insulated liquid refers to many factors, such as contact area with the solid surface, the contact time, and so forth. However, current theories agree that the amount of charge created during flow electrification is proportional to the contact surface. In this paper, the classical wall current theory is applied to establish an interfacial electrical double-layer model of flow electrification phenomena when an insulated liquid passes over metal pipe surface. Meanwhile, in conjunction with charge relaxation function, the relation between the charge density and flow velocity, the contact time and the contact area is obtained during the liquid flowing process. The experimental result demonstrates that the flowing charge carried in the insulated liquid is not simply proportional to the contact area, but has a non-linear dependence on the contact area and the contact time. Moreover, down flow experimental equipment pipes of different length and diameter, and dielectric hydraulic oil VG46 are used in an experimental study of laminar flow, in order to understand electrification phenomena in dielectric liquid flowing over metal pipes of different length and aperture. If they both increase linearly, charge relaxation will increase exponentially. As a result, the test result verifies related theoretical analysis, and the method given provides a theoretical basis to analyze interfacial electrical phenomena.
2012, 26(6).
Abstract:
The current research on pulse continuously variable transmission(CVT) is mainly focused on reducing the pulse degree and making pulse degrees a constant value. Current research mainly confined to find out new design parameters by using the method of optimization, and reduce the pulse degree of pulse CVT and its range of variation. But the fact is that the reduction of the pulse degree is not significant. This article presents a new structure of mechanical pulse CVT—the rotational swashplate pulse CVT with driven by helical gear axial meshing. This transmission is simple and compact in structure and low in pulsatile rate (it adopts 6 guide rods), and the pulsatile degree is irrelevant to the transmission ratio. Theoretically, pulsatile rate could be reduced to zero if appropriate curved surface of the swashplate is used. Compared with the connecting rod pulse CVT, the present structure uses helical gear mechanism as transmission part and it avoids unbalanced inertial force in the former model. This paper analyzes the principle of driving of this transmission, presents its mechanical structure, and discusses its motion characteristics. Experimental prototype of this type of CVT has been manufactured. Tests for the transmission efficiency(when the rotational speed of the output shaft is the maximum) and the angular velocity of the output shaft have been carried out, and data have been analyzed. The experimental results show that the speed of the output shaft for the experimental prototype is slightly lower than the theoretical value, and the transmission efficiency of the experimental prototype is about 70%. The pulse degree of the CVT discussed in this paper is less than the existing pulse CVT of other types, and it is irrelevant to the transmission ratio of the CVT. The research provides the new idea to the CVT study.
The current research on pulse continuously variable transmission(CVT) is mainly focused on reducing the pulse degree and making pulse degrees a constant value. Current research mainly confined to find out new design parameters by using the method of optimization, and reduce the pulse degree of pulse CVT and its range of variation. But the fact is that the reduction of the pulse degree is not significant. This article presents a new structure of mechanical pulse CVT—the rotational swashplate pulse CVT with driven by helical gear axial meshing. This transmission is simple and compact in structure and low in pulsatile rate (it adopts 6 guide rods), and the pulsatile degree is irrelevant to the transmission ratio. Theoretically, pulsatile rate could be reduced to zero if appropriate curved surface of the swashplate is used. Compared with the connecting rod pulse CVT, the present structure uses helical gear mechanism as transmission part and it avoids unbalanced inertial force in the former model. This paper analyzes the principle of driving of this transmission, presents its mechanical structure, and discusses its motion characteristics. Experimental prototype of this type of CVT has been manufactured. Tests for the transmission efficiency(when the rotational speed of the output shaft is the maximum) and the angular velocity of the output shaft have been carried out, and data have been analyzed. The experimental results show that the speed of the output shaft for the experimental prototype is slightly lower than the theoretical value, and the transmission efficiency of the experimental prototype is about 70%. The pulse degree of the CVT discussed in this paper is less than the existing pulse CVT of other types, and it is irrelevant to the transmission ratio of the CVT. The research provides the new idea to the CVT study.
2012, 26(6).
Abstract:
The development of closed-loop control systems is one of the most effective ways to improve the stability of the keyhole status during keyhole plasma arc welding (K-PAW). Due to the disadvantages of the “one-pulse-one-keyhole” technology based on the conventional square current waveform, the controlled pulse welding current waveform is newly applied to control the keyhole open and close periodically. In order to realize the real-time control on the keyhole behavior with this advanced current waveform, welding experiments and system identification are conducted based on the classical control theory. One complete welding cycle can be divided into 3 periods. The keyhole establishing time is the most important time variable, which determines the keyhole behavior and welding process stability. At the same time, the averaged efflux plasma arc voltage during one pulse cycle can reflect the real keyhole dimension and status in a real-time manner. Therefore, two single-input-single-output (SISO) systems are proposed, in which keyhole establishing time and keyhole average dimension are taken as the system controlled variables respectively. Welding experiments are designed with the peak current varying randomly. Experiments show that the keyhole establishing time changes in an opposite direction to the varied peak current, and the averaged efflux plasma arc voltage varies with the same trend as the peak current. Based on the least squares technique and F test of classical system identification, second order difference equation for keyhole establishing time/peak current system and first order difference equation for keyhole average dimension/peak current system are obtained. It is proved that the calculated data by the two mathematical expressions are well matched with the measured data. The proposed research provides mathematical expressions and theoretical analysis to develop closed-loop systems for the controlled pulse K-PAW.
The development of closed-loop control systems is one of the most effective ways to improve the stability of the keyhole status during keyhole plasma arc welding (K-PAW). Due to the disadvantages of the “one-pulse-one-keyhole” technology based on the conventional square current waveform, the controlled pulse welding current waveform is newly applied to control the keyhole open and close periodically. In order to realize the real-time control on the keyhole behavior with this advanced current waveform, welding experiments and system identification are conducted based on the classical control theory. One complete welding cycle can be divided into 3 periods. The keyhole establishing time is the most important time variable, which determines the keyhole behavior and welding process stability. At the same time, the averaged efflux plasma arc voltage during one pulse cycle can reflect the real keyhole dimension and status in a real-time manner. Therefore, two single-input-single-output (SISO) systems are proposed, in which keyhole establishing time and keyhole average dimension are taken as the system controlled variables respectively. Welding experiments are designed with the peak current varying randomly. Experiments show that the keyhole establishing time changes in an opposite direction to the varied peak current, and the averaged efflux plasma arc voltage varies with the same trend as the peak current. Based on the least squares technique and F test of classical system identification, second order difference equation for keyhole establishing time/peak current system and first order difference equation for keyhole average dimension/peak current system are obtained. It is proved that the calculated data by the two mathematical expressions are well matched with the measured data. The proposed research provides mathematical expressions and theoretical analysis to develop closed-loop systems for the controlled pulse K-PAW.
2012, 26(6).
Abstract:
The temperature fluctuation caused by thermal striping phenomena of hot and cold fluids mixing results in cyclical thermal stress fatigue failure of the pipe wall. Mean temperature difference between hot and cold fluids was often used as thermal load in previous analysis of thermal fatigue failure, thereby the influences of the amplitude and frequency of temperature fluctuation on thermal fatigue failure were neglected. Based on the mechanism of flow and heat transfer which induces thermal fatigue, the turbulent mixing of hot and cold water in a tee junction is simulated with FLUENT platform by using the Large-eddy simulation(LES) turbulent flow model with the sub-grid scale(SGS) model of Smagorinsky-Lilly(SL) to capture the amplitude and frequency of temperature fluctuation. In a simulation case, hot water with temperature of 343.48 K and velocity of 0.15 ms enters the horizontal main duct with the side length of 100 mm, while cold water with temperature of 296.78 K and velocity of 0.3 ms enters the vertical branch duct with the side length of 50 mm. The numerical results show that the mean and fluctuating temperatures are in good agreement with the previous experimental data, which describes numerical simulation with high reliability and accuracy; the power spectrum density(PSD) on top wall is higher than that on bottom wall(as the frequency less than 1 Hz), while the PSD on bottom wall is relatively higher than that on top wall (as the frequency of 1–10Hz). The temperature fluctuations in full mixing region of the tee junction can be accurately captured by LES and can provide the theoretical basis for the thermal stress and thermal fatigue analyses.
The temperature fluctuation caused by thermal striping phenomena of hot and cold fluids mixing results in cyclical thermal stress fatigue failure of the pipe wall. Mean temperature difference between hot and cold fluids was often used as thermal load in previous analysis of thermal fatigue failure, thereby the influences of the amplitude and frequency of temperature fluctuation on thermal fatigue failure were neglected. Based on the mechanism of flow and heat transfer which induces thermal fatigue, the turbulent mixing of hot and cold water in a tee junction is simulated with FLUENT platform by using the Large-eddy simulation(LES) turbulent flow model with the sub-grid scale(SGS) model of Smagorinsky-Lilly(SL) to capture the amplitude and frequency of temperature fluctuation. In a simulation case, hot water with temperature of 343.48 K and velocity of 0.15 ms enters the horizontal main duct with the side length of 100 mm, while cold water with temperature of 296.78 K and velocity of 0.3 ms enters the vertical branch duct with the side length of 50 mm. The numerical results show that the mean and fluctuating temperatures are in good agreement with the previous experimental data, which describes numerical simulation with high reliability and accuracy; the power spectrum density(PSD) on top wall is higher than that on bottom wall(as the frequency less than 1 Hz), while the PSD on bottom wall is relatively higher than that on top wall (as the frequency of 1–10Hz). The temperature fluctuations in full mixing region of the tee junction can be accurately captured by LES and can provide the theoretical basis for the thermal stress and thermal fatigue analyses.
2012, 26(6).
Abstract:
Singular configuration seriously affects the performance of the Gough-Stewart parallel mechanism and has attracted many researchers’ attentions. However, most of existing topics often focus on the position-singularity of the mechanism for a constant-orientation, but few reports research the orientation-singularity for a given position. In order to investigate the orientation-singularity of the Gough-Stewart parallel mechanisms with two dissimilar semi-regular hexagonal platforms for a given position, after constructing the discrimination matrix of the singular configuration of the mechanism and computing the determinant of this matrix by using unit quaternion as the orientation parameters which can avoid the singularities in parameterization, a general symbolic expression representing the three-dimensional orientation-singularity locus for a given position is obtained and the three-dimensional view of the orientation-singularity locus is further described. The orientation-singularity-free void exists inside the orientation-singularity locus, but the shape of the orientation-singularity-free void is irregular and inconvenient for the design of the mechanism. The minimal inscribed sphere of the three-dimensional orientation-singularity locus namely the orientation-singularity- free ball is described. The radius of the ball orientation-capability is used as the measurement for the orientation-singularity-free void size. A new efficient algorithm is proposed for the computation of the orientation-capability. Finally, the influences of the geometry parameters and the different positions of the mechanism on the orientation-capability are discussed. A new method of the singularity analysis of the Gough-Stewart parallel mechanism is advanced based on the unit quaternion, and the research finds have important referential value for the configuration parameters optimization of this class of the parallel mechanisms with the goal of having the maximal singularity-free zone.
Singular configuration seriously affects the performance of the Gough-Stewart parallel mechanism and has attracted many researchers’ attentions. However, most of existing topics often focus on the position-singularity of the mechanism for a constant-orientation, but few reports research the orientation-singularity for a given position. In order to investigate the orientation-singularity of the Gough-Stewart parallel mechanisms with two dissimilar semi-regular hexagonal platforms for a given position, after constructing the discrimination matrix of the singular configuration of the mechanism and computing the determinant of this matrix by using unit quaternion as the orientation parameters which can avoid the singularities in parameterization, a general symbolic expression representing the three-dimensional orientation-singularity locus for a given position is obtained and the three-dimensional view of the orientation-singularity locus is further described. The orientation-singularity-free void exists inside the orientation-singularity locus, but the shape of the orientation-singularity-free void is irregular and inconvenient for the design of the mechanism. The minimal inscribed sphere of the three-dimensional orientation-singularity locus namely the orientation-singularity- free ball is described. The radius of the ball orientation-capability is used as the measurement for the orientation-singularity-free void size. A new efficient algorithm is proposed for the computation of the orientation-capability. Finally, the influences of the geometry parameters and the different positions of the mechanism on the orientation-capability are discussed. A new method of the singularity analysis of the Gough-Stewart parallel mechanism is advanced based on the unit quaternion, and the research finds have important referential value for the configuration parameters optimization of this class of the parallel mechanisms with the goal of having the maximal singularity-free zone.
2012, 26(6).
Abstract:
The existing researches of stepless capacity regulation system by depressing the suction valve for reciprocation compressor always adopt hypothesis that the compressor valves are open or close instantaneously, the valve dynamic has not been taken account into thermal cycle computation, the influence of capacity regulation system on suction valves dynamic performance and cylinder thermal cycle operation has not been considered. This paper focuses on theoretical and experimental analysis of the valve dynamic and thermal cycle for reciprocating compressor in the situation of stepless capacity regulation. The valve dynamics equation, gas forces for normal and back flow, and the cylinder pressure varying with suction valve unloader moment during compression thermal cycle are discussed. A new valve dynamic model based on L-K real gas state equation for reciprocating compressor is first deduced to reduce the calculation errors induced by the ideal gas state equation. The variations of valve dynamic and cylinder pressure during part of compression stroke are calculated numerically. The calculation results reveal the non-normal thermal cycle and operation condition of compressor in stepless capacity regulation situation. The numerical simulation results of the valve dynamic and thermal cycle parameters are also verified by the stepless capacity regulation experiments in the type of 3L-108 reciprocating compressor. The experimental results agree with the numerical simulation results, which show that the theoretical models proposed are effective and high-precision. The proposed theoretical models build the theoretical foundation to design the real stepless capacity regulation system.
The existing researches of stepless capacity regulation system by depressing the suction valve for reciprocation compressor always adopt hypothesis that the compressor valves are open or close instantaneously, the valve dynamic has not been taken account into thermal cycle computation, the influence of capacity regulation system on suction valves dynamic performance and cylinder thermal cycle operation has not been considered. This paper focuses on theoretical and experimental analysis of the valve dynamic and thermal cycle for reciprocating compressor in the situation of stepless capacity regulation. The valve dynamics equation, gas forces for normal and back flow, and the cylinder pressure varying with suction valve unloader moment during compression thermal cycle are discussed. A new valve dynamic model based on L-K real gas state equation for reciprocating compressor is first deduced to reduce the calculation errors induced by the ideal gas state equation. The variations of valve dynamic and cylinder pressure during part of compression stroke are calculated numerically. The calculation results reveal the non-normal thermal cycle and operation condition of compressor in stepless capacity regulation situation. The numerical simulation results of the valve dynamic and thermal cycle parameters are also verified by the stepless capacity regulation experiments in the type of 3L-108 reciprocating compressor. The experimental results agree with the numerical simulation results, which show that the theoretical models proposed are effective and high-precision. The proposed theoretical models build the theoretical foundation to design the real stepless capacity regulation system.
2012, 26(6).
Abstract:
Early bearing faults can generate a series of weak impacts. All the influence factors in measurement may degrade the vibration signal. Currently, bearing fault enhanced detection method based on stochastic resonance(SR) is implemented by expensive computation and demands high sampling rate, which requires high quality software and hardware for fault diagnosis. In order to extract bearing characteristic frequencies component, SR normalized scale transform procedures are presented and a circuit module is designed based on parameter-tuning bistable SR. In the simulation test, discrete and analog sinusoidal signals under heavy noise are enhanced by SR normalized scale transform and circuit module respectively. Two bearing fault enhanced detection strategies are proposed. One is realized by pure computation with normalized scale transform for sampled vibration signal, and the other is carried out by designed SR hardware with circuit module for analog vibration signal directly. The first strategy is flexible for discrete signal processing, and the second strategy demands much lower sampling frequency and less computational cost. The application results of the two strategies on bearing inner race fault detection of a test rig show that the local signal to noise ratio of the characteristic components obtained by the proposed methods are enhanced by about 50% compared with the band pass envelope analysis for the bearing with weaker fault. In addition, helicopter transmission bearing fault detection validates the effectiveness of the enhanced detection strategy with hardware. The combination of SR normalized scale transform and circuit module can meet the need of different application fields or conditions, thus providing a practical scheme for enhanced detection of bearing fault.
Early bearing faults can generate a series of weak impacts. All the influence factors in measurement may degrade the vibration signal. Currently, bearing fault enhanced detection method based on stochastic resonance(SR) is implemented by expensive computation and demands high sampling rate, which requires high quality software and hardware for fault diagnosis. In order to extract bearing characteristic frequencies component, SR normalized scale transform procedures are presented and a circuit module is designed based on parameter-tuning bistable SR. In the simulation test, discrete and analog sinusoidal signals under heavy noise are enhanced by SR normalized scale transform and circuit module respectively. Two bearing fault enhanced detection strategies are proposed. One is realized by pure computation with normalized scale transform for sampled vibration signal, and the other is carried out by designed SR hardware with circuit module for analog vibration signal directly. The first strategy is flexible for discrete signal processing, and the second strategy demands much lower sampling frequency and less computational cost. The application results of the two strategies on bearing inner race fault detection of a test rig show that the local signal to noise ratio of the characteristic components obtained by the proposed methods are enhanced by about 50% compared with the band pass envelope analysis for the bearing with weaker fault. In addition, helicopter transmission bearing fault detection validates the effectiveness of the enhanced detection strategy with hardware. The combination of SR normalized scale transform and circuit module can meet the need of different application fields or conditions, thus providing a practical scheme for enhanced detection of bearing fault.
2012, 26(6).
Abstract:
Motion simulation and performance analysis of mechanism are important methods for analyzing assembly quality after finishing assembly simulation in virtual assembly environment. However, most simulation systems have no function of mechanism motion simulation due to the randomicity of mechanism and lack of universal mechanism modeling method. In order to realize the simulation of any mechanism after finishing assembly simulation in a virtual environment, a new universal mechanism modeling method is presented. Two main models are contained in the mechanism model: information model and mathematical model. Firstly, the information model of mechanism is proposed to describe the data structure of mechanism which contains bottom geometry data, information of constraint, link, kinematic pair and physical data. Because the object of mechanism simulation is the assembly, which is assembled during the process of assembly simulation, the information of mechanism can be obtained automatically through mechanism automatic search method. Secondly, mathematical model of mechanism is presented. The mathematical model uses mathematical method to express the mechanism. In order to realize the automatic expression of any random mechanism, basic constraint library is presented, consequently random mechanism can be described based on the basic constraint library. Finally, two examples are introduced to validate the method in the prototype system named VAPP(Virtual Assembly Process Planning). The validation result shows that the mechanism modeling provides a universal modeling method for mechanism motion simulation in virtual assembly environment. This research has important effect on the development both of mechanism motion simulation and virtual assembly.
Motion simulation and performance analysis of mechanism are important methods for analyzing assembly quality after finishing assembly simulation in virtual assembly environment. However, most simulation systems have no function of mechanism motion simulation due to the randomicity of mechanism and lack of universal mechanism modeling method. In order to realize the simulation of any mechanism after finishing assembly simulation in a virtual environment, a new universal mechanism modeling method is presented. Two main models are contained in the mechanism model: information model and mathematical model. Firstly, the information model of mechanism is proposed to describe the data structure of mechanism which contains bottom geometry data, information of constraint, link, kinematic pair and physical data. Because the object of mechanism simulation is the assembly, which is assembled during the process of assembly simulation, the information of mechanism can be obtained automatically through mechanism automatic search method. Secondly, mathematical model of mechanism is presented. The mathematical model uses mathematical method to express the mechanism. In order to realize the automatic expression of any random mechanism, basic constraint library is presented, consequently random mechanism can be described based on the basic constraint library. Finally, two examples are introduced to validate the method in the prototype system named VAPP(Virtual Assembly Process Planning). The validation result shows that the mechanism modeling provides a universal modeling method for mechanism motion simulation in virtual assembly environment. This research has important effect on the development both of mechanism motion simulation and virtual assembly.
2012, 26(6).
Abstract:
In synthesis of flexure mechanism, parallel arrangement is paid more attention due to its advantages, such as compact structure and higher stiffness. Researchers have derived many parallel flexure mechanisms, but seldom discuss which kind of flexure mechanism can be realized via fully parallel arrangement. The realizable conditions proposed in current work are complicated to engineering applications. To solve two problems on how to judge whether a flexure mechanism can be realized via fully parallel arrangement and how to realize those flexure mechanisms which cannot be realized via fully parallel arrangement, the algebraic condition is derived to judge whether a freedom space is parallel realizable after introducing the definition of parallel realizable and some propositions, and the condition is there exist 6–n independent line constraints in constraint space reciprocal to dimensional freedom space. Then the realizable constraint spaces reciprocal to freedom spaces with 1–3 dimensions are provided. As a result, not all freedom spaces are parallel realizable. For freedom spaces that are not parallel realizable, the criterion of decomposing DOF is proposed to achieve all motion patterns via parallel or hybrid arrangement, that is a high dimensional freedom space can be realized via combining several low dimensional freedom spaces which are parallel realizable. Specific decomposing strategies for 4 and 5 DOF are provided and a complete flowchart is presented to guide designing flexure mechanisms, particularly those which are not parallel realizable. As case studies, synthesis processes of two helical and 3T1R motions are provided to illustrate the proposed approach. The proposed method provides a feasible approach to realize all motion patterns.
In synthesis of flexure mechanism, parallel arrangement is paid more attention due to its advantages, such as compact structure and higher stiffness. Researchers have derived many parallel flexure mechanisms, but seldom discuss which kind of flexure mechanism can be realized via fully parallel arrangement. The realizable conditions proposed in current work are complicated to engineering applications. To solve two problems on how to judge whether a flexure mechanism can be realized via fully parallel arrangement and how to realize those flexure mechanisms which cannot be realized via fully parallel arrangement, the algebraic condition is derived to judge whether a freedom space is parallel realizable after introducing the definition of parallel realizable and some propositions, and the condition is there exist 6–n independent line constraints in constraint space reciprocal to dimensional freedom space. Then the realizable constraint spaces reciprocal to freedom spaces with 1–3 dimensions are provided. As a result, not all freedom spaces are parallel realizable. For freedom spaces that are not parallel realizable, the criterion of decomposing DOF is proposed to achieve all motion patterns via parallel or hybrid arrangement, that is a high dimensional freedom space can be realized via combining several low dimensional freedom spaces which are parallel realizable. Specific decomposing strategies for 4 and 5 DOF are provided and a complete flowchart is presented to guide designing flexure mechanisms, particularly those which are not parallel realizable. As case studies, synthesis processes of two helical and 3T1R motions are provided to illustrate the proposed approach. The proposed method provides a feasible approach to realize all motion patterns.
2012, 26(6).
Abstract:
Water plays a critical role on the performance, stability and lifetime of proton exchange membrane fuel cells(PEMFCs). The addition of poly tetrafluoroethylene(PTFE) to the gas diffusion layer, especially, the cathode side, would optimize the transportation of water, electron and gas and thus improve the performance of the fuel cell. But until now, the studies about directly applying the PTFE to the catalyst layer are rarely reported. In this paper, the membrane electrode is fabricated by using directly coating catalyst to the membrane method(CCM) and applying PTFE directly to the cathode electrode catalyst layer. The performance of the single cell is determined by polarization curves and durability tests. Electrochemical impedance spectroscopy(EIS) and scanning electron microscopy(SEM) techniques are used to characterize the electrochemical properties of PEMFC. Also the performance of a 10-cells stack is detected. Combining the performance and the physical-chemistry characterization of PEMFC shows that addition of appropriate content of PTFE to the electrode enhances the performance of the fuel cell, which may be due to the improved water management. Addition of appropriate content of PTFE enhances the interaction between the membrane and the catalyst layer, and bigger pores and highly textured structure form in the MEA, which favors the oxygen mass transfer and protons transfer in the fuel cell. While superfluous addition of PTFE covers the surface of catalysts and hindered the contact of catalyst with Nafion, which leads to the reduction of electrochemical active area and the decay of the fuel cell performance. The proposed research would optimize the water management of the fuel cell and thus improve the performance of the fuel cell.
Water plays a critical role on the performance, stability and lifetime of proton exchange membrane fuel cells(PEMFCs). The addition of poly tetrafluoroethylene(PTFE) to the gas diffusion layer, especially, the cathode side, would optimize the transportation of water, electron and gas and thus improve the performance of the fuel cell. But until now, the studies about directly applying the PTFE to the catalyst layer are rarely reported. In this paper, the membrane electrode is fabricated by using directly coating catalyst to the membrane method(CCM) and applying PTFE directly to the cathode electrode catalyst layer. The performance of the single cell is determined by polarization curves and durability tests. Electrochemical impedance spectroscopy(EIS) and scanning electron microscopy(SEM) techniques are used to characterize the electrochemical properties of PEMFC. Also the performance of a 10-cells stack is detected. Combining the performance and the physical-chemistry characterization of PEMFC shows that addition of appropriate content of PTFE to the electrode enhances the performance of the fuel cell, which may be due to the improved water management. Addition of appropriate content of PTFE enhances the interaction between the membrane and the catalyst layer, and bigger pores and highly textured structure form in the MEA, which favors the oxygen mass transfer and protons transfer in the fuel cell. While superfluous addition of PTFE covers the surface of catalysts and hindered the contact of catalyst with Nafion, which leads to the reduction of electrochemical active area and the decay of the fuel cell performance. The proposed research would optimize the water management of the fuel cell and thus improve the performance of the fuel cell.
2012, 26(6).
Abstract:
Cross-spring pivots, formed by crossing two identical flexural beams at their midpoint, have been broadly used in precision engineering and aerospace fields. Many researches have been conducted on modeling and analysis of cross-spring pivots. However the influence of application position and magnitude of the external loads on the load-rotation and parasitic motion characteristics has not yet been discussed. In order to reveal the effect of the external loads, this paper develops the accurate load-rotation and center shift models of cross-spring pivots, with generalized planar loads applied including bending moment, horizontal and vertical forces. Firstly, by using the energy method, the load-displacement models of the pivot are derived with the assumption of small rotational angles. Based on the models, the influence of generalized planar loads on the load-rotation relationship is discussed, which shows that both application position and magnitude of the vertical and horizontal forces influence the load-rotation behaviors. Then the accurate center shift expressions of the pivot with generalized planar loads are developed, which shows that the rotational angle is the dominant term for both components of the center shift while the vertical and horizontal forces are small. Finally, the accuracy of the proposed model is validated by finite element analysis(FEA). Comparing the model data with the results obtained from FEA, the relative error of the load-rotation is less than 6% even if the rotational angle reaches 20°; the relative errors of the two components of center shift are less than 5% and 10% respectively when the rotational angle reaches 10°. The proposed model and analytical conclusions can be used to analyze and preliminarily design the compliant mechanisms containing cross-spring pivots.
Cross-spring pivots, formed by crossing two identical flexural beams at their midpoint, have been broadly used in precision engineering and aerospace fields. Many researches have been conducted on modeling and analysis of cross-spring pivots. However the influence of application position and magnitude of the external loads on the load-rotation and parasitic motion characteristics has not yet been discussed. In order to reveal the effect of the external loads, this paper develops the accurate load-rotation and center shift models of cross-spring pivots, with generalized planar loads applied including bending moment, horizontal and vertical forces. Firstly, by using the energy method, the load-displacement models of the pivot are derived with the assumption of small rotational angles. Based on the models, the influence of generalized planar loads on the load-rotation relationship is discussed, which shows that both application position and magnitude of the vertical and horizontal forces influence the load-rotation behaviors. Then the accurate center shift expressions of the pivot with generalized planar loads are developed, which shows that the rotational angle is the dominant term for both components of the center shift while the vertical and horizontal forces are small. Finally, the accuracy of the proposed model is validated by finite element analysis(FEA). Comparing the model data with the results obtained from FEA, the relative error of the load-rotation is less than 6% even if the rotational angle reaches 20°; the relative errors of the two components of center shift are less than 5% and 10% respectively when the rotational angle reaches 10°. The proposed model and analytical conclusions can be used to analyze and preliminarily design the compliant mechanisms containing cross-spring pivots.
2012, 26(6).
Abstract:
The stratosphere airship provides a unique and promising platform for earth observation. Researches on the project design and control scheme for earth observation platforms are still rarely documented. Nonlinear dynamics, model uncertainties, and external disturbances contribute to the difficulty in maneuvering the stratosphere airship. A key technical challenge for the earth observation platform is station keeping, or the ability to remain fixed over a geo-location. This paper investigates the conceptual design, modeling and station-keeping attitude control of the near-space earth observation platform. A conceptual design of the earth observation platform is presented. The dynamics model of the platform is derived from the Newton-Euler formulation, and the station-keeping control system of the platform is formulated. The station-keeping attitude control approach for the platform is proposed. The multi-input multi-output nonlinear control system is decoupled into three single-input single-output linear subsystems via feedback linearization, the attitude controller design is carried out on the new linear systems using terminal sliding mode control, and the global stability of the closed-loop system is proven by using the Lyapunov theorem. The performance of the designed control system is simulated by using the variable step Runge-Kutta integrator. Simulation results show that the control system tracks the commanded attitude with an error of zero, which verify the effectiveness and robustness of the designed control system in the presence of parametric uncertainties. The near-space earth observation platform has several advantages over satellites, such as high resolution, fast to deploy, and convenient to retrieve, and the proposed control scheme provides an effective approach for station-keeping attitude control of the earth observation platform.
The stratosphere airship provides a unique and promising platform for earth observation. Researches on the project design and control scheme for earth observation platforms are still rarely documented. Nonlinear dynamics, model uncertainties, and external disturbances contribute to the difficulty in maneuvering the stratosphere airship. A key technical challenge for the earth observation platform is station keeping, or the ability to remain fixed over a geo-location. This paper investigates the conceptual design, modeling and station-keeping attitude control of the near-space earth observation platform. A conceptual design of the earth observation platform is presented. The dynamics model of the platform is derived from the Newton-Euler formulation, and the station-keeping control system of the platform is formulated. The station-keeping attitude control approach for the platform is proposed. The multi-input multi-output nonlinear control system is decoupled into three single-input single-output linear subsystems via feedback linearization, the attitude controller design is carried out on the new linear systems using terminal sliding mode control, and the global stability of the closed-loop system is proven by using the Lyapunov theorem. The performance of the designed control system is simulated by using the variable step Runge-Kutta integrator. Simulation results show that the control system tracks the commanded attitude with an error of zero, which verify the effectiveness and robustness of the designed control system in the presence of parametric uncertainties. The near-space earth observation platform has several advantages over satellites, such as high resolution, fast to deploy, and convenient to retrieve, and the proposed control scheme provides an effective approach for station-keeping attitude control of the earth observation platform.
2012, 26(6).
Abstract:
For the technology of diamond cutting of optical glass, the high tool wear rate is a main reason for hindering the practical application of this technology. Many researches on diamond tool wear in glass cutting rest on wear phenomenon describing simply without analyzing the genesis of wear phenomenon and interpreting the formation process of tool wear in mechanics. For in depth understanding of the tool wear and its effect on surface roughness in diamond cutting of glass, experiments of diamond turning with cutting distance increasing gradually are carried out on soda-lime glass. The wear morphology of rake face and flank face, the corresponding surface features of workpiece and the surface roughness, and the material compositions of flank wear area are detected. Experimental results indicate that the flank wear is predominant in diamond cutting glass and the flank wear land is characterized by micro-grooves, some smooth crater on the rake face is also seen. The surface roughness begins to increase rapidly, when the cutting mode changes from ductile to brittle for the aggravation of tool wear with the cutting distance over 150 m. The main mechanisms of inducing tool wear in diamond cutting of glass are diffusion, mechanical friction, thermo-chemical action and abrasive wear. The proposed research makes analysis and research from wear mechanism on the tool wear and its effect on surface roughness in diamond cutting of glass, and provides theoretical basis for minimizing the tool wear in diamond cutting brittle materials, such as optical glass.
For the technology of diamond cutting of optical glass, the high tool wear rate is a main reason for hindering the practical application of this technology. Many researches on diamond tool wear in glass cutting rest on wear phenomenon describing simply without analyzing the genesis of wear phenomenon and interpreting the formation process of tool wear in mechanics. For in depth understanding of the tool wear and its effect on surface roughness in diamond cutting of glass, experiments of diamond turning with cutting distance increasing gradually are carried out on soda-lime glass. The wear morphology of rake face and flank face, the corresponding surface features of workpiece and the surface roughness, and the material compositions of flank wear area are detected. Experimental results indicate that the flank wear is predominant in diamond cutting glass and the flank wear land is characterized by micro-grooves, some smooth crater on the rake face is also seen. The surface roughness begins to increase rapidly, when the cutting mode changes from ductile to brittle for the aggravation of tool wear with the cutting distance over 150 m. The main mechanisms of inducing tool wear in diamond cutting of glass are diffusion, mechanical friction, thermo-chemical action and abrasive wear. The proposed research makes analysis and research from wear mechanism on the tool wear and its effect on surface roughness in diamond cutting of glass, and provides theoretical basis for minimizing the tool wear in diamond cutting brittle materials, such as optical glass.
2012, 26(6).
Abstract:
Magnetically levitated stages(MLS) have potentials to obtain good motion performances in high vacuum environment. Yet the electromagnetic forces/torques corresponding to six degrees of freedom(DOF) motions have coupling relationship with each current of coil array, and this coupling is still associated with the relative positions between the mover and the stator of the stage. So it is quite difficult to control the 6-DOF motions of the stage. By reasonable commutation of coil array, this complicated coupling relationship can be decoupled. The analytical force/torque-decomposing model of the stage is established first. Then the initial currents of coil array are commutated based on the pseudo inverse of the analytical force/torque-decomposing model matrix. And then the coil array currents are commutated again with different current bounds given to the initial currents as well as in the sense of minimum 2-norm of currents vector. Using the long stroke magnetically levitated stage with moving coils under investigation as examples, the currents of coil array are commutated with different current bounds adopting the proposed commutation method, the determination of current bound and the current bounds’ influences on the heat-losses in coil array are analyzed, and the effectiveness of implementation algorithm of proposed commutation method is discussed. Simulation, analysis and discussion results indicate that the currents of coil array within the given current bound can be solved analytically by proposed commutation method, and the implementation algorithm does not need any searching or iteration. By the current-bounded commutation method proposed, the amplitude of coil array currents can be limited within an appropriate current bound(This is very beneficial to the improvement of the reliability and motion performance of the stage), as well as these currents can also generate the desired forces and torques
Magnetically levitated stages(MLS) have potentials to obtain good motion performances in high vacuum environment. Yet the electromagnetic forces/torques corresponding to six degrees of freedom(DOF) motions have coupling relationship with each current of coil array, and this coupling is still associated with the relative positions between the mover and the stator of the stage. So it is quite difficult to control the 6-DOF motions of the stage. By reasonable commutation of coil array, this complicated coupling relationship can be decoupled. The analytical force/torque-decomposing model of the stage is established first. Then the initial currents of coil array are commutated based on the pseudo inverse of the analytical force/torque-decomposing model matrix. And then the coil array currents are commutated again with different current bounds given to the initial currents as well as in the sense of minimum 2-norm of currents vector. Using the long stroke magnetically levitated stage with moving coils under investigation as examples, the currents of coil array are commutated with different current bounds adopting the proposed commutation method, the determination of current bound and the current bounds’ influences on the heat-losses in coil array are analyzed, and the effectiveness of implementation algorithm of proposed commutation method is discussed. Simulation, analysis and discussion results indicate that the currents of coil array within the given current bound can be solved analytically by proposed commutation method, and the implementation algorithm does not need any searching or iteration. By the current-bounded commutation method proposed, the amplitude of coil array currents can be limited within an appropriate current bound(This is very beneficial to the improvement of the reliability and motion performance of the stage), as well as these currents can also generate the desired forces and torques
2012, 26(6).
Abstract:
Transient operations are commonly founded in fluid machineries such as the starting, stopping, and variations of rotor speeds, etc. Flow generated from a started flat plate is of fundamental importance. Experiments have been done to observe the flow evolution in current researches. And in order to explore the flow in more detailed scale, some vortex methods with high resolution and other numerical methods were developed to solve various related problems by some researchers. But the promotion of vortex method to engineering application is rare due to its complexity and difficulty in specifying the boundary conditions. In order to build up a method of numerical study for such problems, a simplified model is built up with a flat plate. The development of two-dimensional viscous incompressible flow generated from an impulsively started and uniformly accelerated infinitesimally thin flat plate is simulated numerically. A dynamic mesh(DM) method based on the spring analogue and local remeshing is applied to realize the mesh motion caused by the started plate. Researches show that the mesh quality will decline under large grid shear force during the updating process. To conquer this problem, a region near the plate is separated to guarantee the mesh quality at location of interest which is the innovation of the present paper. All computations at least cover a period during which the plate translates 6 times its length. The simulated instantaneous velocity profiles, flow structures and drag coefficients under several Reynolds numbers (20 Re 126) and accelerations (20 ms2 a 152 ms2) are presented and compared with existing results in literatures. Comparisons are found to be satisfactory, confirming the validity of the current proposed method(region separated DM). The proposed DM method is firstly used to study the transient flow generated from a started flat plate and can be used in further study of transient characteristics during transient operations of turbo machineries.
Transient operations are commonly founded in fluid machineries such as the starting, stopping, and variations of rotor speeds, etc. Flow generated from a started flat plate is of fundamental importance. Experiments have been done to observe the flow evolution in current researches. And in order to explore the flow in more detailed scale, some vortex methods with high resolution and other numerical methods were developed to solve various related problems by some researchers. But the promotion of vortex method to engineering application is rare due to its complexity and difficulty in specifying the boundary conditions. In order to build up a method of numerical study for such problems, a simplified model is built up with a flat plate. The development of two-dimensional viscous incompressible flow generated from an impulsively started and uniformly accelerated infinitesimally thin flat plate is simulated numerically. A dynamic mesh(DM) method based on the spring analogue and local remeshing is applied to realize the mesh motion caused by the started plate. Researches show that the mesh quality will decline under large grid shear force during the updating process. To conquer this problem, a region near the plate is separated to guarantee the mesh quality at location of interest which is the innovation of the present paper. All computations at least cover a period during which the plate translates 6 times its length. The simulated instantaneous velocity profiles, flow structures and drag coefficients under several Reynolds numbers (20 Re 126) and accelerations (20 ms2 a 152 ms2) are presented and compared with existing results in literatures. Comparisons are found to be satisfactory, confirming the validity of the current proposed method(region separated DM). The proposed DM method is firstly used to study the transient flow generated from a started flat plate and can be used in further study of transient characteristics during transient operations of turbo machineries.
2012, 26(6).
Abstract:
The case-based reasoning(CBR) and rule-based reasoning(RBR) fusion systems include a diverse range of fusion methods and their tasks are characterized by interleaving combination of the reasoning procedures. Existing approaches cannot clarify the complex relationships between data from the knowledge sources nor uniformly represent the heterogeneous case and rule knowledge in one fusion space. As a result, existing approaches fail to solve system fragility due to knowledge uncertainty and reasoning unreliability. For the purpose of addressing the difficulties, a novel algorithm for CBR-RBR fusion with robust thresholds(CRFRT) is proposed. Heterogeneous case and rule knowledge are uniformly represented in one defined fusion unitary space. The robust thresholds have been achieved to distinguish the complex relationships between meta-knowledge in the fusion space and to enhance system capacity of knowledge identification. Furthermore, fusion reasoning strategies are constructed for CRFRT and its procedure based on which robust solution of the fusion reasoning problem is obtained. Finally, CRFRT is validated by benchmark problems in machine learning. Compared with other CBR and RBR approaches, the reasoning efficiency and accuracy are increased by 5% and 2.2% respectively. The variations of system accuracy are decreased by 2% to 3.8%. The above results show that the CRFRT algorithm boosts the system’s effectiveness and robustness. The proposed CRFRT can solve the fragility of complex intelligence decision system and give quality performance for fault diagnosis.
The case-based reasoning(CBR) and rule-based reasoning(RBR) fusion systems include a diverse range of fusion methods and their tasks are characterized by interleaving combination of the reasoning procedures. Existing approaches cannot clarify the complex relationships between data from the knowledge sources nor uniformly represent the heterogeneous case and rule knowledge in one fusion space. As a result, existing approaches fail to solve system fragility due to knowledge uncertainty and reasoning unreliability. For the purpose of addressing the difficulties, a novel algorithm for CBR-RBR fusion with robust thresholds(CRFRT) is proposed. Heterogeneous case and rule knowledge are uniformly represented in one defined fusion unitary space. The robust thresholds have been achieved to distinguish the complex relationships between meta-knowledge in the fusion space and to enhance system capacity of knowledge identification. Furthermore, fusion reasoning strategies are constructed for CRFRT and its procedure based on which robust solution of the fusion reasoning problem is obtained. Finally, CRFRT is validated by benchmark problems in machine learning. Compared with other CBR and RBR approaches, the reasoning efficiency and accuracy are increased by 5% and 2.2% respectively. The variations of system accuracy are decreased by 2% to 3.8%. The above results show that the CRFRT algorithm boosts the system’s effectiveness and robustness. The proposed CRFRT can solve the fragility of complex intelligence decision system and give quality performance for fault diagnosis.
2012, 26(6).
Abstract:
Though the traditional energy regeneration system(ERS) which used a hydraulic motor and a generator in hybrid excavators can regenerate part of the energy, the power of the motor and the generator should be larger and the time for regenerating energy is so short. At first, the structure of new ERS that combines the advantages of an electric and hydraulic accumulator is analyzed. The energy can be converted into both the electric energy and the hydraulic energy at the lowering of the boom and the generator can still works when the boom stops going down. Then, a method how to set the working pressure of the hydraulic accumulator is proposed. To avoid the excess loss, extra noise and shock pressure, a two-level pressure threshold method that the generator starts to work at the rising edge of the high pressure threshold and stops working at the falling edge of the low pressure threshold is presented to characterize the working mode of the generator. The control strategies on how to control the boom velocity at the lowering of the boom and how to improve the recovery efficiency when the boom stops going down are presented. The test bench of hybrid excavator with ERS is constructed, with which the studies on the influences of ERS on energy conversion efficiency and control performance are carried out. Experimental results show that the proposed ERS features better speed control performance of the boom than traditional ERS. It is also observed that an estimated 45% of the total potential energy could be regenerated at the lowering of the boom in the proposed ERS, and the power level of the generator and the hydraulic motor could be reduced by 60%. Hence, the proposed ERS has obvious advantages over the traditional ERS on the improvement of energy regeneration time, energy efficiency, control performance and economy.
Though the traditional energy regeneration system(ERS) which used a hydraulic motor and a generator in hybrid excavators can regenerate part of the energy, the power of the motor and the generator should be larger and the time for regenerating energy is so short. At first, the structure of new ERS that combines the advantages of an electric and hydraulic accumulator is analyzed. The energy can be converted into both the electric energy and the hydraulic energy at the lowering of the boom and the generator can still works when the boom stops going down. Then, a method how to set the working pressure of the hydraulic accumulator is proposed. To avoid the excess loss, extra noise and shock pressure, a two-level pressure threshold method that the generator starts to work at the rising edge of the high pressure threshold and stops working at the falling edge of the low pressure threshold is presented to characterize the working mode of the generator. The control strategies on how to control the boom velocity at the lowering of the boom and how to improve the recovery efficiency when the boom stops going down are presented. The test bench of hybrid excavator with ERS is constructed, with which the studies on the influences of ERS on energy conversion efficiency and control performance are carried out. Experimental results show that the proposed ERS features better speed control performance of the boom than traditional ERS. It is also observed that an estimated 45% of the total potential energy could be regenerated at the lowering of the boom in the proposed ERS, and the power level of the generator and the hydraulic motor could be reduced by 60%. Hence, the proposed ERS has obvious advantages over the traditional ERS on the improvement of energy regeneration time, energy efficiency, control performance and economy.
2012, 26(6).
Abstract:
The law governing the movement of particles in the centrifugal pump channel is complicated; thus, it is difficult to examine the solid-liquid two-phase turbulent flow in the pump. Consequently, the solid-liquid two-phase pump is designed based only on the unary theory. However, the obvious variety of centrifugal-pump internal flow appears because of the existence of solid phase, thus changing pump performance. Therefore, it is necessary to establish the flow characteristics of the solid-liquid two-phase pump. In the current paper, two-phase numerical simulation and centrifugal pump performance tests are carried out using different solid-particle diameters and two-phase mixture concentration conditions. Inner flow features are revealed by comparing the simulated and experimental results. The comparing results indicate that the influence of the solid-phase characteristics on centrifugal-pump performance is small when the flow rate is low, specifically when it is less than 2 m3h. The maximum efficiency declines, and the best efficiency point tends toward the low flow-rate direction along with increasing solid-particle diameter and volume fraction, leading to reduced pump steady efficient range. The variation tendency of the pump head is basically consistent with that of the efficiency. The efficiency and head values of the two-phase mixture transportation are even larger than those of pure-water transportation under smaller particle diameter and volume fraction conditions at the low-flow-rate region. The change of the particle volume fraction has a greater effect on the pump performance than the change in the particle diameter. The experimental values are totally smaller than the simulated values. This research provides the theoretical foundation for the optimal design of centrifugal pump.
The law governing the movement of particles in the centrifugal pump channel is complicated; thus, it is difficult to examine the solid-liquid two-phase turbulent flow in the pump. Consequently, the solid-liquid two-phase pump is designed based only on the unary theory. However, the obvious variety of centrifugal-pump internal flow appears because of the existence of solid phase, thus changing pump performance. Therefore, it is necessary to establish the flow characteristics of the solid-liquid two-phase pump. In the current paper, two-phase numerical simulation and centrifugal pump performance tests are carried out using different solid-particle diameters and two-phase mixture concentration conditions. Inner flow features are revealed by comparing the simulated and experimental results. The comparing results indicate that the influence of the solid-phase characteristics on centrifugal-pump performance is small when the flow rate is low, specifically when it is less than 2 m3h. The maximum efficiency declines, and the best efficiency point tends toward the low flow-rate direction along with increasing solid-particle diameter and volume fraction, leading to reduced pump steady efficient range. The variation tendency of the pump head is basically consistent with that of the efficiency. The efficiency and head values of the two-phase mixture transportation are even larger than those of pure-water transportation under smaller particle diameter and volume fraction conditions at the low-flow-rate region. The change of the particle volume fraction has a greater effect on the pump performance than the change in the particle diameter. The experimental values are totally smaller than the simulated values. This research provides the theoretical foundation for the optimal design of centrifugal pump.
2012, 26(6).
Abstract:
Existing research on the traction control system(TCS) mainly focuses on control methods, such as the PID control, fuzzy logic control, etc, aiming at achieving an ideal slip rate of the drive wheel over long control periods. The initial output of the TCS (referred to as the torque base in this paper), which has a great impact on the driving performance of the vehicle in early cycles, remains to be investigated. In order to improve the control performance of the TCS in the first several cycles, an algorithm is proposed to determine the torque base. First, torque bases are calculated by two different methods, one based on states judgment and the other based on the vehicle dynamics. The confidence level of the torque base calculated based on the vehicle dynamics is also obtained. The final torque base is then determined based on the two torque bases and the confidence level. Hardware-in-the-loop(HIL) simulation and vehicle tests emulating sudden start on low friction roads have been conducted to verify the proposed algorithm. The control performance of a PID-controlled TCS with and without the proposed torque base algorithm is compared, showing that the proposed algorithm improves the performance of the TCS over the first several cycles and enhances about 5% vehicle speed by contrast. The proposed research provides a more proper initial value for TCS control, and improves the performance of the first several control cycles of the TCS.
Existing research on the traction control system(TCS) mainly focuses on control methods, such as the PID control, fuzzy logic control, etc, aiming at achieving an ideal slip rate of the drive wheel over long control periods. The initial output of the TCS (referred to as the torque base in this paper), which has a great impact on the driving performance of the vehicle in early cycles, remains to be investigated. In order to improve the control performance of the TCS in the first several cycles, an algorithm is proposed to determine the torque base. First, torque bases are calculated by two different methods, one based on states judgment and the other based on the vehicle dynamics. The confidence level of the torque base calculated based on the vehicle dynamics is also obtained. The final torque base is then determined based on the two torque bases and the confidence level. Hardware-in-the-loop(HIL) simulation and vehicle tests emulating sudden start on low friction roads have been conducted to verify the proposed algorithm. The control performance of a PID-controlled TCS with and without the proposed torque base algorithm is compared, showing that the proposed algorithm improves the performance of the TCS over the first several cycles and enhances about 5% vehicle speed by contrast. The proposed research provides a more proper initial value for TCS control, and improves the performance of the first several control cycles of the TCS.
2012, 26(6).
Abstract:
MoS2 metal composite coatings have been successful used in dry turning, but its suitability for dry drilling has not been yet established. Therefore, it is necessary to study the friction and wear behaviors of MoS2/Zr coated HSS in sliding wear and in drilling processes. In the present study, MoS2/Zr composite coatings are deposited on the surface of W6Mo5Cr4V2 high speed steel(HSS). Microstructural and fundamental properties of these coatings are examined. Ball-on-disc sliding wear tests on the coated discs are carried out, and the drilling performance of the coated drills is tested. Test results show that the MoS2/Zr composite coatings exhibit decreases friction coefficient to that of the uncoated HSS in sliding wear tests. Energy dispersive X-ray(EDX) analysis on the wear surface indicates that there is a transfer layer formed on the counterpart ball during sliding wear processes, which contributes to the decreasing of the friction coefficient between the sliding couple. Drilling tests indicate that the MoS2/Zr coated drills show better cutting performance compared to the uncoated HSS drills, coating delamination and abrasive are found to be the main flank and rake wear mode of the coated drills. The proposed research founds the base of the application of MoS2 metal composite coatings on dry drilling.
MoS2 metal composite coatings have been successful used in dry turning, but its suitability for dry drilling has not been yet established. Therefore, it is necessary to study the friction and wear behaviors of MoS2/Zr coated HSS in sliding wear and in drilling processes. In the present study, MoS2/Zr composite coatings are deposited on the surface of W6Mo5Cr4V2 high speed steel(HSS). Microstructural and fundamental properties of these coatings are examined. Ball-on-disc sliding wear tests on the coated discs are carried out, and the drilling performance of the coated drills is tested. Test results show that the MoS2/Zr composite coatings exhibit decreases friction coefficient to that of the uncoated HSS in sliding wear tests. Energy dispersive X-ray(EDX) analysis on the wear surface indicates that there is a transfer layer formed on the counterpart ball during sliding wear processes, which contributes to the decreasing of the friction coefficient between the sliding couple. Drilling tests indicate that the MoS2/Zr coated drills show better cutting performance compared to the uncoated HSS drills, coating delamination and abrasive are found to be the main flank and rake wear mode of the coated drills. The proposed research founds the base of the application of MoS2 metal composite coatings on dry drilling.
2012, 26(6).
Abstract:
Traditional technique such nanoindenter(NI) can’t measure the local elastic modulus at nano-scale(lateral). Atomic force acoustic microscopy (AFAM) is a dynamic method, which can quantitatively determine indentation modulus by measuring the contact resonance spectra for high order modes of the cantilever. But there are few reports on the effect of experimental factors, such length of cantilever, contact stiffness on measured value. For three different samples, including copper(Cu) film with 110 nm thickness, zinc(Zn) film of 90 nm thickness and glass slides, are prepared and tested, using referencing approach in which measurements are performed on the test and reference samples (it’s elastic modulus is known), and their contact resonance spectra are measured used the AFAM system experimentally. According to the vibration theory, from the lowest two contact resonance frequencies, the tip-sample contact stiffness is calculated, and then the values for the elastic properties of test sample, such as the indentation modulus, are determined. Using AFAM system, the measured indentation modulus of copper nano-film, zinc nano-film and glass slides are 113.53 GPa, 87.92 GPa and 57.04 GPa, which are agreement with literature values MCu105–130 GPa, MZn 88.44 GPa and MGlass 50–90 GPa. Furthermore, the sensitivity of contact resonance frequency to contact stiffness is analyzed theoretically. The results show that for the cantilevers with the length 160 m, 225 m and 520 m respectively, when contact stiffness increases from 400 Nm to 600 Nm, the increments of first contact resonance frequency are 126 kHz, 93 kHz and 0.6 kHz, which show that the sensitivity of the contact resonance frequency to the contact stiffness reduces with the length of cantilever increasing. The novel method presented can characterize elastic modulus of near surface for nano-film and bulk material, and local elasticity of near surface can be evaluated by optimizing the experimental parameters using the AFAM system.
Traditional technique such nanoindenter(NI) can’t measure the local elastic modulus at nano-scale(lateral). Atomic force acoustic microscopy (AFAM) is a dynamic method, which can quantitatively determine indentation modulus by measuring the contact resonance spectra for high order modes of the cantilever. But there are few reports on the effect of experimental factors, such length of cantilever, contact stiffness on measured value. For three different samples, including copper(Cu) film with 110 nm thickness, zinc(Zn) film of 90 nm thickness and glass slides, are prepared and tested, using referencing approach in which measurements are performed on the test and reference samples (it’s elastic modulus is known), and their contact resonance spectra are measured used the AFAM system experimentally. According to the vibration theory, from the lowest two contact resonance frequencies, the tip-sample contact stiffness is calculated, and then the values for the elastic properties of test sample, such as the indentation modulus, are determined. Using AFAM system, the measured indentation modulus of copper nano-film, zinc nano-film and glass slides are 113.53 GPa, 87.92 GPa and 57.04 GPa, which are agreement with literature values MCu105–130 GPa, MZn 88.44 GPa and MGlass 50–90 GPa. Furthermore, the sensitivity of contact resonance frequency to contact stiffness is analyzed theoretically. The results show that for the cantilevers with the length 160 m, 225 m and 520 m respectively, when contact stiffness increases from 400 Nm to 600 Nm, the increments of first contact resonance frequency are 126 kHz, 93 kHz and 0.6 kHz, which show that the sensitivity of the contact resonance frequency to the contact stiffness reduces with the length of cantilever increasing. The novel method presented can characterize elastic modulus of near surface for nano-film and bulk material, and local elasticity of near surface can be evaluated by optimizing the experimental parameters using the AFAM system.
2012, 26(6).
Abstract:
Energy management(EM) is a core technique of hybrid electric bus(HEB) in order to advance fuel economy performance optimization and is unique for the corresponding configuration. There are existing algorithms of control strategy seldom take battery power management into account with international combustion engine power management. In this paper, a type of power-balancing instantaneous optimization(PBIO) energy management control strategy is proposed for a novel series-parallel hybrid electric bus. According to the characteristic of the novel series-parallel architecture, the switching boundary condition between series and parallel mode as well as the control rules of the power-balancing strategy are developed. The equivalent fuel model of battery is implemented and combined with the fuel of engine to constitute the objective function which is to minimize the fuel consumption at each sampled time and to coordinate the power distribution in real-time between the engine and battery. To validate the proposed strategy effective and reasonable, a forward model is built based on Matlab/Simulink for the simulation and the dSPACE autobox is applied to act as a controller for hardware in-the-loop integrated with bench test. Both the results of simulation and hardware-in-the-loop demonstrate that the proposed strategy not only enable to sustain the battery SOC within its operational range and keep the engine operation point locating the peak efficiency region, but also the fuel economy of series-parallel hybrid electric bus(SPHEB) dramatically advanced up to 30.73% via comparing with the prototype bus and a similar improvement for PBIO strategy relative to rule-based strategy, the reduction of fuel consumption is up to 12.38%. The proposed research ensures the algorithm of PBIO is real-time applicability, improves the efficiency of SPHEB system, as well as suite to complicated configuration perfectly.
Energy management(EM) is a core technique of hybrid electric bus(HEB) in order to advance fuel economy performance optimization and is unique for the corresponding configuration. There are existing algorithms of control strategy seldom take battery power management into account with international combustion engine power management. In this paper, a type of power-balancing instantaneous optimization(PBIO) energy management control strategy is proposed for a novel series-parallel hybrid electric bus. According to the characteristic of the novel series-parallel architecture, the switching boundary condition between series and parallel mode as well as the control rules of the power-balancing strategy are developed. The equivalent fuel model of battery is implemented and combined with the fuel of engine to constitute the objective function which is to minimize the fuel consumption at each sampled time and to coordinate the power distribution in real-time between the engine and battery. To validate the proposed strategy effective and reasonable, a forward model is built based on Matlab/Simulink for the simulation and the dSPACE autobox is applied to act as a controller for hardware in-the-loop integrated with bench test. Both the results of simulation and hardware-in-the-loop demonstrate that the proposed strategy not only enable to sustain the battery SOC within its operational range and keep the engine operation point locating the peak efficiency region, but also the fuel economy of series-parallel hybrid electric bus(SPHEB) dramatically advanced up to 30.73% via comparing with the prototype bus and a similar improvement for PBIO strategy relative to rule-based strategy, the reduction of fuel consumption is up to 12.38%. The proposed research ensures the algorithm of PBIO is real-time applicability, improves the efficiency of SPHEB system, as well as suite to complicated configuration perfectly.
2012, 26(6).
Abstract:
The pressure fluctuation caused by unsteady flow in runner is one of the main reasons of vibration for a large Francis hydraulic turbine. It directly affects the steady operation of the hydraulic turbine unit. The existing research of the pressure fluctuation in hydraulic turbine mainly focuses on the unsteady flow in draft tube. Accurate distribution of pressure fluctuations inside a runner is not very clear. In this paper, the numerical method for predicting the pressure fluctuations in runner is investigated and the numerical simulation is performed for a large Francis hydraulic turbine. It is proved that the combination of shear-stress transport(SST) k- turbulence model and pressure-implicit with splitting of operators(PISO) algorithm could give more reliable prediction of pressure fluctuations in runner. The frequencies of pressure fluctuations in runner are affected by the flow in guide vane and the flow in draft tube. The first dominant frequency is significantly determined by the flow in draft tube, especially at part load condition. This frequency is approximately equal to one-third of the runner rotating frequency. The evident second dominant frequency is exactly equal to the guide vane passing frequency. The peak-to-peak amplitudes of pressure fluctuations in runner at small guide vane open angle are larger than that at large open angle at the same operating head. The amplitudes at points on blade pressure surface are generally greater than that on suction surface. The research results could be used to direct the hydraulic design and operation stability improvement of a large Francis hydraulic turbine.
The pressure fluctuation caused by unsteady flow in runner is one of the main reasons of vibration for a large Francis hydraulic turbine. It directly affects the steady operation of the hydraulic turbine unit. The existing research of the pressure fluctuation in hydraulic turbine mainly focuses on the unsteady flow in draft tube. Accurate distribution of pressure fluctuations inside a runner is not very clear. In this paper, the numerical method for predicting the pressure fluctuations in runner is investigated and the numerical simulation is performed for a large Francis hydraulic turbine. It is proved that the combination of shear-stress transport(SST) k- turbulence model and pressure-implicit with splitting of operators(PISO) algorithm could give more reliable prediction of pressure fluctuations in runner. The frequencies of pressure fluctuations in runner are affected by the flow in guide vane and the flow in draft tube. The first dominant frequency is significantly determined by the flow in draft tube, especially at part load condition. This frequency is approximately equal to one-third of the runner rotating frequency. The evident second dominant frequency is exactly equal to the guide vane passing frequency. The peak-to-peak amplitudes of pressure fluctuations in runner at small guide vane open angle are larger than that at large open angle at the same operating head. The amplitudes at points on blade pressure surface are generally greater than that on suction surface. The research results could be used to direct the hydraulic design and operation stability improvement of a large Francis hydraulic turbine.
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