2014 Vol.27(2)
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2014, 28(2).
Abstract:
There have been various theoretical attempts by researchers worldwide to link up different scales of plasticity studies from the nano-, micro- and macro-scale of observation, based on molecular dynamics, crystal plasticity and continuum mechanics. Very few attempts, however, have been reported in ultra-precision machining studies. A mesoplasticity approach advocated by Lee and Yang is adopted by the authors and is successfully applied to studies of the micro-cutting mechanisms in ultra-precision machining. Traditionally, the shear angle in metal cutting, as well as the cutting force variation, can only be determined from cutting tests. In the pioneering work of the authors, the use of mesoplasticity theory enables prediction of the fluctuation of the shear angle and micro-cutting force, shear band formation, chip morphology in diamond turning and size effect in nano-indentation. These findings are verified by experiments. The mesoplasticity formulation opens up a new direction of studies to enable how the plastic behaviour of materials and their constitutive representations in deformation processing, such as machining can be predicted, assessed and deduced from the basic properties of the materials measurable at the microscale.
There have been various theoretical attempts by researchers worldwide to link up different scales of plasticity studies from the nano-, micro- and macro-scale of observation, based on molecular dynamics, crystal plasticity and continuum mechanics. Very few attempts, however, have been reported in ultra-precision machining studies. A mesoplasticity approach advocated by Lee and Yang is adopted by the authors and is successfully applied to studies of the micro-cutting mechanisms in ultra-precision machining. Traditionally, the shear angle in metal cutting, as well as the cutting force variation, can only be determined from cutting tests. In the pioneering work of the authors, the use of mesoplasticity theory enables prediction of the fluctuation of the shear angle and micro-cutting force, shear band formation, chip morphology in diamond turning and size effect in nano-indentation. These findings are verified by experiments. The mesoplasticity formulation opens up a new direction of studies to enable how the plastic behaviour of materials and their constitutive representations in deformation processing, such as machining can be predicted, assessed and deduced from the basic properties of the materials measurable at the microscale.
2014, 28(2).
Abstract:
Existing biped robots mainly fall into two categories: robots with left and right feet and robots with upper and lower feet. The load carrying capability of a biped robot is quite limited since the two feet of a walking robot supports the robot alternatively during walking. To improve the load carrying capability, a novel biped walking robot is proposed based on a 2-UPU+2-UU parallel mechanism. The biped walking robot is composed of two identical platforms(feet) and four limbs, including two UPU(universal-prismatic-universal serial chain) limbs and two UU limbs. To enhance its terrain adaptability like articulated vehicles, the two feet of the biped walking robot are designed as two vehicles in detail. The conditions that the geometric parameters of the feet must satisfy are discussed. The degrees-of-freedom of the mechanism is analyzed by using screw theory. Gait analysis, kinematic analysis and stability analysis of the mechanism are carried out to verify the structural design parameters. The simulation results validate the feasibility of walking on rugged terrain. Experiments with a physical prototype show that the novel biped walking robot can walk stably on smooth terrain. Due to its unique feet design and high stiffness, the biped walking robot may adapt to rugged terrain and is suitable for load-carrying.
Existing biped robots mainly fall into two categories: robots with left and right feet and robots with upper and lower feet. The load carrying capability of a biped robot is quite limited since the two feet of a walking robot supports the robot alternatively during walking. To improve the load carrying capability, a novel biped walking robot is proposed based on a 2-UPU+2-UU parallel mechanism. The biped walking robot is composed of two identical platforms(feet) and four limbs, including two UPU(universal-prismatic-universal serial chain) limbs and two UU limbs. To enhance its terrain adaptability like articulated vehicles, the two feet of the biped walking robot are designed as two vehicles in detail. The conditions that the geometric parameters of the feet must satisfy are discussed. The degrees-of-freedom of the mechanism is analyzed by using screw theory. Gait analysis, kinematic analysis and stability analysis of the mechanism are carried out to verify the structural design parameters. The simulation results validate the feasibility of walking on rugged terrain. Experiments with a physical prototype show that the novel biped walking robot can walk stably on smooth terrain. Due to its unique feet design and high stiffness, the biped walking robot may adapt to rugged terrain and is suitable for load-carrying.
2014, 28(2).
Abstract:
The fundamental shear horizontal(SH0) wave has several unique features that are attractive for long-range nondestructive testing(NDT). By a careful design of the geometric configuration, electromagnetic acoustic transducers(EMATs) have the capability to generate a wide range of guided wave modes, such as Lamb waves and shear-horizontal(SH) waves in plates. However, the performance of EMATs is influenced by their parameters. To evaluate the performance of periodic permanent magnet(PPM) EMATs, a distributed-line-source model is developed to calculate the angular acoustic field cross-section in the far-field. Numerical analysis is conducted to investigate the performance of such EMATs with different geometric parameters, such as period and number of magnet arrays, and inner and outer coil widths. Such parameters have a great influence on the directivity of the generated SH0 waves that arises mainly in the amplitude and width of both main and side lobes. According to the numerical analysis, these parameters are optimized to obtain better directivity. Optimized PPM EMATs are designed and used for NDT of strip plates. Experimental results show that the lateral boundary of the strip plate has no perceivable influence on SH0-wave propagation, thus validating their used in NDT. The proposed model predicts the radiation pattern of PPM EMATs, and can be used for their parameter optimization.
The fundamental shear horizontal(SH0) wave has several unique features that are attractive for long-range nondestructive testing(NDT). By a careful design of the geometric configuration, electromagnetic acoustic transducers(EMATs) have the capability to generate a wide range of guided wave modes, such as Lamb waves and shear-horizontal(SH) waves in plates. However, the performance of EMATs is influenced by their parameters. To evaluate the performance of periodic permanent magnet(PPM) EMATs, a distributed-line-source model is developed to calculate the angular acoustic field cross-section in the far-field. Numerical analysis is conducted to investigate the performance of such EMATs with different geometric parameters, such as period and number of magnet arrays, and inner and outer coil widths. Such parameters have a great influence on the directivity of the generated SH0 waves that arises mainly in the amplitude and width of both main and side lobes. According to the numerical analysis, these parameters are optimized to obtain better directivity. Optimized PPM EMATs are designed and used for NDT of strip plates. Experimental results show that the lateral boundary of the strip plate has no perceivable influence on SH0-wave propagation, thus validating their used in NDT. The proposed model predicts the radiation pattern of PPM EMATs, and can be used for their parameter optimization.
2014, 28(2).
Abstract:
Due to the insufficiency of utilizing knowledge to guide the complex optimal searching, existing genetic algorithms fail to effectively solve excavator boom structural optimization problem. To improve the optimization efficiency and quality, a new knowledge-based real-coded genetic algorithm is proposed. A dual evolution mechanism combining knowledge evolution with genetic algorithm is established to extract, handle and utilize the shallow and deep implicit constraint knowledge to guide the optimal searching of genetic algorithm circularly. Based on this dual evolution mechanism, knowledge evolution and population evolution can be connected by knowledge influence operators to improve the configurability of knowledge and genetic operators. Then, the new knowledge-based selection operator, crossover operator and mutation operator are proposed to integrate the optimal process knowledge and domain culture to guide the excavator boom structural optimization. Eight kinds of testing algorithms, which include different genetic operators, are taken as examples to solve the structural optimization of a medium-sized excavator boom. By comparing the results of optimization, it is shown that the algorithm including all the new knowledge-based genetic operators can more remarkably improve the evolutionary rate and searching ability than other testing algorithms, which demonstrates the effectiveness of knowledge for guiding optimal searching. The proposed knowledge-based genetic algorithm by combining multi-level knowledge evolution with numerical optimization provides a new effective method for solving the complex engineering optimization problem.
Due to the insufficiency of utilizing knowledge to guide the complex optimal searching, existing genetic algorithms fail to effectively solve excavator boom structural optimization problem. To improve the optimization efficiency and quality, a new knowledge-based real-coded genetic algorithm is proposed. A dual evolution mechanism combining knowledge evolution with genetic algorithm is established to extract, handle and utilize the shallow and deep implicit constraint knowledge to guide the optimal searching of genetic algorithm circularly. Based on this dual evolution mechanism, knowledge evolution and population evolution can be connected by knowledge influence operators to improve the configurability of knowledge and genetic operators. Then, the new knowledge-based selection operator, crossover operator and mutation operator are proposed to integrate the optimal process knowledge and domain culture to guide the excavator boom structural optimization. Eight kinds of testing algorithms, which include different genetic operators, are taken as examples to solve the structural optimization of a medium-sized excavator boom. By comparing the results of optimization, it is shown that the algorithm including all the new knowledge-based genetic operators can more remarkably improve the evolutionary rate and searching ability than other testing algorithms, which demonstrates the effectiveness of knowledge for guiding optimal searching. The proposed knowledge-based genetic algorithm by combining multi-level knowledge evolution with numerical optimization provides a new effective method for solving the complex engineering optimization problem.
2014, 28(2).
Abstract:
Current research on the operational reliability of centrifugal pumps has mainly focused on hydrodynamic instability. However, the interaction between the fluid and structure has not been sufficiently considered; this interaction can cause vibration and dynamic stress, which can affect the reliability. In this study, the dynamic stresses in a single-blade centrifugal pump impeller are analysed under different operating conditions; the two-way coupling method is used to calculate the fluidstructure interaction. Three-dimensional unsteady Reynolds-averaged Navier-Stokes equations are solved with the SST k turbulence model for the fluid in the whole flow passage, while transient structure dynamic analysis is used with the finite element method for the structure side. The dynamic stresses in the rotor system are computed according to the fourth strength theory. The stress results show that the highest stress is near the loose bearing and that the equivalent stress increases with the flow rate because the dynamic stresses are closely related to the pressure load. The stress distributions on the blade pressure side, suction side, leading edge, and trailing edge are each analysed for different flow rates; the highest stress distribution is found on the pressure side. On the blade pressure side, a relatively large stress is found near the trailing edge and hub side. Based on these results, a stress distribution prediction method is proposed for centrifugal pumps, which considers the interaction between the fluid and structure. The method can be used to check the dynamic stress at different flow rates when optimising the pump design to increase the pump reliability.
Current research on the operational reliability of centrifugal pumps has mainly focused on hydrodynamic instability. However, the interaction between the fluid and structure has not been sufficiently considered; this interaction can cause vibration and dynamic stress, which can affect the reliability. In this study, the dynamic stresses in a single-blade centrifugal pump impeller are analysed under different operating conditions; the two-way coupling method is used to calculate the fluidstructure interaction. Three-dimensional unsteady Reynolds-averaged Navier-Stokes equations are solved with the SST k turbulence model for the fluid in the whole flow passage, while transient structure dynamic analysis is used with the finite element method for the structure side. The dynamic stresses in the rotor system are computed according to the fourth strength theory. The stress results show that the highest stress is near the loose bearing and that the equivalent stress increases with the flow rate because the dynamic stresses are closely related to the pressure load. The stress distributions on the blade pressure side, suction side, leading edge, and trailing edge are each analysed for different flow rates; the highest stress distribution is found on the pressure side. On the blade pressure side, a relatively large stress is found near the trailing edge and hub side. Based on these results, a stress distribution prediction method is proposed for centrifugal pumps, which considers the interaction between the fluid and structure. The method can be used to check the dynamic stress at different flow rates when optimising the pump design to increase the pump reliability.
2014, 28(2).
Abstract:
The mass production of printed electronics can be achieved by roll-to-roll(R2R) printing system, so highly accurate web tension is required that can minimize the register error and keep the thickness and roughness of printed devices in limits. The web tension of a R2R system is regulated by the use of integrated load cells and active dancer system for printed electronics applications using decentralized multi-input-single-output(MISO) regularized variable learning rate backpropagation artificial neural networks. The active dancer system is used before printing system to reduce disturbances in the web tension of process span. The classical PID control result in tension spikes with the change in roll diameter of winder and unwinder rolls. The presence of dancer in R2R system shows that improved web tension control in printing span and the web tension can be enhanced from 3.75 N to 4.75 N. The overshoot of system is less than 2.5 N and steady state error is within 1 N where load cells have a signal noise of 0.7 N. The integration of load cells and active dancer with self-adapting neural network control provide a solution to the web tension control of multispan roll-to-roll system.
The mass production of printed electronics can be achieved by roll-to-roll(R2R) printing system, so highly accurate web tension is required that can minimize the register error and keep the thickness and roughness of printed devices in limits. The web tension of a R2R system is regulated by the use of integrated load cells and active dancer system for printed electronics applications using decentralized multi-input-single-output(MISO) regularized variable learning rate backpropagation artificial neural networks. The active dancer system is used before printing system to reduce disturbances in the web tension of process span. The classical PID control result in tension spikes with the change in roll diameter of winder and unwinder rolls. The presence of dancer in R2R system shows that improved web tension control in printing span and the web tension can be enhanced from 3.75 N to 4.75 N. The overshoot of system is less than 2.5 N and steady state error is within 1 N where load cells have a signal noise of 0.7 N. The integration of load cells and active dancer with self-adapting neural network control provide a solution to the web tension control of multispan roll-to-roll system.
2014, 28(2).
Abstract:
Currently, relatively large errors are found in numerical results in some low-specific-speed centrifugal pumps with unshrouded impeller because the effect of clearances and holes are not accurately modeled. Establishing an accurate analytical model to improve performance prediction accuracy is therefore necessary. In this paper, a three-dimensional numerical simulation is conducted to predict the performance of a low-specific-speed centrifugal pump, and the modeling, numerical scheme, and turbulent selection methods are discussed. The pump performance is tested in a model pump test bench, and flow rate, head, power and efficiency of the pump are obtained. The effect of taking into consideration the back-out vane passage, clearance, and balance holes is analyzed by comparing it with experimental results, and the performance prediction methods are validated by experiments. The analysis results show that the pump performance can be accurately predicted by the improved method. Ignoring the back-out vane passage in the calculation model of unshrouded impeller is found to generate better numerical results. Further, the calculation model with the clearances and balance holes can obviously enhance the numerical accuracy. The application of disconnect interface can reduce meshing difficulty but increase the calculation error at the off-design operating point at the same time. Compared with the standard k, renormalization group k, and SpalartAllmars models, the Realizable k model demonstrates the fastest convergent speed and the highest precision for the unshrouded impeller flow simulation. The proposed modeling and numerical simulation methods can improve the performance prediction accuracy of the low-specific-speed centrifugal pumps, and the modeling method is especially suitable for the centrifugal pump with unshrouded impeller.
Currently, relatively large errors are found in numerical results in some low-specific-speed centrifugal pumps with unshrouded impeller because the effect of clearances and holes are not accurately modeled. Establishing an accurate analytical model to improve performance prediction accuracy is therefore necessary. In this paper, a three-dimensional numerical simulation is conducted to predict the performance of a low-specific-speed centrifugal pump, and the modeling, numerical scheme, and turbulent selection methods are discussed. The pump performance is tested in a model pump test bench, and flow rate, head, power and efficiency of the pump are obtained. The effect of taking into consideration the back-out vane passage, clearance, and balance holes is analyzed by comparing it with experimental results, and the performance prediction methods are validated by experiments. The analysis results show that the pump performance can be accurately predicted by the improved method. Ignoring the back-out vane passage in the calculation model of unshrouded impeller is found to generate better numerical results. Further, the calculation model with the clearances and balance holes can obviously enhance the numerical accuracy. The application of disconnect interface can reduce meshing difficulty but increase the calculation error at the off-design operating point at the same time. Compared with the standard k, renormalization group k, and SpalartAllmars models, the Realizable k model demonstrates the fastest convergent speed and the highest precision for the unshrouded impeller flow simulation. The proposed modeling and numerical simulation methods can improve the performance prediction accuracy of the low-specific-speed centrifugal pumps, and the modeling method is especially suitable for the centrifugal pump with unshrouded impeller.
2014, 28(2).
Abstract:
Innovation is a process of taking an original idea and converting it into a business value, in which the engineers face some inventive problems which can be solved hardly by experience. TRIZ, as a new theory for companies in China, provides both conceptual and procedural knowledge for finding and solving inventive problems. Because the government plays a leading role in the diffusion of TRIZ, too many companies from different industries are waiting to be trained, but the quantity of the trainers mastering TRIZ is incompatible with that requirement. In this context, to improve the training effect, an interactive training model of TRIZ for the mechanical engineers in China is developed and the implementation in the form of training classes is carried out. The training process is divided into 6 phases as follows: selecting engineers, training stage-1, finding problems, training stage-2, finding solutions and summing up. The government, TRIZ institutions and companies to join the programs interact during the process. The government initiates and monitors a project in form of a training class of TRIZ and selects companies to join the programs. Each selected companies choose a few engineers to join the class and supervises the training result. The TRIZ institutions design the training courses and carry out training curriculum. With the beginning of the class, an effective communication channel is established by means of interview, discussion face to face, E-mail, QQ and so on. After two years training practices, the results show that innovative abilities of the engineers to join and pass the final examinations increased distinctly, and most of companies joined the training class have taken congnizance of the power of TRIZ for product innovation. This research proposes an interactive training model of TRIZ for mechanical engineers in China to expedite the knowledge diffusion of TRIZ.
Innovation is a process of taking an original idea and converting it into a business value, in which the engineers face some inventive problems which can be solved hardly by experience. TRIZ, as a new theory for companies in China, provides both conceptual and procedural knowledge for finding and solving inventive problems. Because the government plays a leading role in the diffusion of TRIZ, too many companies from different industries are waiting to be trained, but the quantity of the trainers mastering TRIZ is incompatible with that requirement. In this context, to improve the training effect, an interactive training model of TRIZ for the mechanical engineers in China is developed and the implementation in the form of training classes is carried out. The training process is divided into 6 phases as follows: selecting engineers, training stage-1, finding problems, training stage-2, finding solutions and summing up. The government, TRIZ institutions and companies to join the programs interact during the process. The government initiates and monitors a project in form of a training class of TRIZ and selects companies to join the programs. Each selected companies choose a few engineers to join the class and supervises the training result. The TRIZ institutions design the training courses and carry out training curriculum. With the beginning of the class, an effective communication channel is established by means of interview, discussion face to face, E-mail, QQ and so on. After two years training practices, the results show that innovative abilities of the engineers to join and pass the final examinations increased distinctly, and most of companies joined the training class have taken congnizance of the power of TRIZ for product innovation. This research proposes an interactive training model of TRIZ for mechanical engineers in China to expedite the knowledge diffusion of TRIZ.
2014, 28(2).
Abstract:
Bearing ring is the crucial component of bearing. With regard to such problems as material waste, low efficiency and high energy consumption in current process of producing large bearing ring, a new process named casting-rolling compound forming technology is researched by taking the typical 42CrMo slew bearing as object. Through theoretical analysis, the design criteria of the main casting-rolling forming parameters are put forward at first. Then the constitutive relationship model of as-cast 42CrMo steel and its mathematical model of dynamic recrystallization are obtained according to the results of the hot compression experiment. By a coupled thermal-mechanical finite element model for radial-axial rolling of bearing ring, the fraction of dynamic recrystallization is calculated and recrystallized grains size are predicated. Meanwhile, the effects of the initial rolling temperature and feed rate of idle roll on material microstructure evolution are analyzed. Finally, the industrial rolling experiment is designed and performed, based on the simulation results. In addition, mechanical and metallographic tests are conducted on rolled bearing ring to get the mechanical parameters and metallographic structure. The experimental data and results show that the mechanical properties of bearing ring produced by casting-rolling compound forming technology are up to industrial standard, and a qualified bearing ring can be successfully formed by employing this new technology. Through the study, a process of forming large bearing ring directly by using casting ring blank is obtained, which could provide an effective theoretical guidance for manufacturing large ring parts. It also has an edge in saving material, lowering energy and improving efficiency.
Bearing ring is the crucial component of bearing. With regard to such problems as material waste, low efficiency and high energy consumption in current process of producing large bearing ring, a new process named casting-rolling compound forming technology is researched by taking the typical 42CrMo slew bearing as object. Through theoretical analysis, the design criteria of the main casting-rolling forming parameters are put forward at first. Then the constitutive relationship model of as-cast 42CrMo steel and its mathematical model of dynamic recrystallization are obtained according to the results of the hot compression experiment. By a coupled thermal-mechanical finite element model for radial-axial rolling of bearing ring, the fraction of dynamic recrystallization is calculated and recrystallized grains size are predicated. Meanwhile, the effects of the initial rolling temperature and feed rate of idle roll on material microstructure evolution are analyzed. Finally, the industrial rolling experiment is designed and performed, based on the simulation results. In addition, mechanical and metallographic tests are conducted on rolled bearing ring to get the mechanical parameters and metallographic structure. The experimental data and results show that the mechanical properties of bearing ring produced by casting-rolling compound forming technology are up to industrial standard, and a qualified bearing ring can be successfully formed by employing this new technology. Through the study, a process of forming large bearing ring directly by using casting ring blank is obtained, which could provide an effective theoretical guidance for manufacturing large ring parts. It also has an edge in saving material, lowering energy and improving efficiency.
2014, 28(2).
Abstract:
The existing researches of the evaluation method of ride comfort of vehicle mainly focus on the level of human feelings to vibration. The level of human feelings to vibration is influenced by many factors, however, the ride comfort according to the common principle of probability and statistics and simple binary logic is unable to reflect these uncertainties. The random fuzzy evaluation model from people subjective response to vibration is adopted in the paper, these uncertainties are analyzed from the angle of psychological physics. Discussing the traditional evaluation of ride comfort during vehicle vibration, a fuzzily random evaluation model on the basis of annoyance rate is proposed for the human bodys subjective response to vibration, with relevant fuzzy membership function and probability distribution given. A half-car four degrees of freedom suspension vibration model is described, subject to irregular excitations from the road surface, with the aid of software Matlab/Simulink. A new kind of evaluation method for ride comfort of vehicles is proposed in the paper, i.e., the annoyance rate evaluation method. The genetic algorithm and neural network control theory are used to control the system. Simulation results are obtained, such as the comparison of comfort reaction to vibration environments between before and after control, relationship of annoyance rate to vibration frequency and weighted acceleration, based on ISO 26311(1982), ISO 26311(1997) and annoyance rate evaluation method, respectively. Simulated assessment results indicate that the proposed active suspension systems prove to be effective in the vibration isolation of the suspension system, and the subjective response of human being can be promoted from very uncomfortable to a little uncomfortable. Furthermore, the novel evaluation method based on annoyance rate can further estimate quantitatively the number of passengers who feel discomfort due to vibration. A new analysis method of vehicle comfort is presented.
The existing researches of the evaluation method of ride comfort of vehicle mainly focus on the level of human feelings to vibration. The level of human feelings to vibration is influenced by many factors, however, the ride comfort according to the common principle of probability and statistics and simple binary logic is unable to reflect these uncertainties. The random fuzzy evaluation model from people subjective response to vibration is adopted in the paper, these uncertainties are analyzed from the angle of psychological physics. Discussing the traditional evaluation of ride comfort during vehicle vibration, a fuzzily random evaluation model on the basis of annoyance rate is proposed for the human bodys subjective response to vibration, with relevant fuzzy membership function and probability distribution given. A half-car four degrees of freedom suspension vibration model is described, subject to irregular excitations from the road surface, with the aid of software Matlab/Simulink. A new kind of evaluation method for ride comfort of vehicles is proposed in the paper, i.e., the annoyance rate evaluation method. The genetic algorithm and neural network control theory are used to control the system. Simulation results are obtained, such as the comparison of comfort reaction to vibration environments between before and after control, relationship of annoyance rate to vibration frequency and weighted acceleration, based on ISO 26311(1982), ISO 26311(1997) and annoyance rate evaluation method, respectively. Simulated assessment results indicate that the proposed active suspension systems prove to be effective in the vibration isolation of the suspension system, and the subjective response of human being can be promoted from very uncomfortable to a little uncomfortable. Furthermore, the novel evaluation method based on annoyance rate can further estimate quantitatively the number of passengers who feel discomfort due to vibration. A new analysis method of vehicle comfort is presented.
2014, 28(2).
Abstract:
The existing research of the integrated chassis control mainly focuses on the different evaluation indexes and control strategy. Among the different evaluation indexes, the comprehensive properties are usually not considered based on the non-linear superposition principle. But, the control strategy has some shortages on tyre model with side-slip angle, road adhesion coefficient, vertical load and velocity. In this paper, based on belief, desire and intention(BDI)-agent model framework, the TYRE agent, electric power steering(EPS) agent and active suspension system(ASS) agent are proposed. In the system(SYS) agent, the coordination mechanism is employed to manage interdependences and conflicts among other agents, so as to improve the flexibility, adaptability, and robustness of the global control system. Due to the existence of the simulation demand of dynamic performance, the vehicle multi-body dynamics model is established by SIMPACK. And then the co-simulation analysis is conducted to evaluate the proposed multi-agent system(MAS) controller. The simulation results demonstrate that the MAS has good effect on the performance of EPS and ASS. Meantime, the better road feeling for the driver is provided considering the multiple and complex driving traffic. Finally, the MAS rapid control prototyping is built to conduct the real vehicle test. The test results are consistent to the simulation results, which verifies the correctness of simulation. The proposed research ensures the driving safety, enhances the handling stability, and improves the ride comfort.
The existing research of the integrated chassis control mainly focuses on the different evaluation indexes and control strategy. Among the different evaluation indexes, the comprehensive properties are usually not considered based on the non-linear superposition principle. But, the control strategy has some shortages on tyre model with side-slip angle, road adhesion coefficient, vertical load and velocity. In this paper, based on belief, desire and intention(BDI)-agent model framework, the TYRE agent, electric power steering(EPS) agent and active suspension system(ASS) agent are proposed. In the system(SYS) agent, the coordination mechanism is employed to manage interdependences and conflicts among other agents, so as to improve the flexibility, adaptability, and robustness of the global control system. Due to the existence of the simulation demand of dynamic performance, the vehicle multi-body dynamics model is established by SIMPACK. And then the co-simulation analysis is conducted to evaluate the proposed multi-agent system(MAS) controller. The simulation results demonstrate that the MAS has good effect on the performance of EPS and ASS. Meantime, the better road feeling for the driver is provided considering the multiple and complex driving traffic. Finally, the MAS rapid control prototyping is built to conduct the real vehicle test. The test results are consistent to the simulation results, which verifies the correctness of simulation. The proposed research ensures the driving safety, enhances the handling stability, and improves the ride comfort.
2014, 28(2).
Abstract:
The thin-walled tube flexure(TWTF) hinges have important potential application value in the deployment mechanisms of satellite and solar array, but the optimal design of the TWTF hinges havent been completely solved, which restricts their applications. An optimal design method for the qusai-static folding and deploying of TWTF hinges with double slots is presented based on the response surface theory. Firstly, the full factorial method is employed to design of the experiments. Then, the finite element models of the TWTF hinges with double slots are constructed to simulate the qusai-static folding and deploying non-linear analysis. Whats more, the mathematical model of the TWTF flexure hinge quasi-static folding and deploying properties are derived by the response surface method. Considering of small mass and high stability, the peak moment of quasi-static folding and deploying as well as the lightless are set as the objectives to get the optimal performances. The relative errors of the objectives between the optimal design results and the FE analysis results are less than 7%, which demonstrates the precision of the surrogate models. Lastly, the parameter study shows that both the slots length and the slots width both have significant effects to the peak moment of quasi-static folding and deploying of TWTF hinges with double slots. However, the maximum Mises stress of quasi-static folding is more sensitive to the slots length than the slots width. The proposed research can be applied to optimize other thin-walled flexure hinges under quasi-static folding and deploying, which is of great importance to design of flexure hinges with high stability and low stress.
The thin-walled tube flexure(TWTF) hinges have important potential application value in the deployment mechanisms of satellite and solar array, but the optimal design of the TWTF hinges havent been completely solved, which restricts their applications. An optimal design method for the qusai-static folding and deploying of TWTF hinges with double slots is presented based on the response surface theory. Firstly, the full factorial method is employed to design of the experiments. Then, the finite element models of the TWTF hinges with double slots are constructed to simulate the qusai-static folding and deploying non-linear analysis. Whats more, the mathematical model of the TWTF flexure hinge quasi-static folding and deploying properties are derived by the response surface method. Considering of small mass and high stability, the peak moment of quasi-static folding and deploying as well as the lightless are set as the objectives to get the optimal performances. The relative errors of the objectives between the optimal design results and the FE analysis results are less than 7%, which demonstrates the precision of the surrogate models. Lastly, the parameter study shows that both the slots length and the slots width both have significant effects to the peak moment of quasi-static folding and deploying of TWTF hinges with double slots. However, the maximum Mises stress of quasi-static folding is more sensitive to the slots length than the slots width. The proposed research can be applied to optimize other thin-walled flexure hinges under quasi-static folding and deploying, which is of great importance to design of flexure hinges with high stability and low stress.
2014, 28(2).
Abstract:
The existing research of process capability indices of multiple quality characteristics mainly focuses on nonconforming of process output, the concept development of univariate process capability indices, quality loss function and various comprehensive evaluation methods. The multivariate complexity increases the computation difficulty of multivariate process capability indices(MPCI), which makes them hard to be used in practice. In this paper, a new PCA-based MPCI approach is proposed to assess the production capability of the processes that involve multiple product quality characteristics. This approach first transforms the original quality variables into standardized normal variables. MPCI measures are then provided based on the Taam index. Moreover, the statistical properties of these MPCIs, such as confidence intervals and lower confidence bound, are given to let the practitioners understand the capability indices as random variables instead of deterministic variables. A real manufacturing data set and a synthetic data set are used to demonstrate the effectiveness of the proposed method. An implementation procedure is also provided for quality engineers to apply our MPCI approach in their manufacturing processes. The case studies demonstrate the effectiveness and feasibility of this new kind of MPCI, which is easier to be used in production practice. The proposed research provides a novel approach of MPCI calculation.
The existing research of process capability indices of multiple quality characteristics mainly focuses on nonconforming of process output, the concept development of univariate process capability indices, quality loss function and various comprehensive evaluation methods. The multivariate complexity increases the computation difficulty of multivariate process capability indices(MPCI), which makes them hard to be used in practice. In this paper, a new PCA-based MPCI approach is proposed to assess the production capability of the processes that involve multiple product quality characteristics. This approach first transforms the original quality variables into standardized normal variables. MPCI measures are then provided based on the Taam index. Moreover, the statistical properties of these MPCIs, such as confidence intervals and lower confidence bound, are given to let the practitioners understand the capability indices as random variables instead of deterministic variables. A real manufacturing data set and a synthetic data set are used to demonstrate the effectiveness of the proposed method. An implementation procedure is also provided for quality engineers to apply our MPCI approach in their manufacturing processes. The case studies demonstrate the effectiveness and feasibility of this new kind of MPCI, which is easier to be used in production practice. The proposed research provides a novel approach of MPCI calculation.
2014, 28(2).
Abstract:
The classical natural coordinate modeling method which removes the Euler angles and Euler parameters from the governing equations is particularly suitable for the sensitivity analysis and optimization of multibody systems. However, the formulation has so many principles in choosing the generalized coordinates that it hinders the implementation of modeling automation. A first order direct sensitivity analysis approach to multibody systems formulated with novel natural coordinates is presented. Firstly, a new selection method for natural coordinate is developed. The method introduces 12 coordinates to describe the position and orientation of a spatial object. On the basis of the proposed natural coordinates, rigid constraint conditions, the basic constraint elements as well as the initial conditions for the governing equations are derived. Considering the characteristics of the governing equations, the newly proposed generalized- integration method is used and the corresponding algorithm flowchart is discussed. The objective function, the detailed analysis process of first order direct sensitivity analysis and related solving strategy are provided based on the previous modeling system. Finally, in order to verify the validity and accuracy of the method presented, the sensitivity analysis of a planar spinner-slider mechanism and a spatial crank-slider mechanism are conducted. The test results agree well with that of the finite difference method, and the maximum absolute deviation of the results is less than 3%. The proposed approach is not only convenient for automatic modeling, but also helpful for the reduction of the complexity of sensitivity analysis, which provides a practical and effective way to obtain sensitivity for the optimization problems of multibody systems.
The classical natural coordinate modeling method which removes the Euler angles and Euler parameters from the governing equations is particularly suitable for the sensitivity analysis and optimization of multibody systems. However, the formulation has so many principles in choosing the generalized coordinates that it hinders the implementation of modeling automation. A first order direct sensitivity analysis approach to multibody systems formulated with novel natural coordinates is presented. Firstly, a new selection method for natural coordinate is developed. The method introduces 12 coordinates to describe the position and orientation of a spatial object. On the basis of the proposed natural coordinates, rigid constraint conditions, the basic constraint elements as well as the initial conditions for the governing equations are derived. Considering the characteristics of the governing equations, the newly proposed generalized- integration method is used and the corresponding algorithm flowchart is discussed. The objective function, the detailed analysis process of first order direct sensitivity analysis and related solving strategy are provided based on the previous modeling system. Finally, in order to verify the validity and accuracy of the method presented, the sensitivity analysis of a planar spinner-slider mechanism and a spatial crank-slider mechanism are conducted. The test results agree well with that of the finite difference method, and the maximum absolute deviation of the results is less than 3%. The proposed approach is not only convenient for automatic modeling, but also helpful for the reduction of the complexity of sensitivity analysis, which provides a practical and effective way to obtain sensitivity for the optimization problems of multibody systems.
2014, 28(2).
Abstract:
The existing research of the acceleration control mainly focuses on an optimization of the velocity trajectory with respect to a criterion formulation that weights acceleration time and fuel consumption. The minimum-fuel acceleration problem in conventional vehicle has been solved by Pontryagins maximum principle and dynamic programming algorithm, respectively. The acceleration control with minimum energy consumption for battery electric vehicle(EV) has not been reported. In this paper, the permanent magnet synchronous motor(PMSM) is controlled by the field oriented control(FOC) method and the electric drive system for the EV(including the PMSM, the inverter and the battery) is modeled to favor over a detailed consumption map. The analytical algorithm is proposed to analyze the optimal acceleration control and the optimal torque versus speed curve in the acceleration process is obtained. Considering the acceleration time, a penalty function is introduced to realize a fast vehicle speed tracking. The optimal acceleration control is also addressed with dynamic programming(DP). This method can solve the optimal acceleration problem with precise time constraint, but it consumes a large amount of computation time. The EV used in simulation and experiment is a four-wheel hub motor drive electric vehicle. The simulation and experimental results show that the required battery energy has little difference between the acceleration control solved by analytical algorithm and that solved by DP, and is greatly reduced comparing with the constant pedal opening acceleration. The proposed analytical and DP algorithms can minimize the energy consumption in EVs acceleration process and the analytical algorithm is easy to be implemented in real-time control.
The existing research of the acceleration control mainly focuses on an optimization of the velocity trajectory with respect to a criterion formulation that weights acceleration time and fuel consumption. The minimum-fuel acceleration problem in conventional vehicle has been solved by Pontryagins maximum principle and dynamic programming algorithm, respectively. The acceleration control with minimum energy consumption for battery electric vehicle(EV) has not been reported. In this paper, the permanent magnet synchronous motor(PMSM) is controlled by the field oriented control(FOC) method and the electric drive system for the EV(including the PMSM, the inverter and the battery) is modeled to favor over a detailed consumption map. The analytical algorithm is proposed to analyze the optimal acceleration control and the optimal torque versus speed curve in the acceleration process is obtained. Considering the acceleration time, a penalty function is introduced to realize a fast vehicle speed tracking. The optimal acceleration control is also addressed with dynamic programming(DP). This method can solve the optimal acceleration problem with precise time constraint, but it consumes a large amount of computation time. The EV used in simulation and experiment is a four-wheel hub motor drive electric vehicle. The simulation and experimental results show that the required battery energy has little difference between the acceleration control solved by analytical algorithm and that solved by DP, and is greatly reduced comparing with the constant pedal opening acceleration. The proposed analytical and DP algorithms can minimize the energy consumption in EVs acceleration process and the analytical algorithm is easy to be implemented in real-time control.
2014, 28(2).
Abstract:
Expandable profile liner(EPL) is a promising new oil well casing cementing technique, and welding is a major EPLs connection technology. Connection of EPL is still in the stage of manual welding so far, automatic welding technology is a hotspot of EPL which is one of the key technologies to be solved. A robot for automatic welding of 8 type EPL is studied. Four quadrants of mathematical equations of the 8-shaped cross-section track of EPL, consisting of multiple arcs, are established. Mechanism program for complex cross-section welding of EPL based on angle detection is proposed according to characteristics of small size, small valleys, and large forming errors, etc. A welding velocity vector control model is established by linkage control of a welding vehicle, a small driven actuator, and a height tracking mechanism. A constant speed control model based on an angle and symmetrical analysis model of rectangular coordinate system for EPL is built. Constraint conditions of constant speed control between each section are analyzed with 4 sections in first quadrant as an example, and cooperation work mechanism of the welding vehicle and the small tracking actuator is established based on pressure detection. The constant speed control model using angle self-test can be used to avoid the need for a precise mathematical model for tracking control and to adapt manufacture and installation deviation of EPL workpiece. The model is able to solve constant speed and trajectory tracking problems of EPL cross-section welding. EPL seams welded by the studied robot are good in appearance, and non-destructive testing(NDT) shows the seams are good in quality with no welding defects. Bulge tests show that the maximum pressure of welded EPL is 35 MPa, which can fulfill expansion performance requirements.
Expandable profile liner(EPL) is a promising new oil well casing cementing technique, and welding is a major EPLs connection technology. Connection of EPL is still in the stage of manual welding so far, automatic welding technology is a hotspot of EPL which is one of the key technologies to be solved. A robot for automatic welding of 8 type EPL is studied. Four quadrants of mathematical equations of the 8-shaped cross-section track of EPL, consisting of multiple arcs, are established. Mechanism program for complex cross-section welding of EPL based on angle detection is proposed according to characteristics of small size, small valleys, and large forming errors, etc. A welding velocity vector control model is established by linkage control of a welding vehicle, a small driven actuator, and a height tracking mechanism. A constant speed control model based on an angle and symmetrical analysis model of rectangular coordinate system for EPL is built. Constraint conditions of constant speed control between each section are analyzed with 4 sections in first quadrant as an example, and cooperation work mechanism of the welding vehicle and the small tracking actuator is established based on pressure detection. The constant speed control model using angle self-test can be used to avoid the need for a precise mathematical model for tracking control and to adapt manufacture and installation deviation of EPL workpiece. The model is able to solve constant speed and trajectory tracking problems of EPL cross-section welding. EPL seams welded by the studied robot are good in appearance, and non-destructive testing(NDT) shows the seams are good in quality with no welding defects. Bulge tests show that the maximum pressure of welded EPL is 35 MPa, which can fulfill expansion performance requirements.
2014, 28(2).
Abstract:
The current research of real-time observation for vehicle roll steer angle and compliance steer angle(both of them comprehensively referred as the additional steer angle in this paper) mainly employs the linear vehicle dynamic model, in which only the lateral acceleration of vehicle body is considered. The observation accuracy resorting to this method cannot meet the requirements of vehicle real-time stability control, especially under extreme driving conditions. The paper explores the solution resorting to experimental method. Firstly, a multi-body dynamic model of a passenger car is built based on the ADAMS/Car software, whose dynamic accuracy is verified by the same vehicles roadway test data of steady static circular test. Based on this simulation platform, several influencing factors of additional steer angle under different driving conditions are quantitatively analyzed. Then -SVR algorithm is employed to build the additional steer angle prediction model, whose input vectors mainly include the sensor information of standard electronic stability control system(ESC). The method of typical slalom tests and FMVSS 126 tests are adopted to make simulation, train model and test models generalization performance. The test result shows that the influence of lateral acceleration on additional steer angle is maximal (the magnitude up to 1), followed by the longitudinal acceleration-deceleration and the road wave amplitude (the magnitude up to 0.3). Moreover, both the prediction accuracy and the calculation real-time of the model can meet the control requirements of ESC. This research expands the accurate observation methods of the additional steer angle under extreme driving conditions.
The current research of real-time observation for vehicle roll steer angle and compliance steer angle(both of them comprehensively referred as the additional steer angle in this paper) mainly employs the linear vehicle dynamic model, in which only the lateral acceleration of vehicle body is considered. The observation accuracy resorting to this method cannot meet the requirements of vehicle real-time stability control, especially under extreme driving conditions. The paper explores the solution resorting to experimental method. Firstly, a multi-body dynamic model of a passenger car is built based on the ADAMS/Car software, whose dynamic accuracy is verified by the same vehicles roadway test data of steady static circular test. Based on this simulation platform, several influencing factors of additional steer angle under different driving conditions are quantitatively analyzed. Then -SVR algorithm is employed to build the additional steer angle prediction model, whose input vectors mainly include the sensor information of standard electronic stability control system(ESC). The method of typical slalom tests and FMVSS 126 tests are adopted to make simulation, train model and test models generalization performance. The test result shows that the influence of lateral acceleration on additional steer angle is maximal (the magnitude up to 1), followed by the longitudinal acceleration-deceleration and the road wave amplitude (the magnitude up to 0.3). Moreover, both the prediction accuracy and the calculation real-time of the model can meet the control requirements of ESC. This research expands the accurate observation methods of the additional steer angle under extreme driving conditions.
2014, 28(2).
Abstract:
The existing investigations on thermal comfort mostly focus on the thermal environment conditions, especially of the air-flow field and the temperature distributions in vehicle cabin. Less attention appears to direct to the thermal comfort or thermal sensation of occupants, even to the relationship between thermal conditions and thermal sensation. In this paper, a series of experiments were designed and conducted for understanding the non-uniform conditions and the occupants thermal responses in vehicle cabin during the heating period. To accurately assess the transient temperature distribution in cabin in common daily condition, the air temperature at a number of positions is measured in a full size vehicle cabin under natural winter environment in South China by using a discrete thermocouples network. The occupant body is divided into nine segments, the skin temperature at each segment and the occupants local thermal sensation at the head, body, upper limb and lower limb are monitored continuously. The skin temperature is observed by using a discrete thermocouples network, and the local thermal sensation is evaluated by using a seven-point thermal comfort survey questionnaire proposed by American Society of Heating, Refrigerating and Air-Conditioning Engineers, Inc(ASHRAE) Standard. The relationship between the skin temperature and the thermal sensation is discussed and regressed by statistics method. The results show that the interior air temperature is highly non-uniform over the vehicle cabin. The locations where the occupants sit have a significant effect on the occupants thermal responses, including the skin temperature and the thermal sensation. The skin temperature and thermal sensation are quite different between body segments due to the effect of non-uniform conditions, clothing resistance, and the human thermal regulating system. A quantitative relationship between the thermal sensation and the skin temperature at each body segment of occupant in real life traffic is presented. The investigation result indicates that the skin temperature is a robust index to evaluate the thermal sensation. Applying the skin temperature to designing and controlling parameters of the heating, ventilation and air conditioning(HVAC) system may benefit the thermal comfort and reducing energy consumption.
The existing investigations on thermal comfort mostly focus on the thermal environment conditions, especially of the air-flow field and the temperature distributions in vehicle cabin. Less attention appears to direct to the thermal comfort or thermal sensation of occupants, even to the relationship between thermal conditions and thermal sensation. In this paper, a series of experiments were designed and conducted for understanding the non-uniform conditions and the occupants thermal responses in vehicle cabin during the heating period. To accurately assess the transient temperature distribution in cabin in common daily condition, the air temperature at a number of positions is measured in a full size vehicle cabin under natural winter environment in South China by using a discrete thermocouples network. The occupant body is divided into nine segments, the skin temperature at each segment and the occupants local thermal sensation at the head, body, upper limb and lower limb are monitored continuously. The skin temperature is observed by using a discrete thermocouples network, and the local thermal sensation is evaluated by using a seven-point thermal comfort survey questionnaire proposed by American Society of Heating, Refrigerating and Air-Conditioning Engineers, Inc(ASHRAE) Standard. The relationship between the skin temperature and the thermal sensation is discussed and regressed by statistics method. The results show that the interior air temperature is highly non-uniform over the vehicle cabin. The locations where the occupants sit have a significant effect on the occupants thermal responses, including the skin temperature and the thermal sensation. The skin temperature and thermal sensation are quite different between body segments due to the effect of non-uniform conditions, clothing resistance, and the human thermal regulating system. A quantitative relationship between the thermal sensation and the skin temperature at each body segment of occupant in real life traffic is presented. The investigation result indicates that the skin temperature is a robust index to evaluate the thermal sensation. Applying the skin temperature to designing and controlling parameters of the heating, ventilation and air conditioning(HVAC) system may benefit the thermal comfort and reducing energy consumption.
2014, 28(2).
Abstract:
Axial-grooved gas-lubricated journal bearings have been widely applied to precision instrument due to their high accuracy, low friction, low noise and high stability. The rotor system with axial-grooved gas-lubricated journal bearing support is a typical nonlinear dynamic system. The nonlinear analysis measures have to be adopted to analyze the behaviors of the axial-grooved gas-lubricated journal bearing-rotor nonlinear system as the linear analysis measures fail. The bifurcation and chaos of nonlinear rotor system with three axial-grooved gas-lubricated journal bearing support are investigated by nonlinear dynamics theory. A time-dependent mathematical model is established to describe the pressure distribution in the axial-grooved compressible gas-lubricated journal bearing. The time-dependent compressible gas-lubricated Reynolds equation is solved by the differential transformation method. The gyroscopic effect of the rotor supported by gas-lubricated journal bearing with three axial grooves is taken into consideration in the model of the system, and the dynamic equation of motion is calculated by the modified Wilson--based method. To analyze the unbalanced responses of the rotor system supported by finite length gas-lubricated journal bearings, such as bifurcation and chaos, the bifurcation diagram, the orbit diagram, the Poincar map, the time series and the frequency spectrum are employed. The numerical results reveal that the nonlinear gas film forces have a significant influence on the stability of rotor system and there are the rich nonlinear phenomena, such as the periodic, period-doubling, quasi-periodic, period-4 and chaotic motion, and so on. The proposed models and numerical results can provide a theoretical direction to the design of axial-grooved gas-lubricated journal bearing-rotor system.
Axial-grooved gas-lubricated journal bearings have been widely applied to precision instrument due to their high accuracy, low friction, low noise and high stability. The rotor system with axial-grooved gas-lubricated journal bearing support is a typical nonlinear dynamic system. The nonlinear analysis measures have to be adopted to analyze the behaviors of the axial-grooved gas-lubricated journal bearing-rotor nonlinear system as the linear analysis measures fail. The bifurcation and chaos of nonlinear rotor system with three axial-grooved gas-lubricated journal bearing support are investigated by nonlinear dynamics theory. A time-dependent mathematical model is established to describe the pressure distribution in the axial-grooved compressible gas-lubricated journal bearing. The time-dependent compressible gas-lubricated Reynolds equation is solved by the differential transformation method. The gyroscopic effect of the rotor supported by gas-lubricated journal bearing with three axial grooves is taken into consideration in the model of the system, and the dynamic equation of motion is calculated by the modified Wilson--based method. To analyze the unbalanced responses of the rotor system supported by finite length gas-lubricated journal bearings, such as bifurcation and chaos, the bifurcation diagram, the orbit diagram, the Poincar map, the time series and the frequency spectrum are employed. The numerical results reveal that the nonlinear gas film forces have a significant influence on the stability of rotor system and there are the rich nonlinear phenomena, such as the periodic, period-doubling, quasi-periodic, period-4 and chaotic motion, and so on. The proposed models and numerical results can provide a theoretical direction to the design of axial-grooved gas-lubricated journal bearing-rotor system.
2014, 28(2).
Abstract:
Most researches on transient fuel control of port fuel injection S.I. engine are carried out from the perspective of advanced mathematical theories. When it comes to practical control, there exist many limitations although they are more intelligent. In order to overcome the fuel wetting effect of PFI engine, the application-oriented transient fuel control is studied by analyzing the key parameters which are closely related with the engine transient characteristics. Both validity and simplicity are taken into consideration. Based on the fuel wall-wetting theory and popular fuel compensation strategy, short-term transient fuel(STF) and long-term transient fuel(LTF), as well as their individual decay approaches, are introduced. STF is to compensate the drastic fuel film loss caused by sudden throttle change, while the function of LTF is to compensate the fuel film loss by manifold air pressure(p) fluctuation. Each of them has their respective pros and cons. The engine fuel mass and air mass are also calculated for air-fuel ratio(AFR) according to ideal gas state equation and empirical equations. The vehicle acceleration test is designed for model validation. The engine experiences several mild and heavy accelerations corresponding to the gear change during vehicle acceleration. STF and LTF control are triggered reliably. The engine transient fuel control simulation adopts the same inputs as the test to ensure consistency. The logged test data are used to check the model output. The results show that the maximum fuel pulse width(FPW) error reaches 2 ms, and it only occurs under engine heavy acceleration condition. The average FPW error is 0.57 ms. The results of simulation and test are close overall, which indicates the accuracy of steady and transient fuel. The proposed research provides an efficient approach not only suitable for practical engineering application, but also for AFR prediction, fuel consumption calculation, and further studies on emission control.
Most researches on transient fuel control of port fuel injection S.I. engine are carried out from the perspective of advanced mathematical theories. When it comes to practical control, there exist many limitations although they are more intelligent. In order to overcome the fuel wetting effect of PFI engine, the application-oriented transient fuel control is studied by analyzing the key parameters which are closely related with the engine transient characteristics. Both validity and simplicity are taken into consideration. Based on the fuel wall-wetting theory and popular fuel compensation strategy, short-term transient fuel(STF) and long-term transient fuel(LTF), as well as their individual decay approaches, are introduced. STF is to compensate the drastic fuel film loss caused by sudden throttle change, while the function of LTF is to compensate the fuel film loss by manifold air pressure(p) fluctuation. Each of them has their respective pros and cons. The engine fuel mass and air mass are also calculated for air-fuel ratio(AFR) according to ideal gas state equation and empirical equations. The vehicle acceleration test is designed for model validation. The engine experiences several mild and heavy accelerations corresponding to the gear change during vehicle acceleration. STF and LTF control are triggered reliably. The engine transient fuel control simulation adopts the same inputs as the test to ensure consistency. The logged test data are used to check the model output. The results show that the maximum fuel pulse width(FPW) error reaches 2 ms, and it only occurs under engine heavy acceleration condition. The average FPW error is 0.57 ms. The results of simulation and test are close overall, which indicates the accuracy of steady and transient fuel. The proposed research provides an efficient approach not only suitable for practical engineering application, but also for AFR prediction, fuel consumption calculation, and further studies on emission control.
2014, 28(2).
Abstract:
In precision machining of complex curved surface parts with high performance, geometry accuracy is not the only constraint, but the performance should also be met. Performance of this kind of parts is closely related to the geometrical and physical parameters, so the final actual size and shape are affected by multiple source constraints, such as geometry, physics, and performance. These parts are rather difficult to be manufactured and new manufacturing method according to performance requirement is urgently needed. Based on performance and manufacturing requirements for complex curved surface parts, a new classification method is proposed, which divided the complex curved surface parts into two categories: surface re-design complex curved surface parts with multi-source constraints(PRCS) and surface unique complex curved surface parts with pure geometric constraints(PUCS). A correlation model is constructed between the performance and multi-source constraints for PRCS, which reveals the correlation between the performance and multi-source constraints. A re-design method is also developed. Through solving the correlation model of the typical parts performance-associated surface, the mapping relation between the performance-associated surface and the related removal amount is obtained. The explicit correlation model and the method for the corresponding related removal amount of the performance-associated surface are built based on the classification of surface re-design complex curved surface parts with multi-source constraints. Research results have been used in the actual processing of the typical parts such as radome, common bottom components, nozzle, et al., which shows improved efficiency and accuracy of the precision machining for the surface re-design parts with complex curved surface.
In precision machining of complex curved surface parts with high performance, geometry accuracy is not the only constraint, but the performance should also be met. Performance of this kind of parts is closely related to the geometrical and physical parameters, so the final actual size and shape are affected by multiple source constraints, such as geometry, physics, and performance. These parts are rather difficult to be manufactured and new manufacturing method according to performance requirement is urgently needed. Based on performance and manufacturing requirements for complex curved surface parts, a new classification method is proposed, which divided the complex curved surface parts into two categories: surface re-design complex curved surface parts with multi-source constraints(PRCS) and surface unique complex curved surface parts with pure geometric constraints(PUCS). A correlation model is constructed between the performance and multi-source constraints for PRCS, which reveals the correlation between the performance and multi-source constraints. A re-design method is also developed. Through solving the correlation model of the typical parts performance-associated surface, the mapping relation between the performance-associated surface and the related removal amount is obtained. The explicit correlation model and the method for the corresponding related removal amount of the performance-associated surface are built based on the classification of surface re-design complex curved surface parts with multi-source constraints. Research results have been used in the actual processing of the typical parts such as radome, common bottom components, nozzle, et al., which shows improved efficiency and accuracy of the precision machining for the surface re-design parts with complex curved surface.
2014, 28(2).
Abstract:
Condition based maintenance(CBM) issues a new challenge of real-time monitoring for machine health maintenance. Wear state monitoring becomes the bottle-neck of CBM due to the lack of on-line information acquiring means. The wear mechanism judgment with characteristic wear debris has been widely adopted in off-line wear analysis; however, on-line wear mechanism characterization remains a big problem. In this paper, the wear mechanism identification via on-line ferrograph images is studied. To obtain isolated wear debris in an on-line ferrograph image, the deposition mechanism of wear debris in on-line ferrograph sensor is studied. The study result shows wear debris chain is the main morphology due to local magnetic field around the deposited wear debris. Accordingly, an improved sampling route for on-line wear debris deposition is designed with focus on the self-adjustment deposition time. As a result, isolated wear debris can be obtained in an on-line image, which facilitates the feature extraction of characteristic wear debris. By referring to the knowledge of analytical ferrograph, four dimensionless morphological features, including equivalent dimension, length-width ratio, shape factor, and contour fractal dimension of characteristic wear debris are extracted for distinguishing four typical wear mechanisms including normal, cutting, fatigue, and severe sliding wear. Furthermore, a feed-forward neural network is adopted to construct an automatic wear mechanism identification model. By training with the samples from analytical ferrograph, the model might identify some typical characteristic wear debris in an on-line ferrograph image. This paper performs a meaningful exploratory for on-line wear mechanism analysis, and the obtained results will provide a feasible way for on-line wear state monitoring.
Condition based maintenance(CBM) issues a new challenge of real-time monitoring for machine health maintenance. Wear state monitoring becomes the bottle-neck of CBM due to the lack of on-line information acquiring means. The wear mechanism judgment with characteristic wear debris has been widely adopted in off-line wear analysis; however, on-line wear mechanism characterization remains a big problem. In this paper, the wear mechanism identification via on-line ferrograph images is studied. To obtain isolated wear debris in an on-line ferrograph image, the deposition mechanism of wear debris in on-line ferrograph sensor is studied. The study result shows wear debris chain is the main morphology due to local magnetic field around the deposited wear debris. Accordingly, an improved sampling route for on-line wear debris deposition is designed with focus on the self-adjustment deposition time. As a result, isolated wear debris can be obtained in an on-line image, which facilitates the feature extraction of characteristic wear debris. By referring to the knowledge of analytical ferrograph, four dimensionless morphological features, including equivalent dimension, length-width ratio, shape factor, and contour fractal dimension of characteristic wear debris are extracted for distinguishing four typical wear mechanisms including normal, cutting, fatigue, and severe sliding wear. Furthermore, a feed-forward neural network is adopted to construct an automatic wear mechanism identification model. By training with the samples from analytical ferrograph, the model might identify some typical characteristic wear debris in an on-line ferrograph image. This paper performs a meaningful exploratory for on-line wear mechanism analysis, and the obtained results will provide a feasible way for on-line wear state monitoring.
2014, 28(2).
Abstract:
The aerodynamic braking is a clean and non-adhesion braking, and can be used to provide extra braking force during high-speed emergency braking. The research of aerodynamic braking has attracted more and more attentions in recent years. However, most researchers in this field focus on aerodynamic effects and seldom on issues of position control of the aerodynamic braking board. The purpose of this paper is to explore position control optimization of the braking board in an aerodynamic braking prototype. The mathematical models of the hydraulic drive unit in the aerodynamic braking system are analyzed in detail, and the simulation models are established. Three control functionsconstant, linear, and quadraticare explored. Two kinds of criteria, including the position steady-state error and the acceleration of the piston rod, are used to evaluate system performance. Simulation results show that the position steady state-error is reduced from around 122 mm by applying a linear instead of a constant function, while the acceleration is reduced from 25.713.70 ms2 with a quadratic control function. Use of the quadratic control function is shown to improve system performance. Experimental results obtained by measuring the position response of the piston rod on a test-bench also suggest a reduced position error and smooth movement of the piston rod. This implies that the acceleration is smaller when using the quadratic function, thus verifying the effectiveness of control schemes to improve to system performance. This paper proposes an effective and easily implemented control scheme that improves the position response of hydraulic cylinders during position control.
The aerodynamic braking is a clean and non-adhesion braking, and can be used to provide extra braking force during high-speed emergency braking. The research of aerodynamic braking has attracted more and more attentions in recent years. However, most researchers in this field focus on aerodynamic effects and seldom on issues of position control of the aerodynamic braking board. The purpose of this paper is to explore position control optimization of the braking board in an aerodynamic braking prototype. The mathematical models of the hydraulic drive unit in the aerodynamic braking system are analyzed in detail, and the simulation models are established. Three control functionsconstant, linear, and quadraticare explored. Two kinds of criteria, including the position steady-state error and the acceleration of the piston rod, are used to evaluate system performance. Simulation results show that the position steady state-error is reduced from around 122 mm by applying a linear instead of a constant function, while the acceleration is reduced from 25.713.70 ms2 with a quadratic control function. Use of the quadratic control function is shown to improve system performance. Experimental results obtained by measuring the position response of the piston rod on a test-bench also suggest a reduced position error and smooth movement of the piston rod. This implies that the acceleration is smaller when using the quadratic function, thus verifying the effectiveness of control schemes to improve to system performance. This paper proposes an effective and easily implemented control scheme that improves the position response of hydraulic cylinders during position control.
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