Modern Machinery Research Articles

Practical adaptive robust tracking control of the dual-valve parallel electro-hydraulic servo system with reduced-order model

To meet the increasing demand for trajectory tracking accuracy and high-efficiency requirements in modern mobile machinery, this paper proposes a practical adaptive robust control method based on the dual-valve parallel electro-hydraulic servo system. Existing tracking control strategies for such servo systems rely on a backstepping method and assume that full states are known, which is stringent in practice. To cope with the problem, we reduce the mathematical model order of the studied system using singular perturbation theory in this paper, and only the position feedback is required for the control implementation. Then, to achieve high accuracy tracking control, a direct adaptive robust control scheme combing with a dynamic flow allocation layer is adopted to synthesize the controller. With this method, parameter uncertainties and load disturbance are rejected, and valve characteristics are considered in the dynamic flow allocation layer to solve the flow redundancy problem, respectively. Convergence of the simplified system tracking results is proved theoretically. Extensive co-simulations and experimental tests are carried out to illustrate the effectiveness of the proposed strategy, both tracking precision and flow distribution can be achieved efficiently by simple parameter adjustments in the field.

AN IMPROVEMENT DESIGN OF MULTI-FUNCTION CONTROLLER FOR HIGH-TECH SHRIMP FARM

Shrimp farming is one of the highest potential areas in the coastal provinces of Vietnam. The technical level of shrimp farming is developing strongly in the direction of high technology based on applying modern equipment and machinery. However, the efficiency of shrimp farming is still not high, the monitoring and control of the actuators are mainly manual. Shrimp farmers are not interested in using smart controllers for shrimp farms. In this article, the author evaluates the limitations of the current controllers and proposes a multi-function controller which is suitable for the practical requirements of high-tech shrimp farms (HTSFs) with significant functions such as soft configuration, overload protection, and engine damage warning for actuator devices. In addition, the proposed controller also allows monitoring and automatically controlling HTSFs on a mobile application.

An Efficient Siamese Network and Transfer Learning-Based Predictive Maintenance System for More Sustainable Manufacturing

Legacy machinery poses a specific challenge when integrated into modern manufacturing lines. While modern machinery provides swift methods of integration and inbuilt predictive maintenance (PdM), older machines, while physically fully functional, are less attractive to reuse, a specific reason being their lack of ready-to-implement PdM hardware and models. More sustainable manufacturing operations can be achieved if the useable lifespan of functional older machinery can be extended through retrofittable PdM and modern industrial communication systems. While PdM models can be developed for a class (make/model) of machine with retrofitted sensing, it is often found that legacy machines will deviate greatly from their original form, through nonstandard maintenance and component replacement actions during their lengthy lifespan. This would mean that each legacy machine would require a custom PdM model, a cost often leading to the removal or nonusage of legacy machines. This paper proposes a framework designed for the generation of an efficient PdM algorithm which would allow for the reuse of legacy machines retrofitted with low-cost sensing in modern manufacturing for increased sustainability. Given a limited number of data samples collected from a machine to be maintained, we aim to predict a failure or/and maintenance time by making use of the difference between the characteristics of the variation of the healthy and unhealthy data collected from the machine. We measure the healthiness of the machine by using a Siamese network trained with a public dataset and fine-tuned with data samples obtained from machines with similar characteristics. Although we use different training and testing datasets coming from completely different sources, we obtain reasonable results thanks to the proposed technique. The results of simulations and the statistical analysis enable us to devise a transfer learning technique and a Siamese network employed for failure detection in the machine. The proposed system will allow for the continued use of older machines in modern facilities, enabling more sustainable manufacturing models.

MATLAB-based fault diagnosis of industrial rotor-bearing systems

Continuous monitoring of critical rotor-bearing systems is crucial in order to prevent machine downtime, which would otherwise lower the overall output and quality. Complex modern machinery demands an upgraded intelligent fault diagnosis method that leaves minimal room for human error. This paper presents a MATLAB-based condition monitoring and fault diagnosis method for rotating machines used in sugar factories. The vibration responses are acquired through the use of data acquisition and the fast Fourier transform (FFT) analyser on real industrial machines. These signals are supplied as the input to a specially developed MATLAB program for processing in order to detect the fault and help to suggest remedies. The simple and user-friendly approach saves time and increases the effectiveness of condition monitoring in the reduction of downtime and the avoidance of catastrophic failure in industrial machines.

ОБЕСПЕЧЕННОСТЬ РЫНКА СПЕЦИАЛИЗИРОВАННОЙ ТЕХНИКИ ГИДРАВЛИЧЕСКИМИ РАСПРЕДЕЛИТЕЛЯМИ РОССИЙСКОГО ПРОИЗВОДСТВА

Currently, a relevant task for self-propelled machinery manufacturers is to replace hydraulic system components of the leading global manufacturers with hydraulic system components of alternative Russian manufacturers. The price share of a hydraulic system within the production cost of complete machinery is estimated by experts to be 5% to 25%. At the same time in the Russian Federation, hydraulic system components are produced in insignificant volumes. The components produced in the territory of the Russian Federation often fail to meet state-of-the-art requirements; therefore, it is the foreign components that are mainly used. The task of organizing production of state-of-the-art components for hydraulic systems is a very important one and is aimed at provision of production of modern equipment for various purposes in the Russian Federation. This work was carried out in order to assess the possibility of consolidated inquiry arrangement, qualitative development of the existing production of hydraulic equipment and creation of new production facilities. In the work, a list of typical hydraulic distribution equipment used in the modern special-purpose machinery design was compiled, and a dimensional range of hydraulic distribution equipment parameters was justified. Based on the results of analysis of the special-purpose machinery market, forecast market demand for hydraulic distribution equipment by segments until 2030 was determined. In order to assess the hydraulic distribution equipment market for types of machines not included in this study, based on expert opinions, we assume that their market is 50% of the considered types of machines. The analysis showed that when producing special-purpose machinery, hydraulic distribution equipment from various manufacturers is used, and hydraulic distribution equipment is one of the expensive components taking up to 20% of the total cost of a hydraulic system of special-purpose machines. The hydraulic distribution equipment potential market capacity in the Russian Federation in 2030 perspective will amount to 1.34 million pcs for a total of 56.9 billion rubles.

Implementasi Alat dan Mesin Pertanian dalam Mendukung Kedaulatan Pangan Indonesia

Indonesia is preparing to face three global crises, namely the food, energy and financial crises simultaneously. The world is heading for the Covid-19 Endemic which has an impact on inflation. Food sovereignty is the implementation of agricultural tools and machines in Indonesia. Therefore, this study aims to describe the choice of implementation tools and modern agricultural machinery that can be used in Indonesia. This study uses a literature study research method. At this time, the implementation of agricultural tools and machinery is an important component for modern agriculture in achieving the target of sustainable food self-sufficiency. Even technological advances in the implementation of agricultural tools and machinery will make agriculture victorious, so that Indonesia can become a world food barn. , Indonesia must also be able to independently produce its own machines.. Even further, it can become a producer and export its agricultural machinery abroad as well as being a solution to the global crisis and the current endemic Covid-19, so that it is required to pay more attention to environmental problems..In the future , there are still many obstacles that must be faced, bearing in mind that the production of weapons, especially rice, in the future will face several problems such as limited arable land, air, and manpower.

Fatigue life prediction of welded joints based on improved support vector regression model under two‐level loading

AbstractTo meet the lightweight needs of modern machinery equipment, welded structure is widely used in practical engineering. During the service period, the welded structure is often subjected to multilevel variable amplitude loading, and fatigue failure is easy to occur. Due to the complexity and stochasticity of fatigue process, the traditional life prediction models cannot meet the demand of practical engineering. In this work, a novel prediction model based on the whale optimization algorithm (WOA) together with the support vector regression (SVR), namely, a WOA‐SVR model, is established. It combines the advantages of WOA and SVR for global searching optimization and high prediction accuracy dealing with small sample size. By taking into account the sequence of loadings and the interaction effect between loadings, the proposed WOA‐SVR model could overcome the deficiencies and shortcomings in existing models. Experiment results show that WOR‐SVR has better prediction performance than five models.

A Novel Convolution Network Based on Temporal Attention Fusion Mechanism for Remaining Useful Life Prediction of Rolling Bearings

Rolling bearing is one of the core components of modern machinery and is widely used in rotating machinery. It is of great significance to judge the running state and predict the remaining useful life (RUL) of bearings for preventive maintenance of rotating machinery. Due to the complexity of the fault mechanism, traditional prediction methods cannot clearly describe the relationship between local and global temporal features in bearing vibration signals. To overcome this shortcoming, a novel convolution network based on temporal attention fusion (TAF) mechanism, i.e., TAF convolutional network (TAFCN), is proposed in this article. Its core part is a TAF module, which consists of a separable temporal self-attention (STSA) submodule and a competitive TAF (CTAF) submodule. In particular, the STSA submodule focuses on the internal correlation of local temporal features, and the CTAF submodule aims to enhance the extraction and fusion of global temporal features across different levels. The comparison results based on XJTU-SY datasets show that the TAF module is robust to signal disturbance and noise, and the prediction accuracy of TAFCN for the RUL of rolling bearings is also better than some existing models.

A review on nanofluids coupled with extended surfaces for heat transfer enhancement

Recently, due to the increasing demands for effective and efficient devices, the thermal sections of modern machinery deserve considerable attention. Researchers in the field of thermal engineering have since devised strategies of combined passive methods for further heat transfer enhancement. From the available literature, the employment of nanofluids, coupled with extended surfaces is scarce, with limited studies optimizing both techniques. The current investigation summarizes the combined effects of nanofluids coupled with various types of extended surfaces, within numerous applications. Parameters involving the nanofluid type, volume concentration, fin geometry, and flow conditions were examined, whereby their respective effects were investigated on the thermal performances. It was deduced that the effects of surfactants, nanoparticle volume concentration, and Reynolds number significantly contributed to the heat transfer enhancement. The review presents a trend finding that nanoparticle volume concentration would positively contribute to heat transfer enhancement, up to an extent. Surpassing the optimal concentration would lead to lower Brownian motions associated with higher viscosity and density. In terms of extended surfaces, the state-of-the-art review denoted that each fin design possesses a unique attribute that alters the thermal and hydraulic performances. Nevertheless, researchers fabricating novel fin designs should highly prioritize the effects on pressure drop when employing fins. Combining both techniques, the nanofluids and extended surfaces achieved remarkable results. The outstanding results could potentially achieve the standards of active methods, for a fraction of the operational cost. Concluding, the information surrounding the present review may be of aid to researchers developing new approaches utilizing nanofluids and extended surfaces.

An Increase in the Energy Efficiency of Axial Turbines by Ensuring Vibration Reliability of Blade Milling

Ensuring the vibration reliability of power equipment is one of the fundamental problems in modern power machinery. This problem has become more critical due to a permanent increase in the machining performance of high-speed milling of axial turbine blades. This article aims to identify reliable vibration parameters for high-speed milling of turbine blades to increase the energy efficiency of gas and steam turbines. For this purpose, mathematical models of free and forced oscillations of turbine blades during machining were developed. As a result of considering experimental and finite element analysis data, critical frequencies and corresponding mode shapes of free oscillations were identified using regression procedures by the best fit of analytical and empirical approaches. Additionally, after considering the forced oscillations of blades during high-speed machining, the magnitude of the specific cutting force and external damping ratio in the system ‘axial turbine blade and milling head’ were evaluated. The resulting magnitude of forced oscillations during machining was calculated. Finally, the amplitude–frequency response was also assessed, considering the machining parameters. Overall, the proposed methodology increases energy efficiency due to a decrease in the obtained machining quality of turbine blades.

Adoption of Smart Farming Technology Among Rice Farmers

Application of smart farming technology in rice farming activity is relevant in facing the challenges in achieving food security and improving the wellbeing of farmers. In Malaysia, food security is synonymous with the adequacy of rice domestic supply for the Malaysian population. Therefore, to achieve the target set in Sustainable Development Goal 2 which is to achieve zero hunger, the rice sector needs to be more competitive by encouraging farmers to utilize modern technology. Smart farming is an emerging concept of farm management that combines information and communication technologies into modern machinery like IoT, drones, and Artificial Intelligence to increase the value of agricultural products as well as reduce the cost of production while improving the well-being of farmers through income increment. Therefore, this study is conducted to explore the adoption of smart farming among paddy farmers in one of the country’s granary areas which is in Barat Laut Selangor under the administration of the Integrated Agriculture Development Area. This study will employ qualitative methods and interviews will be conducted. This study is urgently needed due to the twofold agenda: Malaysia is moving towards a high-income country and the importance for food security assurance has been acknowledged.

Agriculture-related energy consumption, food policy, and CO2 emission reduction: New insights from Pakistan

Fossil fuel energy consumption in the agriculture sector of Pakistan has created serious climate change issues, adding extremely to CO2 emissions, economic growth, and food production. The current research has investigated the most carbon-emitting agriculture factors based on human activities, such as transportation, land, multiple crops, distribution, and consumption under various crops. The study objective is to provide a roadmap for decarbonizing the food supply chain and its current framework toward food policy. The different machines and frameworks applied in agricultural farming can mitigate the CO2 emissions of the agriculture sector if renewable energy technologies (RETs) and renewable energy sources are organized with proper agrarian loads. The major concerns of this paper show a roadmap among a) CO2 emissions in the food supply chain and per capita CO2 emissions, b) food chain activities in the agriculture farming process, c) the agriculture output units and energy consumption, and d) the decarbonization of traditional agriculture and sustainable development in the agriculture sector. The analysis shows that the RETs and mitigation frameworks can lessen the CO2 emissions of farming depending on the type of farm and energy utilization. Finally, the present research highlights possibilities and opportunities for gaining CO2 emissions in crop production linked to Pakistan’s good management practices. In respect to agriculture efficiency and productivity, the government should increase the water, energy, and modern machinery for huge productivity and sustainability. Further policies are provided below.

There are just too many labours: productivity improvement in collecting waste at ASL

Research methodology One of the major reasons of layout-related difficulties faced by manufacturing industries is non-value-adding and redundant work. Plant layout study aims at economic production with larger volumes and variety as well. Method studies focus on the effectiveness with efficiency by a systematic critical scrutiny of work being done. The intention is to identify logical sequence of activities highlighting and eliminating the unnecessary mudas. Time and motion study is a combination of time study and motion study analysing and eliminating any unnecessary movement for productivity optimization of that job or process. Thus, through the elimination of unnecessary motions, times for performing the processes may be reduced and productivity increased. The intention is to subdivide the different operations of a job or process into measurable elements. Hence this case has been developed based on the primary data. The primary data was collected using Industrial Engineering Studies like layout study, method study and time and motion study. This case has been classroom tested with MBA students in their Lean Management Course. Case overview/synopsis Arin Synthetics Ltd. (ASL) though had installed modern machinery in its facility, process efficiency and optimization were a concern. Top Brass at ASL believed that ASL was overstaffed and its processes had creep as far as efficiency is concerned. This case focuses on ways to improve the process efficiency to rationalize the manpower at ASL. Presence in large growing global markets put cost pressure on ASL, thus mandating improvement in the efficiency of its processes through manpower rationalization. This case, therefore, discusses one of the highly staffed process of waste collection. Could ASL achieve reduction in the manpower in waste reduction without affecting the overall process? Was there a strategic mistake in the thought process of disposing of the waste generated by the manufacturing complex? Complexity academic level Operations management, Productivity and performance, Quality management, Lean management.

Analysis on the Future Development and Existing Problems in the Application of Mechanical Engineering and Automation Technology in China

The rapid growth of science and technology has had a significant impact on all sectors. As part of the reform and development of various social sectors, the traditional manual labor mode has been supplanted by modern machinery and automation technology. It reflects the progress in science and technology of China as well as the development of social civilization. This paper describes the existing problems in the application of mechanical engineering and automation technology and its future development. In short, the current mechanical engineering and automation technology still have issues to be solved in environmental protection, independent innovation, market research, and specialized talents and education. In China, mechanical engineering and automation technology should be heading in the direction of intelligence, automation, user-friendliness, scientific modernization, and integration.

DESIGN AND FABRICATION OF SUGARCANE BUD CHIPPER MACHINE TO IMPROVE THE FARM PRODUCTIVITY

Sugarcane holds immense significance, particularly in a nation like Pakistan, where it is a staple for millions of people. Sugarcane farming in Pakistan spans from small individual farms to corporate enterprises. While modern machinery with advanced technology has been developed to simplify sugarcane cultivation, it’s primarily accessible to corporate farmers due to its high cost. Consequently, there is a pressing need for a cost-effective, user-friendly machine that can deliver excellent results, enhance profits, and be more accessible. In the traditional method of planting sugarcane, the sugarcane is typically cut into pieces and buried. However, only a single bud-chip is required for sugarcane growth, leading to wastage of the remaining sugarcane. The machine is designed to precisely extract single bud-chips from sugarcane, saving time compared to manual and other cutting methods. The primary objective of this project is to streamline the bud-chip extraction process through the aforementioned machine, which demands less human labor, reduces investment costs, and saves time, making it a profitable investment for all farmers. The core purpose of this development is to enhance sugarcane germination while using a smaller quantity of sugarcane. In this method, only bud-chips are utilized to cultivate the sugarcane nursery. The initial weight of the sugarcane ranged from 0.92 kg to 1.21 Kg, and the length of the sugarcane from these selected stalks varied between 53 and 84 inches. The combined weight of the three sugarcane stalks was 3.28 kg, but after removing the buds, it reduced to 2.45 kg, with the bud-chips themselves accounting for a weight of approximately 0.74 kg. This approach to sugarcane production will bolster farm productivity and sustainability.

Remaining Useful Life Prediction for Rolling Bearings With a Novel Entropy-Based Health Indicator and Improved Particle Filter Algorithm

Due to the importance of bearings in modern machinery, the prediction of the remaining useful life (RUL) of rolling bearings has been widely studied. When predicting the RUL of rolling bearings in engineering practice, the RUL is usually predicted based on historical data, and as the historical data increases, the prediction results should be more accurate. However, the existing methods usually have the shortcomings of low prediction accuracy, large cumulative error and failure to dynamically give prediction results with the increase of historical data, which are not suitable for engineering practice.To address the above problems, a novel RUL prediction method is proposed. The proposed method consists of 3 parts: First, the multi-scale entropy-based feature – namely “average multi-scale morphological gradient power spectral information entropy (AMMGPSIE)” – from the rolling bearings as the Health indicator (HI) is extracted to ensure all the fault-related information is well-included; Then, the HI is processed with the enhanced Hodrick Prescott trend-filtering with boundary lines (HPTF-BL) to ensure good performance and small fluctuation on the HI; Finally, the deterioration curve is predicted using an LSTM neural network and the improved Particle Filter algorithm that we proposed. The proposed method is validated using the experimental bearing degradation dataset and the casing data of a centrifugal pump bearing from an actual industrial site. Comparing the results with other recent RUL prediction methods, the proposed method achieved state-of-the-art feasibility and effectiveness, conform to the needs of practical application of the project.

Investigations of tool wear of coated carbide tool while machining X-750 nickel alloy

Modern advanced structures and machinery rely heavily on advanced materials. Ni-based superalloys have applications in nuclear power plants, gas engines, airplane engines, turbines, etc. All these environments have high temperatures, thus; the material is selected such that it demonstrates sufficient strength at high temperatures. Ni-based superalloys present this characteristic due to their “high strength temperature resistant” (HSTR) nature. In the present work, an attempt has been made to machine X-750 nickel alloy on conventional machining considering rotational speed (TRS), feed (F) and depth of cut (DoC) as input machining variables. The coated carbide insert has been used at different machining cutting of input machining variables. The tool wear is assumed as an output parameter and the effect of input of parameters on the tool wear has been investigated. It has been observed that with the increase in rotational speed, feed and depth of cut the value of flank wear increases. The main mechanisms of tool wear exist in the present study are abrasion, adhesion and chipping, which are observed after the analysis of tool inserts by optical as well as scanning electron microscopy. The optimized setting for minimum TW (0.2716 mm) is TRS: 1362RPM; DoC: 01 mm and F: 0.07 mm/rev.

Study on the selection of the type and parameters of moldboard plow for combined tillage system

This article highlights information on the development of new techniques for preparing the planting area of nurseries for growing seedlings of ornamental trees and rare flowers. In forestry, the use of modern energy-saving agricultural machinery to create optimal conditions for plant growth allows for high volumes of product with minimal labor and material costs. Agricultural machines used today do not fully meet the agrotechnical requirements of technological operations. Therefore, it became necessary to improve the design of the combined tillage used, which in one pass carry out various work on preparing the soil for sowing, and for this, first of all, it is necessary to improve their working bodies that will produce a good air-water soil exchange. In the proposed technology, the furrow former of the complex tillage system reduces the accumulation of soil clods under the working body, forming optimal furrows for planting ornamental trees and seedlings of rare flowers. And since a complex operation is carried out in one run, it reduces the other cost. A plow with two moldboard bodies, of a combined tillage system, must comply with the requirements for use, and at the same time, the height of the moldboard plow opening furrows must be at least 20.5 cm, opening angle of the share wings is 60-65º, the angle of entry into the soil is 35-40º, the angle of the side cut of the wings of the working body is 37-40º, the width of the share wings is not less than 41 cm, the body length of plow must be not less than 78 cm.

ДИАГНОСТИКА МОСТОВЫХ ПЕРЕЕЗДОВ НА МАЛЫХ РЕКАХ И МЕЛИОРАТИВНЫХ СИСТЕМАХ С УЧЕТОМ УГРОЗЫ ВНЕЗАПНОГО ПАВОДКА НА ЮГЕ РОССИИ

Purpose: to study the features of the diagnostics of bridge crossings on small rivers and reclamation systems to improve their technical efficiency operation during burst showers. Materials and methods. Climate changes in the south of Russia occur in the direction of increasing precipitation, namely, catastrophic downpours leading to flooding of both mountainous and flat territories (Nevinnomyssk 2002, Novorossiysk 2002, Krymsk 2012, Krymsk 2012, Sochi 2022). The studies were conducted in April 2022 on the example of bridge crossing over the river Ubin in stanitsa Azovskaya Krasnodar Territory. The small rivers of the south of Russia are not cleared properly, garbage accumulates, branches, whole trees, the channels of small rivers are littered almost all over. When burst showers occur, the level of small rivers instantly rises, the soil no longer absorbs anything, the flow rate increases, the river turns into a mudflow, and the jams begin to be formed at bridge crossings. Results. It has been determined that the bridge crossing begins to work as a pressure dam, in the upstream, backwater flooding, a kind of barricades are formed, leading to great damage and what is the worst, the loss of life. The bridge crossings on small rivers and reclamation systems lose their operation life due to increased technogenic loads. In connection with the increasing development of rural areas in the south of Russia, the increase in the amount of modern road transport and agricultural machinery and the number of vehicles moving along this reinforced concrete hydraulic structure, a technical problem to meet operational requirements arises. Conclusions. In the course of the survey, multiple deviations from the requirements of the current regulatory documentation and the project were revealed. Based on the combination of features, the operation of the erected hydraulic structures without the use of compensatory measures is impossible.

DESIGN AND FABRICATION OF SUGARCANE BUD CUTTER MACHINE FOR IMPROVED FARM PRODUCTIVITY

Sugarcane is a very important crop especially in a country like Pakistan where millions of people use it regularly. The sugarcane farming in Pakistan is extended from small land farms to cooperate farming. The modern machinery equipped with high technology tool is developed to make the easier cultivation of the sugarcane. But this access to this machinery is only to the corporate farmers due to its high cost. It is therefore necessary to develop a machine that can provide better results, offer higher profits but still cost less and is easier to operate. As, in the traditional method of planting sugarcane, sugarcane is cut into pieces and buried. However, only a sprout is needed to grow sugarcane and the other part of sugarcane is wasted. The design of our machine helps to cut single bud from sugarcane and saves time compared to hand-made and other cutting processes. This project aims to simplify the process of extracting buds using the above-mentioned machine that requires less human labor, less investment and saves time thus proving a lucrative investment for every farmer. The purpose of the development is to improve the sugarcane germination with the less quantity of sugarcane used. In this method only buds will be used to grow the sugarcane nursery. The initial weight of the sugarcane ranges from 0.85 kg to 1.15 Kg. the length of the sugarcane varies from these selected stalks were 50 to 79 inches. The total weight of these three sugarcanes was 3.05 kg, while after the removal of the buds it was 2.31 Kg as the buds’ weights about 0.74 Kg. This method of sugarcane production will improve the farm productivity and sustainability.