Rotational Speed Research Articles

A study of multi-model identification and fusion control algorithms for rotary limit devices

In order to improve the control performance of rotating limit device on the motion range of rotating parts of mechanical equipment, the multi model identification and fusion control algorithm of rotating limit device is studied. The angle sensor and speed sensor are used to collect the rotation angle and speed of rotating machinery equipment. Taking the collected data as the input of multiple support vector machines, the D-S evidence theory is selected to fuse the status of rotating machinery equipment identified by multiple models and determine the final status of rotating machinery equipment. Set the deviation between the target angle and the actual angle of the rotating mechanical equipment as the input of the PID controller. The PID controller determines the limit control quantity of the rotating limit device to the rotating machinery equipment, and realizes the rotating limit control of the rotating machinery equipment. The rotary table is selected as the mechanical equipment controlled by the rotary limit device. The experimental results show that the rotary limit device can control the rotation of the rotary table in the ideal angle range, achieve smooth tracking of the rotation angular velocity, and has excellent control performance.

Design and testing of a microwave Doppler-based yield estimation system for machine-picked seed cotton

Abstract Accurately obtaining crop yields is an important part of the precision agriculture technology system; with the increased mechanisation of cotton planting and harvesting, it has become particularly important to accurately obtain seed cotton yield data. In order to achieve accurate estimation of machine-picked seed cotton yield, this paper designs a machine-picked seed cotton yield estimation system based on microwave Doppler principle. Based on LabVIEW software, the signal acquisition circuit is designed; the power spectrum of the echo signal is estimated; the signal echo power is obtained; the relationship model between echo power and seed cotton mass is established by using multiple regression equations; and the reliability of the model is verified by using statistical methods. By adjusting the rotational speed of the fan, the wind speed at the inlet of the cotton pipeline was 10 m s−1, 15 m s−1 and 20 m s−1, and the yield estimation tests were carried out at the three wind speeds, and the data showed that the average absolute percentage errors of the estimation at the three wind speeds were 7.36%, 7.72% and 8.17%, and the mean squared errors were 2.699, 4.938 and 4.026, respectively. The test results show that the accuracy of seed cotton mass estimation under the three wind speeds basically meets the needs of the yield measurement system, and the systematic error of seed cotton yield estimation is the smallest when the wind speed is 10 m s−1.

Study on Phosphorus Variability Characteristics and Response Mechanism of Microbial Community during Sediment Resuspension Process

Submerged plants and related disturbances can affect both the phosphorus (P) release and the microbial communities in sediments. In this study, a sediment resuspension system was constructed, and P variability characteristics influenced by Vallisneria natans (V. natans) and the response mechanism of the microbial community were studied. The results indicated that the total phosphorus (TP) content increased from 678.875 to 1019.133 mg/kg and from 1126.017 to 1280.679 mg/kg in sediments and suspended solids (SSs) during the sediment resuspension process, respectively. Organic P (OP) increased by 127.344 mg/kg and 302.448 mg/kg in sediments and SSs after the disturbance, respectively. The microbial communities in the sediments and the leaves of V. natans had higher Chao values after the disturbance, while Shannon values decreased after the disturbance compared to the control in SSs. Proteobacteria had the highest abundance with the value of 51.1% after the disturbance in the sediments and SSs, and the abundance values of Proteobacteria in rhizomes and leaves of V. natans could reach 73.2% on average. Chloroflexi, Acidobacteria, and Firmicutes were also the main phyla in the sediment resuspension system. Sodium hydroxide extractable P (NaOH-P) in sediments could reduce the bioavailability of this P fraction under disturbance conditions. The decrease in the abundance of Bacteroidetes and Nitrospirae indicated that they were more sensitive to the disturbance, and the rotational speed changed the survival conditions for the Bacteroidetes and Nitrospirae. The response mechanism of microbial community during the sediment resuspension process could reflect the influence of the microbial community on the changing characteristics of P and could provide a theoretical foundation for P control at the micro level.

Design and Testing of an Integrated Corn Stubble Residual Film-Recycling Machine

The existing residual film-recycling machines struggle to efficiently recover and separate film stubble in a single operation. With roller-type film-rolling device unloading difficulties and other problems, in order to improve the recovery efficiency of film stubble and the separation effect while reducing human labor and to improve work efficiency, we designed an automatic hydraulic unloading film stubble-recycling integrated residual film-recycling machine. The angle of the membrane lifting device was determined by theoretical calculations using the method of coupled simulation of EDEM and ANSYS Workbench. We analyzed the amount of resistance as well as the maximum stress and deformation during the working process of the membrane-lifting device and focused on the design of the membrane–soil separating device and membrane-rolling device. The depth of the film shovel, the forward speed of the machine, and the rotational speed of the driving wheel of the jogging chain were selected as the test factors, and the residual film recovery rate was taken as the evaluation index. A three-factor, three-level test was designed by applying the principles of the Box–Behnken experimental design. The results show that when the forward speed is 1.36 m/s, the soil depth is 147.16 mm, and the rotational speed of the driving wheel of the shaking chain is 77.89 r/min, the recovery rate of the residual film is 87.56%, and the relative error between the experimental value and the optimized value is 2.73%. The experimental results can provide a theoretical basis for the design of the residual film-recycling machine.

Study on control strategies of the MW-scale supercritical CO2 recompression Brayton cycle for lead-cooled fast reactor

The supercritical CO2 (sCO2) Brayton cycle for the lead-cooled fast reactor (LFR) is an ideal power generation system for the distributed energy supply in remote islands. To figure out the optimal operating modes of the MW-scale sCO2 LFR unit in different load demands, this work performs a dynamic simulation based on the developed control modules. A parametric analysis is conducted about the effects of rotational speed, split ratio, and main gas temperature on the dynamic characteristics. Control strategies are further studied based on the thermodynamic performance and safety under four variable temperature load regulation modes and three fixed temperature rapid load regulation modes. Results show that the tracking αopt mode has the highest average net efficiency (ηnetav) of 19.13 %. The tracking αsafe mode allows compressors to operate in the safest range by sacrificing a little ηnetav. Excellent load change rates are revealed by using the main circuit regulating valve control mode and the turbine bypass control mode, with −12.48 %Pe/min & 11.92 %Pe/min, and −8.25 %Pe/min & 9.70 %Pe/min, respectively. Though the load change rate of the RS control mode is −3.96 %Pe/min & 3.47 %Pe/min, its ηnetav is higher. Our work guides the efficient, flexible, and safe operation of the sCO2 LFR unit.

Effects of Structure Parameters on Static Performance of Gas Foil Bearings Based on a New Fully Coupled Elastic–Aerodynamic Model

Abstract: Accurately predicting the performance of gas foil bearings (GFBs) is important. This paper presents a new fully coupled elastic–aerodynamic model for analyzing the static performance of gas foil journal bearings (GFJBs). The gas compressible lubrication model was solved in MATLAB to obtain the gas pressure. The foil structure deformation was solved in COMSOL by considering the Coulomb friction and allowing the contact surfaces to be separated from each other. Under given load and rotational speed conditions, the calculated minimum gas film thickness and attitude angle match well with the literature data, validating the accuracy of the developed model. Based on the model developed, a comprehensive and systematic analysis of the effects of the structural parameters on the static performance was performed. The results showed that as the bump height, top foil thickness, and bump foil thickness increased, the load capacity could be improved to different degrees. The bump foil thickness had the greatest effect on the load capacity. These results provide theoretical guidance for the structural design and practical applications of GFJBs.

Experimental investigation of FSW induced property changes in welded dissimilar Mg–Al–Zn alloys

Intense plastic deformation and intermixing during friction stir welding of dissimilar alloys may suppress the properties in welded zone. To suitably control these changes, careful study is required. Present research investigates microstructure, mechanical performance and corrosion behaviour at different rotational speeds in friction stir welded dissimilar AZ31–AZ91 Mg alloys. Very small cracks were present in welded zone due to formation of magnesium oxide (MgO). The EBSD analysis suggest more concentrated fibre texture at 1000 rpm tool rotational speed as compared to 700 rpm tool rotational speed in welded zone and the texture maximum intensity was 39.447 times of random distribution at tool rotational speed of 1000 rpm. The obtained maximum microhardness was 82 Hv at tool rotational speed of 700 rpm. The maximum values of tensile strength (234.86 ± 7.77 MPa) and flexural strength (350.89 ± 17.67 MPa) of welded samples were decreased as compared to base materials. The corrosion rate of welded samples was increased and corroded surface have some pits and corroded rings. The highest corrosion rate (2.1596 mm / year ) was obtained at 700 rpm. This experimental work suggests that in overall, sample welded at 1000 rpm tool rotational speed has better weld property.

Simulation of Friction Stir Welding of AZ31 Mg Alloys.

Friction stir welding has been extensively applied for the high-quality bonding of Mg alloys. The welding temperature caused by friction and plastic deformation is essential for determining the joint characteristics, especially the residual stress and weld microstructure. In this work, a modified moving heat source model was proposed by considering the variations in heat generation caused by friction shear stress at both the side and bottom surfaces of the tool. The application of this model was further extended to the entire welding process, especially in the plunging stage. The relative errors between the experimental and simulated peak temperatures at characteristic points were small, with a maximum of 10%, thereby validating the model for accurate temperature prediction. Furthermore, the influence of welding and rotational speed on temperature fields was systematically investigated. At relatively low welding and rotational speeds, the welding temperature increased significantly with either an increase in rotational speed or a decrease in welding speed. However, this effect gradually diminished at higher welding and rotational speeds. These results provide some valuable guidelines for controlling heat generation to improve the quality of Mg alloy welds.

Study on the Process of Preparing Aluminum Foam Sandwich Panel Precursor by Friction Stir Welding

In recent years, high-performance lightweight and multifunctional aluminum foam sandwiches (AFSs) can be successfully applied to spacecraft, automobiles, and high-speed trains. Friction stir welding (FSW) has been proposed as a new method for the preparation of AFS precursors in order to improve the cost-effectiveness and productivity of the preparation of AFS. In this study, the AFS precursors were prepared using the FSW process. The distribution of foaming agents in the AFS precursors and the structure and morphology of AFS were observed using optical microscopy (OM), scanning electron microscopy (SEM), and X-ray energy dispersive spectroscopy (EDS). The effects of the temperature and material flow on the distribution of the foaming agent during the FSW process were analyzed through experimental study and numerical simulation using ANSYS Fluent 19.0 software. The results show that the uniform distribution of the foaming agent in the matrix and excellent densification of AFS precursor can be prepared when the rotation speed is 1500 r/min, the travel speed is 25 mm/min, the tool plunge depth is 0.2 mm, and the tool moves along the retreating side (RS). In addition, the experimental and numerical simulations show that increasing the welding temperature improves the uniformity of foaming agent distribution and the area of AFS precursor prepared by single welding, shortening the thread length inhibits the foaming agent from reaching the upper sandwich plate and moving along the RS leads to a more uniform distribution of the foaming agent. Finally, the AFS with porosity of 74.55%, roundness of 0.97, and average pore diameter of 1.192 mm is prepared.

The effects of tool rotational speed and post-weld heat treatment of friction stir welded AZ31-B magnesium alloy

Abstract This research article examines the effect of increasing the tool rotational speed and post-weld heat treatment behavior of friction stir-welded AZ31-B magnesium alloy. The variable tool rotational speeds of 1000 rpm, 1200 rpm, 1400 rpm, and 1600 rpm with fixed tool traverse speeds of 30 mm min−1 were chosen based on the trial welding method. Results reveal that the as-welded tensile strength values of 133 MPa, 209 MPa, 215 MPa, and 213 MPa for the corresponding tool rotation speeds and post-weld heat-treated tensile strength values of 140 MPa, 213 MPa, 223 MPa, and 227 MPa significantly increased joint strength when compared to the as-welded process. The measured grain size values are reduced when the tool rotational speed increases due to material dynamic recrystallization. Al-Mg brittle intermetallic compounds significantly reduced the mechanical strength during the increase of the tool’s rotational speed. Fractography analysis reveals all welded samples fractured at the center of the stir zone with a ductile fracture angle of 45°.

Mechanical and Tribological Properties of Laminated (NbTaMoW)Nx Films.

Laminated (NbTaMoW)Nx films were prepared via co-sputtering. The sputtering variables were a substrate holder rotation speed of 2 and 10 rpm and a nitrogen flow ratio (fN2 = N2/(Ar + N2)) of 0.1, 0.2, and 0.4. The (NbTaMoW)Nx films fabricated at 30 rpm displayed columnar structures. The phase structures of the laminated (NbTaMoW)Nx films varied from multiple body-centered cubic phases to a nanocrystalline and a face-centered cubic phase as the fN2 increased from 0.1 to 0.2 and 0.4. The mechanical and tribological properties of the laminated (NbTaMoW)Nx films were evaluated. The laminated (NbTaMoW)Nx films deposited at an fN2 of 0.4 had hardnesses of 25.2 and 26.1 GPa when prepared at 2 and 10 rpm, respectively, lower than the value of 29.9 GPa for the columnar (NbTaMoW)Nx film prepared at an fN2 of 0.4 and 30 rpm. In contrast, the wear resistances of the laminated (NbTaMoW)Nx films were superior to those of the columnar (NbTaMoW)Nx films.

Design, Analysis, and Optimization Testing of a Novel Modular Walking Device for Pipeline Robots

This article investigates the limitations associated with traditional wheel-type pipeline walking devices, which are characterized by a single movement mode and an inability to navigate complex or irregular pipeline structures. A modular walking device (MWD) designed for pipeline robots was developed utilizing structural and mechanical analysis techniques. The reliability of the mechanical analysis was validated through single-factor dynamic testing. To analyze and optimize the factors influencing the maneuverability and obstacle-crossing capabilities of the MWD, a three-factor, three-level orthogonal testing method was utilized. The factors examined included the rotational speed of the walking wheel (RS), the pre-tightening force of the wheel brackets (PF), and the height of the annular obstacle (OH). The evaluation metrics used were the slip rate and passability. The results indicated that a parameter combination of RS at 70 rpm, PF at 30 N, and OH at 10 mm produced a slip rate of 11.6% ± 1.5%. During the obstacle traversal process, the remainder of the device maintained a safe distance from the obstacles, with only the walking wheel making contact. The verification testing also confirmed that the MWD is capable of executing three distinct modes of motion: rectilinear, rotational, and helical. The MWD designed and developed in this study can switch between multiple motion modes and successfully overcome obstacles within 15 mm, providing a new equipment for universities to enhance mechanized pipeline detection technology.

The Role of the Working Fluid and Non-Ideal Thermodynamic Effects on Performance of Gas Lubricated Bearings

Abstract Small-scale turbomachinery operating at high rotational speed is a key technology for increasing the power density of energy and propulsion systems. A notable example is the turbine of an organic Rankine cycle turbogenerator for thermal recuperation from prime engines and industrial processes. Such systems typically operate with organic compounds characterized by complex molecular structures, to allow the design of efficient fluid machinery and flexibility in matching the heat source and sink temperature profiles. Gas bearings are considered advantageous compared to traditional oil-lubricated rolling element bearings for supporting the turbine rotor, enabling greater machine compactness and reduced complexity, and to avoid contamination of the working fluid. In certain operating conditions, however, the lubricant of the bearing is in thermodynamic states near the saturated vapor line or in the vicinity of the fluid critical point whereby non-ideal effects are relevant and may affect bearing performance. This work investigates the physics of thin film flows in gas bearings operating with fluids made by complex molecules. The influence of non-ideal thermodynamic effects on gas bearing performance is discussed by analysis of the fluid bulk modulus. Reduced values of the non-dimensional bulk modulus near the critical point or saturated vapor line decrease bearing performance. The main parameter characterizing the influence of molecular complexity on bearing performance is shown to be the acentric factor. For complex fluids with large acentric factors, the impact of non-ideal thermodynamic effects on non-dimensional bearing load capacity and rotor-dynamic characteristics is less pronounced.

ШЛИФОВАНИЕ ПОВЕРХНОСТИ ВОССТАНОВЛЕННЫХ ПОРОШКОВЫМИ ТРУДНООБРАБАТЫВАЕМЫМИ МАТЕРИАЛАМИ

The article discusses the use of impregnated abrasive wheels for grinding the surface of recovered hard-to-process powder materials. The paper investigates the formation of a rough surface during internal grinding of cylinders of marine engines after restoration to their original dimensions, with powder materials of grades PG-CP2, PG-10H-0.2 containing nickel, chromium, iron and other hard-to-work metals, which during the restoration process create a special protective metal layer on the surface of the cylinders, the processing of which is very difficult It's difficult. Therefore, the grinding of the internal surfaces of the restored cylinders of marine engines is a complex technological process that proceeds in strict compliance with all technological operations, in stages. According to the results of the study, the influence of the rotation speed of the workpiece on the roughness of the inner surface of the sleeve, accompanied by grinding with impregnated grinding wheels, was revealed. It has been experimentally confirmed that when treated with impregnated abrasive wheels, the roughness of the polished surface decreases by about 1.5-1.8 times.

Design and performance evaluation of a reversible bladeless turbo machine

It is well known that bladeless or Tesla turbomachinery idea was proposed by Nikola Tesla over a century ago, and it has several distinct features, such as reversibility of operation, which includes expander and compressor operations obtained by reversing the rotational speed, provided that the statoric channels are purposely designed.The main objective of this paper is to design a reversible Tesla or bladeless machine with optimal design parameter choice that can operate both in compressor and expander modes. As a consequence of the high losses due to rotor and stator interactions, statorless (volute) configurations are investigated here, showing superior performance in both compressor and expander modes of operation. Numerical study has been conducted for both compressor and expander modes of this machine using air as working fluid. In compressor mode, numerical results have been validated with experimental data, while results for expander mode will be validated in the near future. The numerical results predict peak isentropic efficiencies of 57.5 % and 63.5 %, for the compressor and expander modes of operation excluding assembly losses, respectively, while rotor efficiency is quite high > 90 % at very low mass flow rates. Tests on Tesla machine prototype have shown an experimental isentropic efficiency of maximum 32.4 % when operating in compressor mode. The overall assembly efficiency is reduced, compared to numerical predictions, due to leakage and end wall losses. The CFD simulations could match the experimental results at high pressure ratio and low mass flow, with less than 2 % error on pressure ratio. Through the improvement of the sealing system and the reduction of losses (leakage and end wall friction), it is expected that overall prototype efficiency could improve by at least 10 percentage points.

Effects of triflute pin geometry on defect formation and material flow in FSW using CEL approach

Complicated tool pin designs in Friction Stir Welding (FSW) need to be considered in terms of material flow and defect formation. This study investigates the effects of the triflute tool's geometrical parameters on temperature, strain, void formation, and material mixing using a numerical method. The numerical model employs a coupled Eulerian-Lagrangian (CEL) formulation and successfully predicts void formation and material mixing during friction stir welding (FSW). Four tool pin designs are considered for material flow, including one cylindrical pin and three triflute pins with flute radii of 1 mm, 1.5 mm, and 2 mm. The findings indicate that the stir zone is divided into shoulder-driven and pin-driven zones, each exhibiting distinct material flow patterns. In the shoulder-driven zone, material flow toward the advancing side is dominant, while in the pin-driven zone, it flows toward the retreating side. Flutes on the FSW pin tool increase the sweeping rate, strain, and material movement in the stir zone. However, flutes with a larger radius sweep a greater amount of material and thus require more softened material to facilitate movement. Therefore, for defect-free joint formation, a higher rotational speed of the tool will be required, which may adversely affect tool lifespan and joint mechanical properties. The effectiveness of flutes with a smaller radius of 1 mm is significantly greater than that of those with a larger radius (1.5 or 2 mm) in enhancing material flow and achieving defect-free welding.

Tunable diameter of electrospun fibers using empirical scaling laws of electrospinning parameters

This study introduces a new semi-empirical power-law model for predicting electrospun fiber diameter (D), addressing key processing parameters. Polycaprolactone (PCL) fibers were produced using a solvent mixture of Trichloromethane (TCM), Dimethyl Formamide (DMF), and ethanol (EtOH). Systematic experiments validated an existing theoretical model and led to the development of a novel model: D ∼ (c1/2η1/3Q1/5X2/3)/(U2/3ω1/4I1/5). This model incorporates seven crucial parameters: viscosity (η), concentration (c), voltage (U), spinning distance (X), flow–rate (Q), current (I) and collector wheel rotation speed (ω). The model was validated through a partial factorial design experiment, proving to be a valuable and reliable tool for predicting fiber diameters and optimizing electrospinning processes. The ability to control fiber diameter is essential for tailoring electrospun fibers for various applications, including biomedicine, filtration, sensors, and lightweight materials.

Analysis of extremely low water hammer pressures of draft tubes for double units in pumped storage power stations under successive load rejection conditions

With large-scale integration of intermittent energy into power systems, the operating conditions of pumped storage power stations (PSPSs) change frequently, thereby intensifying the risk of load rejections. For multiple units sharing a water conveyance system, when one or more units reject the load, other units also reject the load after a few seconds; this is defined as successive load rejection (SLR). During SLR conditions, pumped storage units produce extreme water hammer pressures, jeopardizing the safe operation of PSPSs. This study reveals the generation mechanism of extremely low draft tube pressure (DTP) during SLR, and clarifies the generating unit and corresponding occurrence moment characteristics of the minimum DTP. The results indicated an extremely low DTP, attributed to the sharp decline in the discharge owing to increased rotational speed in unit's S-shape region and the hydraulic interference owing to the increased discharge of the other unit. When the guide vane closing time (GVCT) was short, the minimum DTP occurred in the subsequent load rejection unit (SLRU) near the first peak of its rotational speed, with the discharge of initial load rejection unit (ILRU) in the rising stage. Conversely, for a large GVCT, the minimum DTP occurred in the ILRU near the second peak of its rotational speed, with SLRU discharge in the rising stage. Finally, engineering measures to improve the extremely low DTP were proposed. Overall, the findings underscore crucial engineering insights for ensuring the safety of PSPSs under extreme conditions.

Analysis of Flow Field Characteristics in a Mechanical Defoaming Device.

To improve the froth breakdown performance of flotation foam, a mechanical defoaming device based on vacuum and rotation was developed. The device is mainly composed of a rotating disk and a baffle and generates negative pressure when rotating at high speed. Through the synergistic effects of negative pressure, collision, extrusion, and shearing, the flotation foam effectively separates the liquid and gas phases. The flow field characteristics of the defoaming device are meticulously analyzed through numerical simulation, leading to a comprehensive evaluation of its defoaming performance. The effects of different rotational speeds on fluid velocity, pressure, turbulence, and traces are studied. It can be obtained that when the rotational speed is 900-1800 rpm, the device generates a pressure zone of -2.5 to -12.5 kPa, which can meet the requirements of the defoaming design.

A Calculation Method of Bearing Balls Rotational Vectors Based on Binocular Vision Three-Dimensional Coordinates Measurement

The rotational speed vectors of the bearing balls affect their service life and running performance. Observing the actual rotational speed of the ball is a prerequisite for revealing its true motion law and conducting sliding behavior simulation analysis. To address the need for accuracy and real-time measurement of spin angular velocity, which is also under high-frequency and high-speed ball motion conditions, a new measurement method of ball rotation vectors based on a binocular vision system is proposed. Firstly, marker points are laid on the balls, and their three-dimensional (3D) coordinates in the camera coordinate system are calculated in real time using the triangulation principle. Secondly, based on the 3D coordinates before and after the movement of the marker point and the trajectory of the ball, the mathematical model of the spin motion of the ball was established. Finally, based on the ball spin motion model, the three-dimensional vision measurement technology was first applied to the measurement of the bearing ball rotation vector through formula derivation, achieving the analysis of bearing ball rolling and sliding characteristics. Experimental results demonstrate that the visual measurement system with the frame rate of 100 FPS (frames per second) yields a measurement error within ±0.2% over a speed range from 5 to 50 RPM (revolutions per minute), and the maximum measurement errors of spin angular velocity and linear velocity are 0.25°/s and 0.028 mm/s, respectively. The experimental results show that this method has good accuracy and stability in measuring the rotation vector of the ball, providing a reference for bearing balls' rotational speed monitoring and the analysis of the sliding behavior of bearing balls.