Virtual Prototype Model Research Articles

Virtual prototype modeling and fuzzy control of the heave compensation system for a 500-ton deep-sea mining vessel

The unexpected heave motion of vessels generated by waves has always threatened the safe operation of mining vessels. The heave compensation system is a critical equipment for offshore cranes to ensure the safety and stability of the deep-sea mining vessel operation. Unfortunately, the nominal load of the mining vessel transporting minerals has become increasingly large, which has led to the dynamic performance of the heave compensation decline and a significant increase in energy consumption. To solve these problems, a semiactive heave compensation system and fuzzy logic-based controller are proposed in this paper. First, an active-passive hybrid heave compensation system is designed to reduce energy consumption greatly. The virtual prototype models of the proposed heave compensation system in a 500-ton deep-sea mining vessel are also built. Then, an adaptive tuning PID controller is developed based on the Transfer function of the heave compensation system and Mamdani-type fuzzy logic. Virtual prototype simulation results of AMESim-Simulink joint simulation illustrate that the accuracy of compensation for the four or six sea states reaches more than 90% with the proposed method and the power of the active compensation system is about 21% of the total power. Finally, the experimental results are included to demonstrate the effectiveness of the proposed semiactive heave compensation system.

Research on Satellite Navigation Control of Six‐Crawler Machinery Based on Fuzzy PID Algorithm

ABSTRACTThe six‐crawler driving mechanism plays a crucial role in the operation of large machines such as bucket‐wheel excavators, dumping machines, and mobile crushing stations, as it serves functions like bearing, movement and steering. The driving characteristics of this mechanism directly influence the safety and efficiency of these machinery systems. To enhance the design methodology for multi‐crawler machinery, improve path controllability, and achieve adaptive driving, a satellite navigation control system for six‐crawler machinery was developed based on the principles of real‐time kinematic (RTK) satellite positioning. This system utilizes the distance deviation and heading angle deviation between the actual path and the predetermined path of the six‐crawler machinery as inputs to a fuzzy proportion integration differentiation (fuzzy PID) controller. This controller regulates the deviation angle of the steering crawler and the driving speeds of each track, thereby ensuring precise path tracking control. To evaluate the path tracking control performance under both straight and curved driving conditions, a virtual prototype model of the six‐crawler mechanical system was established, and co‐simulation analysis was conducted. In addition, an experimental platform for path tracking control of six‐crawler machinery was established to validate the efficacy of the satellite navigation system. The actual tracking data obtained from various driving conditions and initial deviations demonstrated that the RTK satellite navigation path tracking control system exhibited excellent control performance.

Design and Fatigue Life Analysis of the Rope-Clamping Drive Mechanism in a Knotter

A knotter is a core component for the automatic bundling of agricultural materials, and a knotter with double-fluted discs is one type. Currently, the research on knotters with double-fluted discs has gradually transitioned from structural design to reliability optimization. To address rope-clamping failures in the rope-clamping drive mechanisms in knotters, the specific failure position of the rope-clamping mechanism and the failure causes were analyzed first. The redesign of the rope-clamping drive mechanism in knotters with double synclastic fluted discs was proposed, including structure optimization and 3D modeling using the GearTrax/KISSsoft and SolidWorks software. A virtual prototype model of a knotter with a flexible rope was established by combining ANSYS with the ADAMS software. A rigid–flexible coupling dynamic simulation of the knotter was carried out using ADAMS, and the simulation results were used as the data input for the ANSYS nCode DesignLife module for the fatigue life simulation of the weak parts (the worm shaft) of the knotter. The operation test results for the rope-clamping drive mechanism indicate that the redesigned rope-clamping drive mechanism is reliable in transmission, with a rope-clamping success rate of 100%. The actual operation times for the worm shaft exceed the minimum fatigue life obtained through joint simulation. The applied joint simulation method has high simulation accuracy.

Design and Simulation of Intra-Row Obstacle Avoidance Shovel-Type Weeding Machine in Orchard

This paper presents the design of an intra-row obstacle avoidance shovel-type weeding machine. Theoretical analysis of intra-row weeding components guided the determination of the structures and parameters for key parts, including the signal acquisition mechanism, automatic obstacle avoidance mechanism, and weeding shovel. Furthermore, a hydraulic system was designed to support these functions. The design aims to optimize intra-row weeding operations, reduce labor costs, enhance weed control effectiveness, and prevent collisions between weeding equipment and grapevines. Through the construction of a mathematical model, the analysis determined the necessary minimum return speed of the hydraulic cylinder for the intra-row weeding shovel to avoid grapevines. We also established a reasonable range for the extension speed of the hydraulic cylinder to minimize areas missed during weeding. Further analysis showed that using the minimum return speed of the hydraulic cylinder effectively reduced missed weeding areas. A virtual prototype model of the weeding machine was created in ADAMS. Using the coverage rate of weeding operation as the evaluation index, single-factor simulation tests determined that the extension speed of the piston rod in the obstacle avoidance hydraulic cylinder and the forward speed of the weeding machine are the main influencing factors. The preset threshold of the control system, which triggered the automatic obstacle avoidance mechanism when the obstacle avoidance rod reached a specific angle (the “Angle Threshold”), was identified as a secondary influencing factor. Other factors were considered irrelevant. Hydraulic cylinder extension speed, weeding machine forward speed, and angle threshold were chosen as the influencing factors. Following the principles of a Box–Behnken experimental design, a quadratic regression combination experiment was designed using a three-factor, three-level response surface analysis method. The evaluation criterion focused on the coverage rate of weeding operation. A regression model was developed to determine the coverage rate of the weeding operation, identifying the optimal parameters as follows: obstacle avoidance hydraulic cylinder extension speed of 120 mm/s, forward speed of the weeding machine at 0.6 m/s, and an angle threshold of 18°. The optimized coverage rate of the weeding operation achieved 86.1%. This study serves as a reference for further optimization of intra-row weeding machines in vineyards and for other crops.

Research on dynamic balance optimization method of flexible rotor based on GWO

Abstract Aiming at the problem that the dynamic balance process of a flexible rotor needs to start and stop frequently to add test weight, which is time-consuming and labor-consuming, and the balance accuracy is difficult to guarantee, a dynamic balance optimization method of flexible rotor based on grey wolf optimizer (GWO) is proposed. In this paper, a virtual prototype model is established based on a power turbine rotor for a certain type of turboshaft engine, and a rotor test platform is built. The transfer function is used to find the relationship between unbalance and vibration response, and the equilibrium equations are established to solve the problem. In the process of solving the problem that the equilibrium equations are mostly contradictory, GWO is used to solve the contradictory equations to obtain the optimal counterweight scheme at the full working speed of the rotor. The results show that the method proposed in this paper eliminates the cumbersome trial weight process of traditional dynamic balance. The average vibration reduction rate of this method is 33.8% at 5100 r min−1, 5400 r min−1 and 5700 r min−1, which is better than the conventional field dynamic balance. The work of this paper can improve the efficiency and accuracy of flexible rotor dynamic balance and provide technical reference for the vibration control of aero-engine.

Rolling Mechanism of Launch Vehicle during the Prelaunch Phase in Sea Launch

During the sea launch of a launch vehicle in low sea state, a rolling phenomenon of the launch vehicle has been observed. In rough sea conditions, launch may failure. This study utilizes dimensionality reduction-driven spatial system projection methods and virtual prototype modeling technology to reveal that the launch vehicle’s rolling is caused by differences in the motion paths of the center of mass. Additionally, during the prelaunch stage, the variation in the trajectory of the launch vehicle’s center of mass caused by the rolling and pitching motions of the transportation vessel has a significant impact on the roll motion of the launch vehicle. The motion in other degrees of freedom has minimal influence on the launch vehicle’s rolling. The minimum rocket rolling occurs when the dynamic coefficient of friction of the launchpad–launch vehicle contact is 0.05, and the dynamic coefficient of friction of the adapters and guideways is 0.4. The conclusions provide a theoretical foundation for optimizing the sea launch system and enhancing the reliability of sea launch in rough sea conditions.

Design of active vibration isolation system for satellite optical load based on Stewart platform

According to the requirements of hyperstatic environment of a satellite optical load during in orbit operation, the Stewart active vibration isolation platform was designed, and its dynamic equation was established by Newton Euler method. The virtual prototype model was established in ADAMS, and the accuracy of the model was verified by comparing the numerical solution and simulation solution of the modal frequency of the platform; On this basis, the dynamic model is decoupled into six SISO systems, and the optimal controller is designed for each subsystem. Finally, the whole system is simulated by ADAMS/MATLAB, and the displacement response curves of the load before and after control are obtained. The simulation results show that the Stewart active vibration isolation platform can effectively suppress the vibration.

Parameter Analysis of Vibration Damping and Energy Harvesting Performance of Bionic Suspension

The traditional damping structure usually transfers the vibration energy into heat, dissipated and without harvesting. But for harsh environments, such as military activities and lunar probe patrols, the vibration energy can be extracted, and realize the purpose of self-power condition monitoring. In this paper, a bionic suspension with energy-harvesting property is proposed based on bionic configurations. The bionic suspension adopts a symmetrical three-link arrangement to simulate the arrangement of bones, and a horizontal spring to simulate muscles. The micro-generator embedded in the knee joint provides the main damping force for the overall structure and also plays a role in harvesting energy. The dynamic equation and virtual prototype model are established, and the effects of parameter changes on the performance of vibration reduction and energy harvesting are analyzed, and the relationship between the two is revealed. The results show that the parameters to achieve their respective optimal performance are not consistent in the trend, though it is difficult to obtain the best performance of both, it can be designed according to the specific functions to be satisfied. This structure can be utilized as a general model for vibration reduction and energy harvesting scenarios, providing new ideas for self-powered sensing and condition monitoring configurations.

Dynamic Contact Characteristics Analysis of Heavy-duty Track Rollers

As an important component of the crawler walking device, the track roller needs to withstand strong impact and is prone to failure, which can lead to serious economic losses. This paper focuses on the track roller of the spreader as the research subject and investigates the dynamic contact characteristics between the track roller and the track plate. Using RecurDyn software, a virtual prototype model of the crawler walking device is established to analyze the variation in a vertical dynamic load of the track roller under different working conditions. Simultaneously, a finite element model of the contact between the track roller and the track plate is developed using Ansys Workbench, and its accuracy is verified using Hertz contact theory. Finally, the study discusses various influencing factors on the contact characteristics, including load, curvature of the contacting bodies, and material yield strength. The results indicate that the track rollers experience the highest dynamic load when climbing a slope, reaching a maximum load of 1191.44 kN. Moreover, the maximum contact stress is 1750.4 MPa, and the maximum Mises stress is 921.34 MPa during this operation. Importantly, when the load reaches 1218 kN, the maximum Mises stress of the track roller is 930.2 MPa, which may lead to roller failure after prolonged use. These findings provide valuable insights for the design and optimization of heavy-duty track rollers and offer significant assistance for various tracked vehicles.

Improved Sliding Mode Variable Structure Control of Robot Manipulators with Flexible Joints based on Singular Perturbation

This paper discusses the kinematics analysis method of six link mechanism based on virtual prototype technology and Adams. Firstly, the kinematics mathematical model of the six-bar linkage is deduced. Then, based on the design and development process of virtual prototype technology, the virtual prototype model of the six-bar press is established in ADAMS software. Finally, the kinematics simulation analysis is carried out for the model. The proposed method provides a reference for the parametric and optimal design analysis of the multi bar linkage of the mechanical press.

Real-time risk assessment of aircraft landing based on finite element-virtual prototype-machine learning co-simulation on wet runways

The safety of aircraft landing on wet runways is of great importance in runway risk management. In order to ensure landing safety on wet runways, real-time risk warning is required. This paper proposes a method to assess aircraft landing risk in real-time based on finite element-virtual prototype-machine learning co-simulation. Firstly, a tire-water film-runway finite element model was constructed, a virtual prototype model was built based on the Airbus A320 model, and the results of the tire-water film-runway local finite element dynamic analysis were transferred to the system simulation of the virtual prototype for co-simulation. Secondly, considering the influence of wet state parameters on the runway, a database of aircraft anti-skid failure risk was constructed, and three machine learning models were trained to predict aircraft landing risk. The results show that the Support Vector Machine (SVM) model has better generalization capability and should be used to predict the risk level of aircraft landing. The efficacy of the comprehensive taxiing model was validated using an empirical formula for determining the aircraft's landing distance on a wet runway. When an aircraft lands on a runway with an average water film thickness of 8 mm, the braking time is approximately 1.6 times longer than on a dry runway, and the braking distance is roughly 5.3 times greater than on a dry runway. Finally, a risk assessment example was provided: the entire process from landing information input to risk level output for the aircraft model took only 80 ms, which could provide an efficient and real-time aircraft landing risk assessment.

Underactuated Humanoid Peeling Approach for Pickled Mustard Tuber Based on Metamorphic Constraints.

Pickled mustard tuber (PMT), also known as Brassica juncea var. tumida, is a conical tuberous vegetable with a scaly upper part and a coarse fiber skin covering the lower part. Due to its highly distorted and complex heterogeneous fiber network structure, traditional manual labor is still used for peeling and removing fibers from pickled mustard tuber, as there is currently no effective, fully automated method or equipment available. In this study, we designed an underactuated humanoid pickled mustard tuber peeling robot based on variable configuration constraints that emulate the human "insert-clamp-tear" process via probabilistic statistical design. Based on actual pickled mustard tuber morphological cluster analysis and statistical features, we constructed three different types of pickled mustard tuber peeling tool spectral profiles and analyzed the modular mechanical properties of three different tool configurations to optimize the variable configuration constraint effect and improve the robot's end effector trajectory. Finally, an ADAMS virtual prototype model of the pickled mustard tuber peeling robot was established, and simulation analysis of the "insert-clamp-tear" process was performed based on the three pickled mustard tuber statistical classification selection. The results showed that the pickled mustard tuber peeling robot had a meat loss rate of no more than 15% for each corresponding category of pickled mustard tuber, a theoretical peeling rate of up to 15 pieces per minute, and an average residual rate of only about 2% for old fibers. Based on reasonable meat loss, the efficiency of peeling was greatly improved, which laid the theoretical foundation for fully automated pickled mustard tuber peeling.

Dynamics Analysis of a Double-Plunger-Type Turbine Overspeed Protection Mechanism

A double-plunger type overspeed protection mechanism has excellent performance in turbine overspeed protection, but the complicated operating principle thereof makes long-term use difficult. In this study, a dynamic model is established to explain the relationship between the motion state and the force situation. Through the analysis of the dynamic model, the specific process of the linked plunger for achieving overspeed protection with tripping action is determined, and the motion law of the inner and outer plungers is clarified. Additionally, the complete solution method and calculation procedure for the tripping speed of the submerged plunger are established, and the specific process for solving the relevant equations with numerical iteration is clarified. Finally, a rigid-flexible coupling virtual prototype model is established, which validates the conclusion that initial eccentric distance and spring stiffness are key factors affecting tripping speed and the motion process of inner and outer plungers.

Lightweight design of piezoelectric linear displacement accumulation actuator for airfoil deployment

The electromagnetic servo steering gear commonly used in the modern small guided aircraft has parasitic electromagnetic fields that affect the navigation and guidance accuracy, and its deceleration mechanism will increase the volume and mass, and the operating temperature range of the electromagnetic steering gear is small. A recently developed piezoelectric linear displacement accumulating high-power density actuator can solve those problems effectively. A virtual prototype model of piezoelectric linear displacement accumulating high-power density actuator is established, and the reliability of the virtual prototype model is verified by comparing with the experimental data. In order to make the actuator with the lightest weight under the requirements of wing deployment, Isight and Adams co-simulation were used to optimize the parameters of the piezoelectric actuator, such as the outer diameter, length, and excitation frequency. Finally, the output power of 50.8 W/kg is achieved, which is comparable with the power density of the existing servo motor.

Response Characteristics and Suppression of Transverse Vibrations of Mine Hoisting Conveyances Excited by Multiple Faults

The failures of steel guides can excite complex and intense transverse oscillations of hoisting containers in the mine hoisting process. The present paper mainly contributes to reveal the response characteristics of the transverse oscillations of mine conveyances excited by various faults such as interface misalignment, local bulge, orbital gap, bending deformation, and orbital tilt. First, a rigid-flexible coupled virtual prototype model between the conveyance and the steel guide was established. Subsequently, the vibration response characteristics of the container under various single and coupling excitations were simulated and analyzed. Eventually, a new type of roller cage shoe with a magnetorheological damper was put forward to decrease the transverse impact responses. Based on the hyperbolic tangent model of magnetorheological dampers, a semiactive fuzzy PID method was studied to explore the vibration suppression of the container. The results showed the fuzzy PID method can play a good role in the vibration reduction. This paper can give a fine scheme for the virtual simulation and semiactive vibration control of the mine hoisting system.

Tests and dynamic simulation analysis of an automatic instrument

To better study the dynamic characteristics of an automatic instrument and establish a realistic simulation model of automatic instruments, this paper has carried out movement tests of crucial parts under fixed conditions and recoil tests and collected the speed-time and recoil-time curves. Based on ADAMS software, the virtual prototype model of the key parts of the instrument is established, and the dynamic simulation is carried out. The different simulation results are separately compared with the experimental data, which verifies the accuracy of the recoil simulation model and provides a reference for the optimal design and improvement of the automatic instrument.

Dynamic Simulation Analysis of Truck Crane Based on ADAMS

Background: With a reduction in the weight of telescopic boom crane and an increase in its lifting capacity, the contradiction between its speed, stability and safety becomes more prominent. The telescopic arm also has flexible deformation during operation, which will cause vibration of the whole vehicle system. Therefore, in order to ensure safety, accuracy, and efficiency in the working process, it is necessary to accurately predict the dynamic characteristics of the telescopic boom load in the working process. Objective: The purpose of this study is to establish a rigid-flexible coupling dynamic model of the crane, which can accurately reflect the dynamic characteristics of the telescopic boom during its operation in the simulation test. Methods: In theory, this study analyzes the characteristics of a truck crane and simplifies it as a cantilever beam. Based on the Euler-Bernoulli beam theory, the vibration differential equation of the mobile masscantilever beam system is established. In the aspect of simulation, the three-dimensional modeling software Solidworks is used to establish the solid model of the truck telescopic boom, the finite element analysis software is used to establish the finite element model of the telescopic boom, and the modal neutral file is generated and imported into ADAMS to establish the dynamic model of the truck crane multi-level flexible telescopic boom. The dynamic simulation of the virtual prototype model of the truck telescopic boom crane is carried out in ADAMS software to obtain the dynamic characteristics of the key components of crane under specific working conditions. Results: The vibration differential equation derived in theory can be used to solve the dynamic response of the crane jib under specific conditions by MATLAB programming. In the aspect of simulation, the error fluctuation and its causes in the key components of the crane in the working state are analyzed, and the rationality of the virtual prototype model is verified. Finally, through the trajectory planning of the crane under typical working conditions, the purpose of stable control of the telescopic boom system of the truck crane is realized. Conclusion: The derived equation is universal for solving the vibration of crane jib in general cases. The rigid-flexible coupling model also provides a reference for the dynamic modeling, analysis, design, and manufacture of a multi-stage flexible telescopic boom. The findings of this study can provide a reference for related patent research and development.

Virtual Prototyping Modeling and Fault Diagnosis Technology for Mechanical and Electrical Equipment

<p>In order to study common faults in motors and motor transmission systems, this article uses a 5kW motor system as an experimental platform to establish a virtual prototype model. The prototype model includes the following five parts: motor unit, 6-degree of freedom loading mechanism, transmission gearbox, loading spindle, and AC excitation converter. Then, the BP neural network is used to identify typical faults in the virtual prototype. The final recognition time for vibration changes, temperature changes, and current disturbances does not exceed 45 seconds, with an average accuracy rate of over 99%. Overall, the algorithm can accurately diagnose typical faults in a relatively short time.</p> <p> </p>

Modeling and performance analysis of underwater gliders based on the virtual prototype technology

An underwater glider often comprises a buoyancy propulsion system, attitude regulation system, control system, hydrodynamic shape, etc. Numerous dynamic models based on rigid body dynamics have been established to study the motion performance of underwater gliders, which often neglect their attitude regulation and control systems. In this paper, a virtual prototype model of underwater gliders is developed based on the virtual prototype technology and verified by sea trials. Using the virtual model developed, the effects of three different control strategies and passive accumulators on underwater glider motion performance are discussed. The results demonstrate the feasibility of the virtual prototype model for motion performance analysis and control strategy optimization instead of the physical prototype. Thus, the proposed model could cut down the research and design time and reduce design costs.

Simulation Analysis of Tooth Break Faults of Gear Transmission System based on Electromagnetic Torque Signal

The traditional gear fault simulation model focuses on the vibration signal. However, the vibration sensor is not easy to install, and the vibration signal is easily affected by the installation location and environment of the vibration sensor. The motor itself has the characteristic of sensor. But in the traditional integrated model of motor and gear, the gear model is established based on the dynamical equation of the gear. However, the gear transmission established by the dynamics of the gear can’t fully reflect the running state of the gear. Moreover, the more complex the gear transmission system, the more complex and inaccurate the dynamical equation will be. Based on the above situation, in this paper, the virtual prototype model of the two-stage gear transmission system with broken tooth fault in different parts of the gear is established in Adams, which is imported into Matlab and co-simulated with the motor control model built in Matlab. Then the electromagnetic torque signal is analyzed. The results show that different characteristic frequencies of gear faults can be detected in the electromagnetic torque signal. The virtual prototype model of gear transmission system can accurately reflect the motion state of gear, and the fault of the complex gear transmission system can be simulated.