Search Results (16)

The performance of a spindle will gradually decline, the vibration intensity will increase, and the temperature rise will become abnormal with the accumulation of service time. Consequently, the accuracy of the machining product will not meet its production requirements. Studies on the variation characteristics of the spindle unit have clarified the reasons for its abnormal vibration and temperature rise, in principle, to help enterprises conduct preventive maintenance before any serious failure occurs and improve production efficiency. Based on the Timoshenko beam model and rotor dynamics theory, this study uses the finite element method (FEM) to analyze the vibration characteristics of the spindle rotor system. Moreover, it thoroughly analyzes the influence of the spindle bearing heat on the stiffness of the spindle system and identifies the resonance conditions of the spindle rotor within the power frequency range. This research has identified that when the vibration frequency of the spindle operates at a speed of 12,000 r/min, if its vibration frequency is lower than 200 Hz, it will be affected by abnormal vibrations during startup, which will weaken the health status of the spindle and reduce its service life. Similarly, when the working speed of the spindle is 30,000 r/min, if its vibration frequency is lower than 50 Hz, abnormal vibration will occur during startup and operation, thereby reducing its service life. Full article

This paper is the second in a two-part series presenting preliminary results on a passively controlled wind turbine rotor system using a flexible curved blade concept. Building on the initial findings, this segment explores the application of glass-fiber-reinforced polymer (GFRP) composites with strategically oriented layers to enhance blade flexibility and aerodynamic performance and ensure operational safety. Previously, we demonstrated that flexible blades fabricated from isotropic materials with an NACA4415 airfoil profile could self-regulate rotor RPM and power output in response to aerodynamic loads, offering a glimpse of controlled operational behavior, in contrast to straight blades of similar material geometry and aerodynamic characteristics. However, they did not fully meet the design objectives, particularly in achieving nominal power at the intended wind speeds and in safely halting operation at high wind speeds. The current study employs a GFRP blade with a simpler, flat geometry due to manufacturing constraints, diverging from traditional airfoil contours to focus on material behavior under aerodynamic loads. Despite these changes, the blade exhibited all desired operational characteristics: quick startup, stable power output across operational wind speeds, and effective shutdown mechanisms at high speeds. This success illustrates the potential of passively controlled blades designed with appropriately oriented composite layers. Challenges with load application methods—that were identified in the first installment—were addressed by adopting a generator connected to a rheostat, offering improved control over load variations compared to the mechanical brakes used previously. This advancement enabled more consistent data collection, particularly at lower Tip–Speed Ratio (TSR) values, although real-time control for maximum power point tracking was still out of reach. These findings not only confirm the effectiveness of the flexible blade concept but also highlight the need for further refinement in blade design and testing methodology to optimize performance and ease of manufacturing. Future work will continue to refine these designs and explore their scalability and economic viability for broader applications in wind energy technology and in particular to those of small Wind Energy Converter Systems (WECSs). Full article

The effective exploitation of renewable energy sources is one of the most effective solutions to counter the energy, environmental and economic problems associated with the use of fossil fuels. Small-scale wind turbines (converting wind energy into electric energy with a power output lower than 50 kW) have received tremendous attention over the past few decades thanks to their reduced environmental impact, high efficiency, low maintenance cost, high reliability, wide wind operation range, self-starting capability at low wind speed, limited installation space, reduced dependence on grid-connected power and long transmission lines, low capital costs, as well as the possibility to be installed in some urban settings. However, there are significant challenges and drawbacks associated with this technology from many different perspectives, including the significant discrepancy between theoretical performance data provided by the manufacturers and real field operation, that need to be investigated in greater depth in order to enable a more widespread deployment of small-scale wind turbines. In this review, a complete and updated list of more than 200 commercially available small-scale horizontal and vertical wind turbine models is provided and analysed, detailing the corresponding characteristics in terms of the number and material of blades, start-up wind speed, cut-in wind speed, cut-out wind speed, survival wind speed, maximum power, noise level, rotor diameter, turbine length, tower height, and specific capital cost. In addition, several scientific papers focusing on the experimental assessment of field performance of commercially available small-scale horizontal and vertical wind turbines have been reviewed and the corresponding measured data have been compared with the rated performance derived from the manufacturers’ datasheets in order to underline the discrepancies. This review represents an opportunity for the scientific community to have a clear and up-to-date picture of small-scale horizontal as well as vertical wind turbines on the market today, with a precise summary of their geometric, performance, and economic characteristics, which can enable a more accurate and informed choice of the wind turbine to be used depending on the application. It also describes the differences between theoretical and in-situ performance, emphasizing the need for further experimental research and highlighting the direction in which future studies should be directed for more efficient design and use of building-integrated small-scale wind turbines. Full article

To accurately evaluate the size and distribution characteristics of the emission particles exhausted from in-use motor vehicle engines, we independently developed a condensation particle counter (CPC) known as BHCPC. It was calibrated by conducting the calibration procedures stated in the International Standard ISO 27981. After calibration, we conducted on-site measurements and offline sampling analysis of soot particles exhausted from different engines at a motor vehicle inspection center. The calibration results show that the detection efficiency is 90% when the particle diameter is 20.6 nm and the startup response time of the instrument is 3.53 s. The experiment results show that the self-developed BHCPC demonstrates good consistency in measuring particle-number concentration (PNC) in motor vehicle exhaust, with significant count fluctuations only occurring when PNC is higher than 25,000 P/cc. Under idle conditions, motor vehicles compliant with China VI emission regulations exhibit markedly lower exhaust emission PNC compared to those adhering to China IV emission regulations. Moreover, the results obtained from the offline electron microscope analysis show that fuel content in particle samples significantly decreases as engine speed increases, and a similar variation was also found in particle size. The micro-characteristics of the particle can give potential support to the combustion diagnostics. Full article

Breeze energy is a widely distributed renewable energy source in the natural world, but its efficient exploitation is very difficult. The conventional harvester with fixed arm length (HFA) has a relatively high start-up wind speed owing to its high and constant rotational inertia. Therefore, this paper proposes a harvester with a helix s-type vertical axis (HSVA) for achieving random energy capture in the natural breeze environment. The HSVA is constructed with two semi-circular buckets driven by the difference of the drag exerted, and the wind energy is transferred into mechanical energy. Firstly, as the wind speed changes, the HSVA harvester can match the random breeze to obtain highly efficient power. Compared with the HFA harvester, the power coefficient is significantly improved from 0.15 to 0.2 without additional equipment. Furthermore, it has more time for energy attenuation as the wind speeds dropped from strong to moderate. Moreover, the starting torque is also better than that of HFA harvester. Experiments showed that the HSVA harvester can improve power performance on the grounds of the wind speed ranging in 0.8–10.1 m/s, and that the star-up wind speed is 0.8 m/s and output peak power can reach 17.1 mW. In comparison with the HFA harvester, the HSVA harvester can obtain higher efficient power, requires lower startup speed and keeps energy longer under the same time. Additionally, as a distributed energy source, the HSVA harvester can provide a self-generating power supply to electronic sensors for monitoring the surrounding environment. Full article

Five-phase induction motors have the characteristics of high torque density, low torque ripple, and flexible control, making them suitable for medium- and low-voltage power supply situations. However, with the expansion of application scenarios, five-phase motors need to cope with increasingly complex operating conditions. Five-phase motors for propeller propulsion will face various complex sea conditions during actual use, and five-phase motors for electric vehicles will also face various complex road conditions and operating requirements during use. Therefore, as a propulsion motor, its speed control system must have strong robustness and anti-disturbance performance. The use of traditional PI algorithms has problems, such as poor adaptability and inability to adapt to various complex working conditions, but the use of an active disturbance rejection controller (ADRC) can effectively solve these problems. However, due to the significant coupling between the variables of induction motors and the large number of parameters in the ADRC, tuning the parameters of the ADRC is complex. Traditional empirical tuning methods can only obtain a rough range of parameter values and may have significant errors. Therefore, this paper uses ADRC based on genetic algorithm(GAADRC) to tune the parameters of the control and design an objective function based on multi-objective optimization. The parameters to be adjusted were obtained through multiple iterations. The simulation and experimental results indicate that GAADRC has lower startup overshoot, faster adjustment time, and lower load/unload speed changes compared to the empirically tuned PI controller and ADRC. Meanwhile, using a genetic algorithm for motor ADRC parameter tuning can obtain optimal control parameters while the control parameter range is completely uncertain; therefore, the method proposed in this paper has strong practical value. Full article

Efficient and environmentally friendly ore collecting operation requires that the ore collecting head can provide just enough suction to start the ore particles in different working conditions. In this work, computational fluid dynamics and discrete element method (CFD-DEM) is used to simulate the hydraulic suction process of ore particles. After analyzing the pressure and velocity characteristics of the flow field, the effects of different suction velocities on the lateral displacement offset, drag coefficient C_d and Reynolds number Re_p of particles are studied. It is determined that the lifting force is caused by the different flow velocities of the upper and lower flow fields; particle start-up time and the lateral offset are inversely proportional to suction speed. When h/d ≥ 2.25, the vertical force on particles is no longer affected by h/d. When S/d = 2.5, F_Z decreases to 0 N; when h/d increases from 1.5 to 1.75, F_Z decreases by nearly half. Three empirical equations for F_Z represented by D/d, h/d, and S/d are obtained. After integrating the above three equations, the functional relationship of F_Z with D/d, h/d and S/d is finally obtained within a certain range. The errors of the equations are within 6%. The particle stress characteristics obtained in this paper can be applied to the establishment of ore collecting performance prediction model and provide data support for the research and development of intelligent ore collecting equipment. Full article

Vertical Axis Wind Turbines (VAWTs) are omni-directional, low-cost, low-efficiency wind power extractors. A conventional drag-based VAWT consists of multiple thin rotor blades with a typical peak Tip Speed Ratio (λ) of < 1. Their lower cut-in speed and maintenance cost make them ideal for power generation in urban environments. Numerous studies have been carried out analysing steady operation of VAWTs and quantifying their performance characteristics, however, minimal attention has been paid to their start-up dynamics. There are a few recent studies in which start-up dynamics of lift-based VAWTs have been analysed but such studies for drag-based VAWTs are severely limited. In this study, start-up dynamics of a conventional multi-blade drag-based VAWT have been numerically investigated using a time-dependant Computational Fluid Dynamics (CFD) solver. In order to enhance the start-up characteristics of the drag-based VAWT, a stator has been integrated in the design assembly. The numerical results obtained in this study indicate that an appropriately designed stator can significantly enhance the start-up of a VAWT by directing the flow towards the rotor blades, leading to higher rotational velocity (ω) and λ. With the addition of a stator, the flow fields downstream the VAWT becomes more uniform. Full article

Generating a high startup torque is a critical factor for the application of small wind turbines in regions with low wind speed. In the present study, the blades of a small wind turbine were designed and optimized to maximize the output power and startup torque. For this purpose, the chord length and the twist angle were considered as design variables, and a multi-objective optimization study was used to assess the optimal blade geometry. The blade element momentum (BEM) technique was used to calculate the design goals and the genetic algorithm was utilized to perform the optimization. The BEM method and the optimization tools were verified with wind tunnel test results of the base turbine and Schmitz equations, respectively. The results showed that from the aerodynamic viewpoint, the blade of a small wind turbine can be divided into two sections: r/R < 0.52, which is responsible for generating the startup torque, and r/R ≥ 0.52, where most of the turbine power is generated. By increasing the chord length and twist angle (especially chord length) in the r/R < 0.52 section and following the ideal chord length and twist angle distributions in the r/R ≥ 0.52 part, a 140% rise in the startup torque of the designed blade was observed with only a 1.5% reduction in power coefficient, compared with the base blade. Thereby, the startup wind speed was reduced from 6 m/s for the base blade to 4 m/s for the designed blade, which provides greater possibilities for the operation of this turbine in areas with lower wind speeds. Full article

In today’s engineering industry, technical diagnostics presents many advantages for improving the management of machining centers and automated production lines. As the fourth industrial revolution is currently being implemented, which includes machine diagnostics, the idea of adding information from the field of vibrodiagnostics was born. The vibration of the workpiece or machine tool negatively affects the geometric parameters of the machined surfaces of the workpiece. Through vibrodiagnostics, the influence of cutting parameters on the oscillation of a bearing steel workpiece during centerless grinding is investigated. The presented publication deals with the vibration of the mechanical parts of a centerless grinding machine. The oscillations are recorded by acceleration sensors, which are also placed on the support ruler in which the workpieces are guided, and the recorded data are input parameters for statistical processing of acceleration values in the form of statistical characteristics (minimum, lower quartile, median, upper quartile, maximum). In this paper, this procedure was applied for the selection of the optimum cutting parameters (for the speed of the support wheel), where the machining parameters at which the minimum oscillation values occur were selected based on the above-mentioned statistical characteristics. This optimization procedure revealed increased vibration values which reached the highest amplitude on the ruler, namely accelerations of 11 m/s², the origin of which was subsequently detected by STFT because the occurrence of resonance events or the excitation of natural frequencies of the machine were suspected. The STFT analysis identified a resonant region at machine start-up determined by the spindle speed which excites the resonance on the machine. The speed range between 1950 and 2150 rpm, which corresponds to the built-up resonance, was provided to the technologists to ensure that the machine was not operated around this resonance region at 400 and 760 Hz until the undesired phenomenon was eliminated. The results of the individual measurements provided information on the ideal setting of the cutting parameters and the current state of the machine. Full article

This article describes the safety and effectiveness issues related to signal countdown timers (SCT). These devices are used in many countries around the world. The impact of these devices on road safety and the effectiveness of traffic lights is presented. During a literature review, more than 18 aspects of device use were recognized. The research involved measurements carried out at three intersections in Płock (Poland). The initial and final period of the green signal for vehicles was analyzed. Headways, incidences of vehicles passing through after the end of the green signal, and red-light violations were examined. Additionally, a fuel consumption analysis and a case study of a road crash in Szczecin (Poland) are presented. Problems related to signal countdown timers working during traffic light failure are described. The research shows different influences of signal countdown timers at various intersections. It was observed that SCTs increase the number of red-light violations and during the red-amber signal. On the other hand, the number of entries during the amber signal with SCTs is lower. A literature review also indicated that the use of SCT causes a reduction of start-up time (positive impact) and increases vehicle speed (negative impact). The article concludes that SCTs do not always fulfill their role in improving road safety and control efficiency. Conclusions can address various stakeholders, including drivers, road authorities, and traffic engineers. Full article

SARS-COVID-19 vaccine supply for the total worldwide population has a bottleneck in manufacturing capacity. Assessment of existing messenger ribonucleic acid (mRNA) vaccine processing shows a need for digital twins enabled by process analytical technology approaches in order to improve process transfer for manufacturing capacity multiplication, a reduction in out-of-specification batch failures, qualified personal training for faster validation and efficient operation, optimal utilization of scarce buffers and chemicals and speed-up of product release by continuous manufacturing. In this work, three manufacturing concepts for mRNA-based vaccines are evaluated: Batch, full-continuous and semi-continuous. Technical transfer from batch single-use to semi-continuous stainless-steel, i.e., plasmid deoxyribonucleic acid (pDNA) in batch and mRNA in continuous operation mode, is recommended, in order to gain: faster plant commissioning and start-up times of about 8–12 months and a rise in dose number by a factor of about 30 per year, with almost identical efforts in capital expenditures (CAPEX) and personnel resources, which are the dominant bottlenecks at the moment, at about 25% lower operating expenses (OPEX). Consumables are also reduceable by a factor of 6 as outcome of this study. Further optimization potential is seen at consequent digital twin and PAT (Process Analytical Technology) concept integration as key-enabling technologies towards autonomous operation including real-time release-testing. Full article

Toward further implementation of continuous tablet manufacturing, one key issue is the time needed for start-up operation because it could lead to lower product yield and reduced economic performance. The behavior of the start-up operation is not well understood; moreover, the definition of the start-up time is still unclear. This work investigates the effects of process parameters on the start-up operation in continuous wet granulation, which is a critical unit operation in solid drug manufacturing. The profiles of torque and granule size distribution were monitored and measured for the first hour of operation, including the start-up phase. We analyzed the impact of process parameters based on design of experiments and performed an economic assessment to see the effects of the start-up operation. The torque profiles indicated that liquid-to-solid ratio and screw speed would affect the start-up operation, whereas different start-up behavior resulted in different granule size. Depending on the indicator used to define the start-up operation, the economic optimal point was significantly different. The results of this study stress that the start-up time differs according to the process parameters and used definition, e.g., indicators and criteria. This aspect should be considered for the further study and regulation of continuous manufacturing. Full article

The use of alternative fuels to traditional kerosene-based ones in turbo-jet engines is currently being widely explored and researched. However, the application of alternative fuels in the area of small turbojet engines with thrust ratings up to 2 kilo-newtons, which are used as auxiliary power units or to propel small aircraft or drones, is not as well researched. This paper explores the use of ethanol as a sustainable fuel and its effects on the operation of a small turbojet engine under laboratory conditions. Several concentrations of ethanol and JET A-1 mixtures are explored to study the effects of this fuel on the basic parameters of a small turbojet engine. The influence of the different concentrations of the mixture on the start-up process, speed of the engine, exhaust gas temperature, and compressor pressure are evaluated. The measurements shown in the article represent a pilot study, the results of which show that ethanol can be reliably used as an alternative fuel only when its concentration in a mixture with traditional fuel is lower than 40%, yielding positive effects on the operating temperatures and small negative effects on the speed or thrust of the engine. Full article

Sensorless control of electrical drives is still a difficult task, especially in the lower speed region. Moreover, when the machine has a low saliency such as in the case of Surface Mounted Permanent Magnet Synchronous Motor (SMPMSM), high frequency injection techniques are even more challenging. In this paper, an enhanced demodulation algorithm for the sensorless control of a SMPMSM is proposed. The new scheme uses the high frequency injection in the Synchronous Reference Frame (SRF) and employs also the negative sequence content of the measured current for improved accuracy. This allows an improved performance with a lower amplitude of the injected signal, thus reducing the noise and additional losses in the motor. It is found that, by using both components with the algorithm developed the estimation ripple can be greatly reduced and the system can operate properly with a voltage injection of only 2.17% of the rated motor voltage, which is lower than most found in the literature, specially for low saliency machines. Simulations tests are carried out for the validation of the proposed method and experimental results in a 6.7 kW SMPMSM confirm its usefulness and correct operation with a reduced voltage injection, both in no-load and load conditions, for different low speeds, including start-up. Full article