Search Results (3,396)

Volatile organic compounds (VOCs, dominated by xylene, toluene, and benzene) and paint mist emissions from ship painting represent a major environmental and health concern, posing a critical bottleneck to the green transformation of the shipbuilding industry. To tackle this challenge, this study presents an integrated recovery system designed specifically for ship automatic-spraying robots. Guided by the synergistic principle of “air-curtain containment, multi-stage adsorption, and negative-pressure recovery,” the system features a modular design that ensures full compatibility with the robots’ spraying trajectory without operational interference. Core adsorption materials, namely glass fiber filter cotton and honeycomb activated carbon fiber, were selected to suit the high-humidity and high-pollutant-concentration environment typical of ship painting. An appropriately matched axial flow fan maintains stable negative pressure throughout the system. Furthermore, the design integrates an air curtain isolation subsystem and an automated control subsystem, enabling coordinated operation and real-time adjustment. Using ANSYS Fluent, geometric and flow field simulation models were established to analyze airflow distribution and pollutant adsorption behavior, which led to the optimization of key structural and material parameters. Field experiments conducted in shipyard environments demonstrated the system’s superior performance: it achieved a VOC removal efficiency of 88.4% and a paint mist capture efficiency of 85.7% under optimal working conditions, with a maximum simulated paint mist capture efficiency of 86.2%. The system maintained stable performance under complex vertical and overhead spraying conditions, with an efficiency attenuation of less than 1.5%, and its outlet emissions fully complied with the mandatory limits specified in the Emission Standard of Air Pollutants for the Shipbuilding Industry (GB 30981.2-2025). The relative error between experimental data and simulation results is less than 2%, confirming the reliability and practicality of the proposed system. This research provides an efficient and adaptable pollution control solution for green shipbuilding and offers valuable technical insights for the sustainable upgrading of automated painting processes in heavy industries. Full article

To address the issue of significantly reduced coupling coefficient and limited transmission efficiency in traditional flat solenoid magnetic couplers within wireless power transfer (WPT) systems under horizontal lateral offset conditions, this paper proposes a design method for a concave flat solenoid coil magnetic coupler for engineering applications, aiming to achieve high misalignment tolerance. An equivalent model of the LCC/S compensation circuit is established, its output characteristics are analyzed, and the parameter configuration method for its resonant elements is derived. Secondly, from the perspective of winding arrangement, the mechanism by which the coil winding method, turn spacing, and port concavity angle affect the uniformity of magnetic field distribution and the retention rate of the coupling coefficient is analyzed in detail, and corresponding parameter trade-off and optimization methods are proposed. Subsequently, a simulation model of multiple configuration magnetic couplers is established based on Ansys/Maxwell, comparing the magnetic field distribution and coupling coefficient variation of different structures under horizontal offset conditions. The results show that the concave structure with a non-uniform arrangement and a port concavity angle of 30° can still maintain a high coupling coefficient and stable transmission performance under a maximum horizontal offset equal to 60% of the corresponding transmitter-side characteristic dimension. To achieve lightweight and integrated design, the receiver is designed with a flexible printed circuit board (FPC) coil structure, meeting the miniaturization and high power density requirements of low-to-medium power portable devices. Finally, a 100 W experimental prototype was built. Experimental results show that within an offset range of ±15 mm on the X-axis and ±30 mm on the Y-axis at the receiver, the system output voltage fluctuation is controlled within 4%, and the maximum transmission efficiency reaches 87.3%. These results verify the feasibility and practical applicability of the proposed magnetic coupler with high misalignment tolerance. Full article

The present study investigates the thermo-mechanical behaviour and fatigue life associated with the shrink-fit process of shrink-fit tool holders. These holders are an indispensable component of high-precision and high-speed machining processes in modern manufacturing industries. Shrink-fit holders are subjected to elevated levels of stress as a consequence of repeated heating and cooling cycles, which can result in clamping fatigue over time. In this study, a three-dimensional finite element model (FEM) of a holder manufactured from H13 tool steel in accordance with BT40 standards was created using ANSYS software. The numerical analyses included transient thermal and structural analyses, consisting of a 4.5-s induction heating stage at 10 kW power, followed by a 1200-s cooling process. The analysis yielded results that were corroborated by the experimental data. It was established that, upon the conclusion of the heating process, the temperature in the conical region of the holder attained a range of approximately 388–417 °C. Furthermore, it was ascertained that a radial expansion of approximately 17.2–22 µm, which is required for the successful insertion of the cutting tool into the inner bore, was achieved. The fatigue life prediction, which constitutes the main focus of the study, applied the Soderberg criterion and evaluated two basic loading scenarios: the first tool assembly and repeated tool assembly cycles. The calculations yielded a life estimate of approximately 12,407 cycles for the first tool assembly cycle and approximately 19,400 cycles for the repeated tool assembly cycle. Accordingly, the repeated tool assembly condition exhibited a longer fatigue life than the first tool assembly condition. The enhanced longevity observed in the repeated tool assembly scenario is attributed to the stress cycle not fully reaching zero during this process, resulting in a lower stress amplitude. Full article

To address the low efficiency of finite element modeling and the reliance on manual measurements in electric/magnetic field analysis of complex overhead transmission line structures, this paper develops an IronPython-based automated computational platform within ANSYS Maxwell for 3-D modeling and electric/magnetic field analysis. First, by parsing transmission line data from the Grid Information Model (GIM), a unified coordinate transformation method is proposed to convert geographical coordinates into three-dimensional (3-D) Cartesian coordinates for finite element analysis. Based on the extracted line parameters, conductor sag is calculated and catenary modeling is implemented. An equivalent radius method is also introduced to simplify multi-bundle conductor modeling, enabling fast parametric construction of complex 3-D transmission line models. Second, by combining the IronPython scripting language with the .NET Windows Forms control library, a visualized finite element modeling and computation platform is developed. Finally, a typical double-circuit transmission line on the same tower is taken as a case study to calculate the spatial distribution of electric/magnetic fields. The influence of solution domain size on electric/magnetic field computation results is investigated, and optimal solution domain parameters are determined. The finite element results generated by the developed platform are further validated through comparison with measured data. The results demonstrate good agreement between calculated and measured values, confirming the accuracy and engineering applicability of the developed platform for electric/magnetic environment analysis of overhead transmission lines. Full article

For deep-draft cylindrical platforms with a large annular column boot, the influence of the column boot diameter-to-height ratio (d/h) on motion performance remains unclear. This study investigates the effect of d/h on platform hydrodynamics while keeping the main body geometry, displacement, and draft unchanged. A hybrid numerical model validated against tests is adopted: STAR-CCM+ free-decay simulations identify equivalent linear damping, and ANSYS AQWA predicts hydrodynamic coefficients, response amplitude operators, and coupled time-domain responses under a 100-year survival sea state in the western South China Sea. Increasing d/h substantially increases heave added mass and added pitch moment of inertia, leading to longer natural periods and higher damping in heave and pitch. However, its effect on motion responses is non-monotonic and strongly response-dependent. As d/h increases, the responses are initially reduced markedly. The minimum surge and heave responses occur at d/h = 2.39 and 4.67, with reductions of about 34.0% and 87.2%, respectively, while the pitch response is already reduced by about 67.3% at d/h = 7.22. Further increases in d/h may weaken surge and heave mitigation while providing limited additional benefit for pitch. These findings provide qualitative understanding and quantitative guidance for response-oriented column boot design and optimization of similar platforms. Full article

Objective: To evaluate the biomechanical effects of varying posterior implant inclinations and loading protocols on peri-implant stress distribution in full-arch maxillary rehabilitations using the All-on-Four concept. Methodology: A three-dimensional finite element model of an edentulous atrophic maxilla was developed from a digital point cloud. Four implants were placed according to the All-on-Four protocol: two anterior vertical implants and two posterior implants with inclinations of 0°, 15°, 30°, or 45°. Mini-abutments and a titanium bar prosthesis were included. Material properties were assumed as homogeneous, isotropic, and linearly elastic. Immediate loading was simulated using frictional contacts (µ = 0.3), whereas delayed loading assumed complete osseointegration (bonded contacts). The models were meshed using 10-node quadratic tetrahedral elements (SOLID187) in ANSYS^®. Maximum von Mises stress in cortical bone, cancellous bone, implants, abutments, and the prosthetic bar was assessed. Results: Posterior implant tilt significantly reduced peri-implant stress. Under immediate loading, the highest stress occurred at 0° inclination in the posterior left implant (82.36 MPa) and decreased progressively with increasing tilt, reaching 33.63 MPa at 45° (≈59% reduction). Delayed loading generally produces lower stress magnitudes, particularly at extreme tilts. Anterior implants experienced lower stress levels across all configurations. Comparative analysis demonstrated that immediate loading increased stress at lower angulations, while differences between loading protocols were minimal at higher inclinations. Conclusions: Posterior implant angulation and loading protocol critically influence peri-implant stress distribution. Increased posterior tilt combined with appropriate loading reduces peak cortical bone stresses, supporting biomechanical optimization in All-on-Four maxillary rehabilitations. Full article

Wheeled multifunctional motorized crossing frames represent a new type of crossing equipment for high-voltage transmission line construction. The initial design is too conservative, having a large safety margin and high material redundancy. Therefore, it is necessary to study a lightweight design version. However, as the structure constitutes an assembly consisting of multiple components, it also exhibits relatively high complexity. In a lightweight design, optimizing multi-component and multi-size parameters can lead to structural interference and separation, seriously affecting the smooth progress of design optimization. Therefore, an optimization design method of a multi-parameter complex assembly structure is proposed to solve this problem. Firstly, the typical stress conditions of the wheeled multifunctional motorized crossing frame were analyzed using its structural model. Then, a finite element model of the beam was established in ANSYS 2021 R1 Workbench, and the mechanical characteristics were analyzed. The results show that the arm support is the key load-bearing component and has significant optimization potential. Subsequently, functional mapping relationships were established among the 14 dimension parameters of the arm support, reducing the number of design variables to six and successfully avoiding component separation or interference during optimization. Through global sensitivity analysis, the height, thickness, and length of the arm body were screened out as the core optimization parameters from six initial design variables. Then, 29 groups of sample points were generated via central composite design (CCD), and a response surface model reflecting the relationships among the arm body’s dimensional parameters, total mass, maximum stress, and maximum deformation was established using the Kriging method. Leave-one-out cross-validation (LOOCV) was performed, and the coefficients of determination (R²) for model fitting were all higher than 0.995, indicating extremely high prediction accuracy. Taking mass and deformation minimization as the optimization objectives, the MOGA algorithm was adopted to perform multi-objective optimization and determine the optimal engineering parameters. Simulation verification was conducted on the optimized arm support, and an eigenvalue buckling analysis was performed simultaneously to verify structural stability. Finally, the proposed optimization method was experimentally verified through mechanical performance tests of the full-scale prototype under symmetric and eccentric loads. The results show that the mass of the optimized arm support is reduced from 217.73 kg to 189.8 kg, with a weight reduction rate of 12.8%. Under an eccentric load of 70,000 N, the maximum deformation of the arm support is 8.9763 mm, the maximum equivalent stress is 314.86 MPa, and the buckling load factor is 6.08, all of which meet the requirements for structural stiffness, strength, and buckling stability. The maximum error between the experimental and finite element results is only 4.64%, verifying the accuracy and reliability of the proposed method. The proposed optimization methodology, validated on a wheeled multifunctional motorized crossing frame, serves as a transferable paradigm for the lightweight design of complex assemblies with coupled dimensional constraints, thereby offering a general reference for the structural optimization of multi-component transmission line equipment, construction machinery, and other multi-component engineering systems. Full article

Accurate prediction of thermo-mechanical behavior in Fused Deposition Modeling (FDM) is often limited by mismatches between idealized Computer-Aided Design (CAD) geometry and path-dependent material deposition. This paper presents a G-code-driven, filament-level modeling and process-simulation workflow for complex geometries and infill strategies, especially toolpaths with in-plane inclinations. Extrusion segments are parsed from slicing G-code to obtain endpoints and process parameters, and each filament is reconstructed as a path-aligned rectangular bead using a dedicated local coordinate system. Progressive deposition is simulated in ANSYS Parametric Design Language (APDL) via an element birth–death method, enhanced by a centroid-based element selection strategy that reduces dependence on strictly aligned hexahedral partitions and improves robustness for complex meshes. A nonlinear transient thermal analysis is performed, and temperatures are mapped to the structural model through an indirect thermo-mechanical coupling scheme to predict warpage and residual stresses. Case studies on square plates with triangular and hexagonal infills (with/without sidewalls and a bottom base) show that the high-temperature zone follows newly deposited paths with peak temperatures near 220 °C, while displacement and von Mises stress accumulate and are strongly affected by infill topology and boundary conditions. Full article

Conventional thermoelectric generators (TEGs) suffer from thermal resistance introduced by ceramic substrates and thermal interface materials, which limits the achievable temperature gradient across the junctions and reduces conversion efficiency. To overcome this limitation, a pin-fin integrated thermoelectric device (iTED) is proposed, in which the hot-side heat exchanger is incorporated directly into the hot-side interconnector, eliminating the ceramic and associated greases. An explicitly coupled thermal-fluid-electric finite-volume model is developed in ANSYS Fluent’s user-defined scalar (UDS) environment to quantify the simultaneous thermal-fluid-electric behavior of the iTED for inlet temperatures of 350 $\le T_{\mathrm{in}}\mathrm{K}\le$ 650, Reynolds numbers of 3000 $\le \mathrm{Re}\le$ 15,000, and load resistances ranging from 0.01 to ${10}^6$% of the internal device resistance ($R_{\mathrm{int}}$), for a fixed cold-side temperature of 300 K. The model is validated against established tube-bank correlations (2.2% agreement in pumping power) and a one-dimensional Explicit Thomson Model (1.2–6.9% agreement across all electrical system response quantities). Compared with an equivalently sized conventional TEG, the iTED achieves a 4.6-fold higher maximum power output (23.9 [W] vs. 5.2 [W] at Re = 15,000), a 2.8-fold higher thermal conversion efficiency (8.1% vs. 2.9%), and a 4.8-fold higher performance index (7.8 [-] vs. 1.6 [-] at Re = 3000), all at $T_{\mathrm{in}}$ = 650 K. A performance index analysis reveals that lower Reynolds numbers and higher inlet temperatures maximize the net power benefit, delineating the operational envelope in which the iTED produces more electrical power than is needed for fluid pumping. These findings demonstrate that device-level restructuring—specifically, the elimination of interfacial thermal resistance via integrated pin-fin heat exchangers—can yield performance improvements comparable to or exceeding those achievable through material advances alone. Full article

Thin wall composite fan blades in aircraft engines demand designs that ensure structural integrity under operational loads while resisting foreign object damage and bird strikes. This study presents a finite element investigation of thin wall composite blades with metal leading edge caps, modeled through parametric coupon analyses under static flexure loading using ANSYS APDL. Three metallic leading edge caps, Ti-6Al-4V, Inconel 718, and 15-5 PH stainless steel, were combined with IM7/8551-7 carbon fiber composites. Parametric variations included changes in metal cap material, geometric designs of the joint, and other things. Performance was evaluated in terms of failure stress, interlaminar shear strains, interface integrity, and failure margins. Results reveal that cap design and cap material critically govern structural response, with distinct interchanges between strength-to-weight efficiency, interface stresses, and interlaminar shear strain. Optimal designs reduced interlaminar shear strain levels in thin wall composite blades, while retaining adequate stiffness and strength. The results underscore the importance of interface design for effective load transfer and provide design guidelines for lightweight, damage-tolerant thin wall composite fan blade structures. Full article

This study presents a novel cooperative control strategy designed to mitigate torque ripple and enhance the disturbance rejection capability of switched reluctance motors (SRMs). The proposed approach integrates model predictive control (MPC) with direct instantaneous torque control (DITC), leveraging the torque sharing function (TSF) to generate phase-specific reference torque profiles. MPC employs rolling optimization to compute the optimal duty cycle in real time, achieving low torque ripple and consistent switching frequency during steady-state operation. To overcome the inherent delay in MPC’s dynamic response, DITC is incorporated as a fast-acting compensation loop that activates immediately upon detecting abrupt variations in speed or load, thereby delivering rapid torque adjustment and reinforcing system resilience. For validation, an 8/6-pole SRM control model was developed using Ansys/Maxwell and MATLAB/Simulink, and subjected to multi-scenario simulations. The results reveal that, compared to conventional MPC, the proposed method reduces steady-state torque ripple by 19.4% and shortens dynamic recovery time by 40%, demonstrating superior torque smoothness and improved robustness against external disturbances. Full article

Wind energy has become an essential resource for the development and diversification of the energy sector in México and worldwide. In this context, the mechanical design of turbine blades has emerged as a priority research topic, given its impact on performance and viability. The present research evaluates the aero-structural response of multiple lay-up configurations of a 6 m blade by coupling computational fluid dynamics (CFD) and finite element analysis (FEA). The fluid–structure interaction (FSI) was simulated in ANSYS, a commercial software chosen for its capacity for multivariable analysis. The nominal operating conditions included a wind speed of 10.5 m/s and a rotational speed of 100 rpm, leading to a theoretical power output of 6591 W. For the proposed lay-up configurations, the Tsai-Wu and Puck (Global IRF) criteria were estimated and remained below the critical threshold of 1.0, indicating no risk of structural failure. However, some carbon fiber/epoxy layers, including unidirectional layers in the spar caps and bidirectional layers in the structural shear web, may present failure risks under extreme loading conditions. This applies to configurations with the lowest number of layers in the mid-span spar caps; this fact is reinforced by the main effects analysis. The results emphasize the relevance of conducting comprehensive composite failure evaluations to optimize material selection and structural design, even for small-scale blades. Full article

The present study deals with the problem of irregular temperature distribution, simultaneous under-firing and over-firing, and their resultant efficiency and quality problems in a mechanical lime vertical kiln powered by domestic waste flue gas. The numerical simulation and structure optimization were carried out based on a 150 kg/h pilot-scale kiln. This combined model was built on the ANSYS Fluent 2022 R1 platform with UDF and UDS, incorporating limestone decomposition kinetics to enable the solution of gas and solid energy equations separately, and simulation of complex transfer and reaction processes. To correct the separation of flows at one inlet, a symmetric four-direction (00, 900, 1800, 2700) air intake plan was suggested. The findings show that this design essentially transforms the internal flow field into uniform and symmetrical temperature and concentration distributions. The calcination region contained both gas and solid temperatures in the optimum range to produce active lime. Specifically, the optimized kiln achieved a temperature range of 1190–1450 K in the calcination zone, a decomposition rate of approximately 82.7% (compared to 5.3% in the original model), and an increase in effective CaO content from 81.7% to 87.7%, with validation errors below 15%. It was demonstrated that the model is reliable, since the outlet simulated values correlated well with the measured ones. The preheating, calcining, and cooling zones’ heights of the optimized kiln adhered to the design requirements. This research is innovative in its application of a multi-physics coupling model with a varying heat source in a kiln and, in turn, identifies the synergism improvement process in the flow, temperature, concentration, and reaction fields. Full article

Aiming at the problem that insulation fault location in multi-branch cable networks of train DC medium-voltage power supply systems is disturbed by impedance mismatch at the injection end, this paper proposes an impedance matching method based on a resistance–capacitance composite coupling network to suppress false reflections and improve location accuracy. Firstly, the mechanism of multiple false reflections caused by injection-end mismatch is theoretically analyzed, and the expression of reflected waves and their influence on waveform superposition are derived. On this basis, an RC coupling network is designed to achieve effective matching between the measurement end and the cable characteristic impedance (about 97 Ω) within the 8–12 MHz frequency band, suppressing the amplitude of false reflections to less than 2% of the incident wave. Verification through MATLAB R2022b/ANSYS Q3D 2024R2 co-simulation and a 1:8 scaled experimental platform shows that the proposed coupling network reduces the absolute fault location error in a multi-branch network from 6.936 m to 0.188 m, decreases waveform distortion by about 40.8% and lowers the equivalent noise enhancement factor by about 55.2%. This study provides a reliable front-end matching solution for accurate fault location in complex cable networks, with clear value for engineering applications. Full article

Ensuring the crashworthiness of heavy-duty truck cabs is essential for reducing occupant fatalities and improving passive safety in commercial vehicles. Regulatory frameworks such as UNECE Regulation No. 29 (R29) define structural integrity requirements through full-scale destructive impact tests, which are costly and limit iterative design. In this study, an integrated experimental–numerical methodology is presented for the impact assessment of a real Iveco Eurocargo 120E18 truck cab reconstructed using high-resolution 3D scanning. The scanned geometry was used to generate a dimensionally accurate CAD model of the load-bearing cab structure, which was analysed using explicit finite element simulations in ANSYS Academic Mechanical and CFD Teaching package under impact conditions compliant with UNECE R29 and implemented according to the Swedish regulation VVFS 2003:29. In parallel, a full-scale physical pendulum impact test was performed on the same cab using a cylindrical impactor with a diameter of 580 mm, a length of 1800 mm, and a mass of approximately 1000 kg, impacting the upper region of the A-pillar. The experimental setup was instrumented using high-speed optical measurements and an accelerometer to capture impact kinematics and structural response. The numerical predictions showed good agreement with experimental results in terms of acceleration–time histories, absorbed energy evolution, and structural deformation, with differences generally below 6%. Critical regions susceptible to local buckling and plastic collapse were consistently identified in both approaches, while preservation of the driver survival space was confirmed. The results demonstrate that scan-based finite element models, when properly calibrated and validated, can reliably reproduce certification-level impact behaviour. The proposed workflow provides a robust and cost-effective framework for regulatory pre-validation, structural optimisation, and digitalisation of crashworthiness assessment for heavy-duty truck cabs. Full article