Search Results (207)

To address the bottlenecks of conventional valve-controlled marine steering systems—characterized by high throttling losses, low efficiency, and high leakage risk—as well as the insufficient power density and impact resistance of electro-mechanical actuators (EMAs) for high-load steering of large vessels, this paper proposes and validates a high-performance integrated solution for an electro-hydrostatic actuator (EHA) for ship steering. First, a fifth-order electro–hydraulic–mechanical coupled dynamic model comprising a permanent magnet synchronous motor, hydraulic pump, hydraulic cylinder, and load is established. The validity and applicability boundaries of three simplifying assumptions—neglecting leakage, pipeline pressure losses, and steady-state fluid compressibility effects—are quantitatively analysed, with a total introduced error ≤3%. These assumptions are justified under medium-pressure, short-pipeline, and well-sealed conditions typical of marine EHA systems. Second, a composite control architecture combining outer-loop sliding mode control with inner-loop motor PID dual-loop control is proposed. Parameter tuning is performed using pole placement for the sliding surface and the Ziegler–Nichols critical ratio method for the inner loops, effectively suppressing hydraulic system parameter perturbations and random wave-induced load disturbances. Quantitative comparisons show that the proposed method reduces overshoot by 11.63% and improves sinusoidal tracking accuracy by 90.13% compared to conventional single-loop PID control. An integrated drive-control structure is designed, and a three-phase full-bridge inverter main circuit with wide-voltage input capability—including EMI filtering, soft-start, and LC filtering—is developed to accommodate the ±20% voltage fluctuations typical of ship power grids, thereby enhancing system integration and grid adaptability. Phased bench tests demonstrate that the settling time from no-load start-up to 200 r/min is only 0.01 s. When a sudden 20 N·m load is applied, the speed drop is less than 3%, and the recovery time is less than 0.025 s. The steady-state steering angle error does not exceed 0.12°, the maximum average steering rate reaches 3.33°/s, and the steering response time is within 0.3 s. All core performance indicators exceed the general technical standards for marine steering systems, with a 65.7% improvement in steady-state accuracy and a 62.5% improvement in response speed over conventional PID control. The research findings provide an effective general technical solution and experimental data support for the performance optimization and engineering application of marine EHA systems. Full article

The continuous rotating valve plate piston pump (CRVPPP) can efficiently drive actuators such as hydraulic cylinders or hydraulic motors to generate excitation motion. This CRVPPP-driven excitation system can avoid the throttling losses associated with servo-valve-controlled excitation systems. However, this excitation system exhibits an asymmetric excitation phenomenon during actual operation. Through theoretical analysis and experimental research on the mechanical characteristics of the valve plate pair in the CRVPPP, it was found that the asymmetric excitation originates from the annular grooves of the fixed valve plate alternating between oil suction and discharge states. This alternation subjects the rotating valve plate to an overturning moment, which in turn causes a periodic variation in the end-face clearance of the valve plate. Targeting the asymmetric and nonlinear leakage characteristics of the CRVPPP, an adaptive neural network module was established based on the Amesim-Matlab/Simulink co-simulation framework. This module incorporates the mapping from the rotational speeds of the rotating valve plate and cylinder block to the equivalent leakage opening of the distribution grooves. By training with experimental data, the CRVPPP- driven excitation system model was formulated. Experimental results show that the established model achieves a correlation coefficient of 0.99786 on the training set, indicating its excellent fitting accuracy. Furthermore, the mean squared error on the test set is within 0.04 mm², demonstrating the model’s good generalization ability. It can reproduce the dynamic characteristics of the CRVPPP-driven excitation system with high precision, thereby laying a solid modeling foundation for the characteristic analysis, structural optimization, and high-precision control of such excitation systems. Full article

To investigate the dynamic characteristics of key parameters in a piston gravity energy-storage system, an experimental system for novel piston gravity energy storage is designed and developed. Firstly, the structure and working principle of the piston gravity energy-storage system are analyzed. Adopting a modular modeling approach, the system is divided into four core modules, and the piston motion, vertical cylinder chamber pressure, hydraulic actuator, and turbine power models are established. Subsequently, a case study simulation is conducted on the piston gravity energy-storage system to model its dynamic characteristics during discharge conditions, analyzing the variation patterns of key parameters such as the chamber pressure, flow rate, and output power within the system. Finally, the experimental system integrates a digital controller with proportional–integral power regulation and an automatic mode switching logic to enable the constant power closed-loop control, with real-time acquisition of the chamber height, pressure, flow rate, and electrical parameters. The dynamic responses of various system parameters are analyzed. Experimental results indicate that under constant power charging and discharging conditions, the height of the upper chamber exhibits a linear trend, the pressure in the lower chamber is inversely proportional to the height of the upper chamber, and the flow rate remains stable with charging and discharging power. Neglecting energy losses of the pump and hydraulic turbine and only considering friction and hydraulic losses, the charge–discharge efficiency of the energy-storage experimental system is 65%. Full article

To elucidate the wear evolution and failure mechanisms of VL-type composite seals in aviation hydraulic actuators under multiple operating conditions, a two-dimensional plane-strain finite element model was developed for a VL seal consisting of a PTFE L-ring and an NBR O-ring. The model incorporated the Mooney–Rivlin hyperelastic constitutive law and the Archard wear model. The effects of O-ring compression ratio, hydraulic pressure, sliding velocity, and temperature on cumulative wear, wear rate, and contact state were systematically investigated. The results show that the compression ratio has a nonlinear influence on wear. Within 8–16%, the peak wear increases approximately linearly with compression ratio; above 16%, the peak wear reaches a plateau and a secondary wear zone appears, indicating a transition from single-contact to multi-contact sealing. Hydraulic pressure promotes wear over the range of 4–28 MPa, and at 28 MPa the opposite lip edge of the L-ring comes into contact with the cylinder wall, weakening the sealing effectiveness. Within 0.1–0.3 m/s, wear increases approximately linearly with sliding velocity. However, under high velocity and insufficient hydraulic pressure, the L-ring may undergo inversion, resulting in complete seal failure. Temperature exhibits a non-monotonic effect: material softening reduces local contact stress and wear from −55 to 80 °C, whereas excessive softening at 135 °C causes the peak wear rate to increase again. A parametric analysis scheme involving an increased L-ring height and thickness, a reduced O-ring cross-section diameter, and reserved deformation space raises the critical compression ratio for stable single-contact sealing from 16% to above 20%. These findings clarify the contact-stress/contact-area competition mechanism governing VL seal wear and provide guidance for the design of aviation hydraulic actuator seals. Full article

To address the issues of poor operational stability and insufficient omnidirectional leveling capability of tracked electric agricultural machinery in hilly and mountainous areas, this paper presents an electromechanical omnidirectional leveling chassis architecture based on a dual-layer independently driven architecture. Utilizing servo electric cylinders as actuators, a leveling mechanism with physically decoupled upper lateral and lower longitudinal layers was constructed. Based on this structure, a mathematical model relating the electric cylinder displacement to the platform posture was established. Furthermore, an ADAMS dynamics simulation platform was built to conduct simulation analysis and prototype experiments. The results indicate that the designed dual-layer independently driven chassis can achieve a theoretical leveling range of ±28.6° laterally and ±27.7° longitudinally, operating smoothly under the rated 25° slope condition. Dynamic tests demonstrate that when the prototype travels at 3 km/h, the residual inclination angle of the platform can be controlled within ±0.9° in 3 s. The simulation and experimental results are in high agreement, comprehensively revealing the dynamic coupling relationship among the electric cylinder displacement, platform posture, and driving thrust. The experiments verify that the electromechanical omnidirectional leveling system can accomplish adaptive leveling under slope conditions, exhibiting superior performance regarding response speed, control accuracy, and disturbance rejection, with the thrust deviation rate between simulation and experiment within 6.71%. Full article

Tribotronic machine elements achieve active control by incorporating sensing, control and actuation into engineering components that are otherwise conventionally passive. There has been a trend towards the development and use of active tribological (tribotronic) components over recent years. This paper briefly recounts the historical development of tribotronics, then presents two examples of research on components as case studies based on research by the authors to demonstrate how tribotronics can drive forward the technical capabilities of two common machine elements. In this context, this paper deals with the tribotronics of tilting-pad thrust bearings as well as active lubrication for internal combustion engine cylinder systems. The aim of the paper is to demonstrate how tribotronic technology can be applied to realise transformative reductions in energy loss by controlling friction well beyond those that could be gained by more conventional improvements in design or the use of enhanced materials, In addition to the technical discussion, this paper incorporates a short reflection the very significant financial and environmental gains that can potentially be obtained by using tribotronic components in the field. Finally, closing remarks are made regarding the more general advantages of tribotronic approaches and the potential future of this technology. Full article

The rotary steerable system (RSS) is the core equipment for precise wellbore trajectory control in deep oil and gas drilling, and its performance is directly determined by the coordination and adaptability of the tool’s offset actuator and control platform. To overcome the limitations of complex control architectures and low positioning accuracy of conventional offset actuators for rotary steering drilling tools, a novel three hydraulic cylinder synchronous steering offset actuator driven by a drilling fluid rotary valve distributor, along with its dedicated control strategy, is proposed. Laboratory experiments and numerical simulations are performed to analyze the piston displacement characteristics of the three hydraulic cylinder under different drilling fluid flow rates and rotary valve rotational speeds. The results demonstrate that the proposed actuator exhibits controllable piston displacement behavior. The simulated and experimental data show consistent variation tendencies with a relative error of less than 8%, thus validating the reliability of the proposed numerical model. Increasing the flow rate from 1 to 1.5 L/s increases the cycle-averaged peak-to-peak piston displacement by 14.5 mm, while raising the rotational speed from 60 rpm to 120 rpm reduces it by 25.3 mm, corresponding to a dogleg severity variation of approximately 1.9–3.1°/30 m. Piston displacement deviations are mainly attributed to valve port machining tolerance, drilling fluid compressibility, pipeline pressure loss, and internal leakage, and these discrepancies are exacerbated as the rotary valve speed or flow rate increases. Finally, optimization strategies for improving synchronization performance are proposed, thereby providing theoretical and technical support for the engineering implementation and parameter optimization of the proposed actuator. Full article

Hybridization in vehicle powertrains extends beyond the aggregate system level and can target individual components to enhance engine performance. While prior studies have highlighted the performance benefits of electrified turbochargers, this work focuses on mitigating engine-out emissions for a medium- to heavy-duty diesel engine with an electrified airpath. Unlike conventional engines and actuators, the alternative engine architecture with an electrified airpath provided superior airpath control. This is critical for fuel-led diesel engines, where the initial combustion cycles during the tip-in phase of a transient operate at a rich equivalence ratio. In this work, a 3.2 L two-cylinder opposed piston two-stroke (OP2S) engine equipped with an Electrically Assisted Turbocharger (EAT) and an electrically operated EGR pump was experimentally tested in a Hardware in the Loop (HIL) setup under transient conditions. Actuator positions were varied to identify strategies that mitigate soot and NO_x without compromising transient response. The experiments are discussed case-wise, where the effects of each airpath actuator, including fuel rate shaping, are analyzed, showing to what extent each strategy mitigates emissions. At the end, an optimized case is presented to the readers for their perusal. The electrified airpath, along with fuel rate shaping, demonstrated cumulative soot reduction up to 92% and NO_x emissions by 77% for a transient load step between 3 and 13 bar BMEP at a mid-engine speed of 1250 rpm. Full article

This paper presents the design, simulation, and experimental validation of a novel type of pneumatic rotary positioner that is based on a three-cylinder radial mechanism driven by independently controlled pressures. The system uses standard off-the-shelf industrial components, including pneumatic cylinders, proportional pressure regulators, and a programmable logic controller. In order to obtain angular positioning, a three-phase sinusoidal pressure commutation scheme is adopted, similar to the three-phase electrical motors. Analytical expressions for piston kinematics and torque generation are derived and used to design direct open-loop, open-loop with friction compensation, and closed-loop position control strategies. The technical implementation, with the prototype tested unloaded, can achieve accurate positioning (±3° in open-loop mode with feedforward to ±0.3° in closed-loop mode with PD controller), with very good repeatability on average (<0.5°) and smooth theoretical torque (average 1.4 Nm, with 0.51% ripple) at low speeds (<60 rpm). The experimental prototype was designed as a compact device, having approx. 94 mm diameter and 110 mm depth. When used in open-loop mode, the actuator is connected to the control system using just three pneumatic tubes and thus is completely free of any electromagnetic fields, making it suitable for some environment-critical applications. These advantages promote the proposed positioner as a practical rotary actuator in specialized automation and robotics applications where established electrical servomotors cannot be used. Full article

This paper presents an original positional pneumatic actuator for long-stroke coordinate mechanisms. The design integrates a rodless pneumatic cylinder, a jet control system, and an external braking device. It achieves a positioning accuracy of 200 microns, a discrete step of 2 mm, and an average speed of 0.15 m/s over a maximum stroke of 6 m. This solution offers a two-fold improvement in technical, economic, and operational performance compared to electromechanical drives. A mathematical model of the drive was developed using SimInTech software and validated with a custom-built experimental stand. The discrepancy between calculated and experimental data does not exceed 18%. The study established the dependence of positioning accuracy on the load and kinematic characteristics of the drive, which helps reduce design time for coordinate mechanisms. As a result of the research, a new scheme of a positional pneumatic actuator has been developed and experimentally confirmed, which allows for a two-fold improvement in technical and economic indicators compared to electromechanical analogs due to the original combination of a rodless cylinder, a jet control system, and an external braking device. Full article

As manufacturing progresses, the demand for precision inspection of complex parts has intensified. To guarantee functionality and sensory performance, high-efficiency 3D shape measurement is required. In this paper, a collaborative robot-based approach for efficient and high-precision 3D shape inspection of complex parts is proposed. The system employs a collaborative robot to drive the scanner along optimized trajectories. First, the configuration of the inspection system is presented, and the ideal measurement mode for the sensor is analyzed. Subsequently, adaptive viewpoints are generated through parametric discretization based on surface geometric features. For inter-region scanning path planning, the problem is modeled as the Shortest Path Problem (SPP) within the framework of the Traveling Salesman Problem (TSP) and solved by constructing a Successive Approximation Algorithm (SAA). Furthermore, a Modified Denavit-Hartenberg (MDH) method is applied to establish the precise kinematic model of the collaborative robot. Inverse kinematics solutions are derived to convert planned viewpoints into target joint configurations, thereby achieving precise end-effector pose control. Simulation and experimental results on an engine cover and a cylinder head demonstrate that the proposed approach enables comprehensive 3D shape inspection of complex parts in a single setup and achieves higher efficiency and accuracy compared to existing methods. This work offers a viable solution for integrating robotic actuation and active sensing in the automated inspection of complex geometries. Full article

Traditional dexterous hands can readily grasp objects but face limitations in dexterous manipulation due to complex control systems and high actuation demands. This paper presents a novel dexterous hand designed to address these challenges. The hand consists of four fingers, each equipped with two mecanum wheels at the fingertips to allow for the omnidirectional manipulation of objects. Continuous rotation of the mecanum wheels enables unbounded motion of grasped objects without the need for finger gaiting. Object pose adjustment is achieved by controlling the rotation of mecanum wheels, thus significantly reducing operational complexity and enhancing manipulative agility. Furthermore, to address the control difficulty of multi-finger coordinated motion, a four-finger coupled mechanism is implemented, resulting in a dexterous hand with three degrees of freedom. Kinematic models of omnidirectional manipulation are established for typical geometric objects, including a flat plate, a cuboid, a sphere, and a cylinder. Simulations confirm the correctness of the kinematic models. Experimental results show that the hand can achieve omnidirectional manipulation of objects. Finally, the extended functionality of the dexterous hand is briefly presented, which allows it to be reconfigured into an omnidirectional mobile robot. Full article

Pneumatic drives remain widely used in industrial automation due to their simplicity and reliability, yet their overall energy efficiency is typically low. This study introduces an energy-efficient pneumatic drive concept that enhances braking control and enables compressed air recovery without modifying the actuator’s mechanical design. A transient one-dimensional mathematical model is developed to describe system dynamics and is combined with a particle swarm optimization (PSO) algorithm to determine optimal switching coordinates for the braking phase under constraints on piston motion and positioning accuracy. To assess the validity and limitations of simplified models, the optimized process is additionally investigated using a three-dimensional CFD model with moving mesh and valve control. The CFD model is validated experimentally using pressure measurements in the cylinder chambers. The results reveal that conventional isothermal 1D models underestimate transient pressure and energy parameters by up to 30–35% in systems with air recovery, highlighting the necessity of 3D analysis for accurate energy assessment. Optimization increases the duration of the recovery phase by a factor of 2.8 while maintaining cycle time and improving positioning accuracy. The resulting cycle energy efficiency reaches 53.4%, significantly exceeding typical industrial values. The proposed methodology provides a practical framework for designing energy-efficient pneumatic drives. Full article

As a critical component for motion control in heavy machinery, high-speed hydraulic actuators require effective buffering to mitigate end-impact. This paper proposes a compact buffering cylinder with a multi-orifice sleeve. A theoretical model was established to derive the throttling area profile for constant deceleration. A detailed numerical simulation model was then developed, and the key orifice parameters (diameter and spacing) were optimized using a Particle Swarm Optimization (PSO) algorithm to maximize buffering efficiency and smoothness. A prototype based on the optimal design was manufactured and tested dynamically. Experimental results demonstrate that the buffer smoothly arrested a piston with an initial velocity of 8 m/s and a moving mass of 80 kg within a 250 mm stroke. The optimized design achieved a 14% increase in buffering efficiency and reductions in peak force and pressure compared to the initial design, validating the proposed optimization methodology and providing a reliable solution for high-speed actuator protection. Full article

The brake-by-wire system is a fundamental and critical component of intelligent electric vehicles. Achieving precise actuator motor response is essential for brake-by-wire braking performance. To address this issue, this article proposes a fuzzy sliding-mode control method for a dual-motor electro-hydraulic braking system. An innovative model of the braking system is established, incorporating the motor, deceleration mechanism, brake master cylinder, brake wheel cylinder, and hydraulic system. Firstly, dynamic models for the permanent magnet synchronous motor (PMSM), the reduction mechanism, the brake master cylinder, and the brake wheel cylinder are developed. Subsequently, the feasibility of the redundant structure is verified. Finally, a novel composite convergence law-based fuzzy adaptive sliding mode control (SMC) method is designed. Simulation results demonstrate that this approach effectively reduces motor response time and enhances braking performance. Full article