Search Results (50)

Aerostatic conical bearings with micro-orifices (ACBMOs) can simultaneously withstand both radial and axial external loads and have high power density. Nevertheless, due to the larger surface-to-volume ratio and length-to-diameter ratio of micro-orifices, the gas flow through micro-orifices is more susceptible to frictional loss. Since frictional loss in micro-orifices has been ignored in the literature, an aerostatic conical bearing lubrication model with frictional loss in micro-orifices and a transient model of their nonlinear dynamics are established. The effects of the micro-orifice length-to-diameter ratio and relative roughness on lubrication performance, nonlinear behaviors, and ACBMO–rotor system stability are investigated, followed by experimental validation. The results indicate that the gas mass flow rate of the micro-orifices, gas film pressure, and load capacity in the ACBMOs decrease with the increase in micro-orifice relative roughness and length-to-diameter ratio, which cannot be observed in the conventional model without frictional loss. Meanwhile, both the onset speed of instability and the failure speed decrease when frictional loss occurs in micro-orifices are considered. Full article

Advancements in manufacturing technology have facilitated the use of micro-orifice restrictors (MORs) in aerostatic bearings. However, the understanding of their effectiveness in journal bearings remains limited. This study utilizes FEM for solving the nonlinear Reynolds equation, incorporating velocity terms, to analyze the characteristics of aerostatic journal bearings (AJBs). The concepts of air impedance and pressure range are introduced and applied to explain the advantages of MORs over traditional orifice restrictors (TORs). Furthermore, the centrifugal deformation of the air film induced by high-speed operations and its consequential impact on bearing performance are methodically examined in detail. Finally, an experimental study is executed to confirm the proposed model and support the pertinent design principles. The experiment indicates that the air film thickness, accounting for centrifugal deformation, aligns more closely with the high-speed operating conditions characteristic of AJBs. Full article

Due to the restrictions associated with the actual deployment time, the flight performance of traditional aerostat systems in the climbing process needs to be improved to reduce the climbing time and the horizontal movement. This paper presents a scheme comprising a dual-balloon system, including an assisting system and a station-keeping system. In this study, a thermal and dynamic model for an aerostat system in the climbing course was established. To verify the theoretical model, flight experiments including traditional and improved aerostat systems were conducted. The performance of the improved aerostat system was compared with that of the traditional aerostat system. In addition, in this paper, the effects of helium mass in the tow balloon and payload mass on the climbing performance and equilibrium height of the improved aerostat system are discussed in detail. The results demonstrate that larger tow balloon volume does not guarantee better performance. With a fixed payload mass, equilibrium height initially rises sharply with helium mass but soon plateaus. Compared to traditional zero-pressure balloons, the dual-balloon system cuts ascent time by two-thirds. The proposed conceptual design and theoretical model could be a pathway towards achieving rapid deployment in high-altitude dual-balloon systems. Full article

Aerostatic bearings were proven to be an optimal choice in situations where low friction, cleanliness, and high motion accuracy are required. Their functionality relies heavily on flow restrictors, which are responsible for regulating and controlling the supply flow, and consequently, the thickness and stiffness of the fluid film. A diverse range of restrictors with varying characteristics is used, among which are the porous restrictors. The current work introduces a novel solution involving a porous, highly compressible restrictor, whose element of novelty compared to its predecessors consists of its variable thickness and corresponding permeability, regulated by the load on the bearing. The gas is supplied through an annular, elastic, deformable, porous disc, which is compressed by a metal plate, subjected to compression by the recess pressure on one side and by the supply pressure on the other side. One or more springs are used in parallel with the porous disc to obtain the optimum elastic response. The objective of this study is to evaluate the performance characteristics and compare them to a conventional restrictor. A parametric analysis is performed to define the size and properties of the porous restrictor. Full article

As the core component of ultra-precision machine tools, the manufacturing errors of aerostatic spindles are inevitable due to the limitations of machining and assembly processes, and these errors significantly affect the spindle’s static and dynamic performance. To address this issue, a force model of the unbalanced air film, considering the straightness errors of the rotor’s radial and thrust surfaces, was constructed. Unlike conventional studies that rely solely on idealized error assumptions, this research integrates actual straightness measurement data into the simulation process, enabling a more realistic and precise prediction of bearing performance. Rotors with different tolerance specifications were fabricated, and static performance simulations were carried out based on the measured geometry data. An experimental setup was built to evaluate the performance of the aerostatic spindle assembled with these rotors. The experimental results were compared with the simulation outcomes, confirming the validity of the proposed model. To further quantify the influence of straightness errors on the static characteristics of aerostatic spindles, ideal functions were used to define representative manufacturing error profiles. The results show that a barrel-shaped error on the radial bearing surface can cause a load capacity variation of up to 46.6%, and its positive effect on air film load capacity is more significant than that of taper or drum shapes. For the thrust bearing surface, a concave-shaped error can lead to a load capacity variation of up to 13.4%, and its enhancement effect is superior to those of the two taper and convex-shaped errors. The results demonstrate that the straightness errors on the radial and thrust bearing surfaces are key factors affecting the radial and axial load capacities of the spindle. Full article

In this paper, we develop technology to improve the stability and quality of boat equipment manufacturing through vacuum injection process fusion to increase the safety of boats. Safe mold design and fabrication are carried out to determine the resin flow rate and water flow rate of a boat, and the performance of vacuum maintenance work is guaranteed through the tensile and compressive strength of the manufactured hull and deck. When manufacturing the boat air mechanism (Aerostat), the adhesion between equipment materials and the deformation of the joints are very important factors for safety. Due to the nature of equipment manufacturing, process fusion to minimize manual process minimizes deformation after manufacturing through accurate manufacturing ratio. Accordingly, it is possible to accurately control the mixing ratio of resin and hardener as optimal conditions for boat drying and securing safety, and to convert optimal information into a database by analyzing working conditions over time such as resin flow rate and flow rate, thereby improving durability and quality. Through this, it is expected that production efficiency and safety design will be improved by enabling efficient production process management with a small number of personnel. Full article

The principle of electro-analogy analysis treats a gas path structure as analogous to a circuit, offering significant potential for performance analysis in aerostatic systems. However, research on gas resistance remains in an early stage. This study investigates pipe gas resistance and its series characteristics using a slender circular pipe as the subject. First, gas resistance is redefined based on a derivation of the Bernoulli equation, resulting in formulas covering low and high speeds and a calculation model for series gas resistance. Simulations are conducted to model the pipe, focusing on the coefficient of frictional resistance at low speeds. The results provide insights into the gas resistance of pipes with varying inner diameters and related series connections. An experiment is conducted to validate predictions, indicating that, at low speeds, the defined and determined gas resistance values for pipelines with inner diameters ranging from 1 to 6 mm are largely consistent. Both gas and series gas resistances decrease as the pressure difference between the two pipe ends increases. Relative errors below 5% are typically regarded as very good, especially when dealing with complex systems. The maximum relative error between the experimentally measured single gas resistance, based on the defining formula and the simulation value, is 3.1%. Furthermore, the maximum relative errors for the measured single and series gas resistance values are 5% and 3.8%, respectively, according to the defining and determining formulas. The theoretical model is effective and reliable, providing valuable theoretical support for impedance analysis of aerostatic systems. Full article

Micro-hole aerostatic bearings have emerged as critical components in ultra-precision machining systems, offering a superior load capacity, stiffness, and stability compared to traditional orifice-based designs. These enhancements are primarily attributed to the high-density configurations of micro-holes and the reduction in hole diameter. However, research on the design and analysis of micro-hole aerostatic bearings for high-rotational-speed applications remains limited. In this study, the finite element method (FEM) was employed to solve the Reynolds equation, thereby conducting a systematic evaluation of the static and high-speed performance characteristics of micro-hole aerostatic thrust bearings. The effects of restrictor types, micro-hole layouts, structural parameters, and centrifugal deformation under high-rotational-speed conditions on bearing performance have been comprehensively examined. The objective of this study is to provide a basis for the design of micro-hole high-speed aerostatic spindles. Full article

Traditional aerostat deployment systems within the Earth’s atmosphere face various limitations, such as high risk and lengthy deployment times. In contrast, rapid-deployment aerostat systems have the advantage of high efficiency and flexibility. To improve the deceleration and stability performance, a dynamic model of the parachute and dynamic and thermodynamic models of the aerostat are established in this work. The impact of different parachute radii, rise–radius ratios (h_p/R_p), and filling-time coefficients during the deceleration and inflation process is investigated in detail. Additionally, the comparative analysis of different aerostats is discussed. The results show that the radius and h_p/R_p of the parachute mainly affect its deceleration ability, while the filling-time coefficient affects the dynamic load. For radii of balloons exceeding 8 m, increasing the parachute radius cannot enable deployment above 10,000 m. As the radius of the balloon increases, a larger filling-time coefficient is required. A parachute with h_p/R_p = 0.8 is recommended for a balloon with a radius below 6.5 m, and h_p/R_p = 0.6 is recommended for a radius over 6.5 m. These findings provide valuable references for rapid-deployment aerostat systems. Full article

Amid rapid global aviation development and increasingly stringent safety standards, aerostats demonstrate vast potential in environmental monitoring, communication relay, cargo transportation, and other applications. However, their operational safety has become a critical focus. These systems face complex flight environments and dynamic mission requirements that demand exceptionally high safety control standards. As the core component, the safety control computer directly determines the overall safety and stability of aerostat operations. This study employed a systems engineering methodology integrating hardware selection, software architecture design, fault diagnosis, and fault tolerance to develop a universal safety control computer system with high reliability, robust real-time performance, and adaptive capabilities. By adopting high-performance processors, redundant design techniques, and modular software programming, the system significantly enhanced anti-interference performance and fault recovery capabilities. These improvements ensured precise and rapid safety control monitoring under diverse operational conditions. Experimental validation demonstrated the system’s effectiveness in supporting both remote and autonomous safety control modes, substantially mitigating flight risks. This technological breakthrough provides robust technical support for the large-scale development and safe operation of universal aerostat systems, while offering valuable insights for safety control system design in other aerospace vehicles. Full article

Firstly, the Reynolds equation considering gas inertia force is theoretically deduced in the cylindrical coordinate system, and then a mathematical model of aerostatic thrust bearing with three degrees of freedom (3-DOF) is constructed. Secondly, the Reynolds equation and velocity control equation are solved by the finite difference method (FDM), and the characteristics of gas pressure and velocity distribution in the gas film under steady-state conditions are revealed. On this basis, in the single-factor analysis, the bearing capacity error and recovery torque error caused by the inertia force term are quantitatively analyzed. It is found that the bearing rotating speed has a significant influence on the inertial force error, and the bearing radius also has a certain influence on the inertial force error, while the initial clearance, gas supply pressure, and torsion angle have relatively little influence on the inertial force error. Finally, in the multi-factor analysis, the sample regression equation of relative error of bearing capacity and relative error of restoring torque is established by using the multiple regression analysis method. By comparing the estimated values with the simulation results, the validity of the constructed regression equation is verified. Full article

Aerostatic thrust bearings are widely used in advanced equipment such as lithography machines due to their excellent lubrication performance. In this study, computational fluid dynamics (CFD) was employed for the analysis of errors in the calculation of static characteristics of bearings based on the pressure behind the orifice. We put forth an analytical model for calculating the static characteristics of bearings utilizing the average pressure (P_dAVE) within the area surrounded by orifice. By analyzing the influence of various structural parameters, film thickness, and gas supply pressure on P_dAVE in aerostatic bearings, we derived an approximate expression for the average pressure coefficient, which was subsequently verified through experiments. The findings demonstrate that the analytical model for aerostatic bearings, formulated using P_dAVE, can accurately predict the static characteristics of the bearings. The working range corresponding to the optimal stiffness of the bearings is entirely consistent, and the prediction error of the bearing capacity within the optimal working range is less than 5%. This provides a more precise and effective performance prediction model for rectangular aerostatic thrust bearings in engineering design. Full article

Based on the SST k-ω turbulence model, this study investigated the flow fields of annular groove and non-groove small-hole throttling aerostatic bearings (AGSTABs and STABs). It examined the formation mechanisms of static and dynamic pressure effects in both flow fields at high speed, evaluating how parameters such as eccentricity, groove width ratio, and depth ratio influence the average load capacity and static and dynamic pressure effects. The findings show that STABs combine static and dynamic pressure effects at high speeds, while AGSTABs decouple them to enhance load capacity, simultaneously reducing vortex and backflow intensity. At low eccentricities, AGSTABs exhibit superior performance over STABs, achieving 20% higher average load capacity at 0.1 eccentricity. Additionally, increasing eccentricity enhances static and dynamic pressure effects in both bearings. A larger groove width ratio decreases the throttling efficiency and dynamic pressure, with pressure dropping from 3.5 MPa (static) to 1.6 MPa, and 6.3 MPa (dynamic) to 1.7 MPa respectively, at 30,000 RPM. In contrast, the depth ratio of annular groove has only a minor impact on static and dynamic pressure effects. Full article

The EtherCAT fieldbus system is widely applied in different types of computerized numerical control (CNC) machine tools due to its outstanding communication performance. In the field of ultra-precision CNC, some machine tools employ controllers that integrate EtherCAT master functionality to achieve real-time communication with other devices; however, the open-source IgH EtherCAT master has rarely been applied to the CNC systems of ultra-precision machine tools. The feasibility of using the IgH EtherCAT master to meet the communication performance requirements of ultra-precision machine tools remains uncertain; therefore, it is necessary to validate the control effect on precision axes under the application of the IgH EtherCAT master. In this work, EtherCAT applications were developed on a personal computer (PC) to alter it to a bus-type controller with the IgH EtherCAT master function. To provide the EtherCAT master with real-time and accurate motion data of the axes, an interpolation algorithm tailored for control experiments was designed, and a G-code data processing method was proposed. Moreover, precision aerostatic linear axes and servo drivers were chosen as EtherCAT slaves for single-axis motion and dual-axis linkage control experiments. The experimental results showed that the motion controller based on IgH can effectively control the precision axes to execute ultra-precision linear and circular interpolation motion. Full article

To investigate the effect of recess structures on the static and dynamic performance of aerostatic thrust bearings and to explore superior designs, this study analyzes the load-capacity theoretical model, identifying that the throttling effect and pressure-holding effect of the recess are the key factors determining the bearings’ static performance. Computational fluid dynamics (CFD) was used to evaluate three types of recess structures: a simple-orifice recess (SOR), a rectangular-compound recess (RCR), and a bionic-compound recess (BCR). The results indicate that the BCR structure demonstrates efficient transmission performance by reducing flow resistance and diverting air, while ensuring a reasonable pressure drop as the radial ratio α_i changes. Additionally, the smaller air capacity of the BCR structure contributes to enhanced bearing stability, showing clear advantages in both static and dynamic performance. This research illustrates the practical application of bionics in mechanical design and provides new theoretical foundations and design strategies for improving aerostatic bearing performance. Full article