Search Results (30)

There have been numerous reported accidents of lightning strikes damaging wind turbine blades, which poses a serious problem. In certain accidents, the blades that were struck by lightning continued to rotate, resulting in breakage due to centrifugal force. Considering this background, wind turbines situated in Japan have been mandated to be equipped with emergency stop devices. Consequently, upon detection of a lightning strike by the device installed on the wind turbine, the turbine is promptly stopped. In order to restart the wind turbine, it is necessary to verify its soundness by conducting a visual inspection. However, conducting prompt inspections can be difficult due to various factors, including inclement weather. Therefore, this process prolongs the downtime of wind turbines and reduces their availability. In this study, an approach was proposed: a SCADA data analysis method using an autoencoder to assess the soundness of wind turbines without visual inspection. The present method selected wind speed and rotational speed as effective features, employing a sliding window for pre-processing, based on previous studies. Besides, the assessment of a trained autoencoder was conducted through the utilization of the confusion matrix and the receiver operating characteristic curve. It was suggested that the availability of wind turbines could be improved by employing this proposed method to remotely and automatically verify the soundness after lightning detection. Full article

This review investigates interlayer hybrid fiber composites for wind turbine blades (WTBs), focusing on their potential to enhance blade damage tolerance and maintain structural integrity. The objectives of this review are: (I) to assess the effect of different hybrid lay-up configurations on the damage tolerance and failure analysis of interlayer hybrid fiber composites and (II) to identify potential fiber combinations for WTBs to supplement or replace existing glass fibers. Our method involves comprehensive qualitative and quantitative analyses of the existing literature. Qualitatively, we assess the damage tolerance—with an emphasis on impact load—and failure analysis under blades operational load of six distinct hybrid lay-up configurations. Quantitatively, we compare tensile and flexural properties—essential for WTBs structural integrity—of hybrid and glass composites. The qualitative review reveals that placing high elongation (HE)-low stiffness (LS) fibers, e.g., glass, on the impacted side reduces damage size and improves residual properties of hybrid composites. Placing low elongation (LE)-high stiffness (HS) fibers, e.g., carbon, in middle layers, protects them during impact load and equips hybrid composites with mechanisms that delay failure under various load conditions. A sandwich lay-up with HE-LS fibers on the outermost and LE-HS fibers in the innermost layers provides the best balance between structural integrity and post-impact residual properties. This lay-up benefits from synergistic effects, including fiber bridging, enhanced buckling resistance, and the mitigation of LE-HS fiber breakage. Quantitatively, hybrid synthetic/natural composites demonstrate nearly a twofold improvement in mechanical properties compared to natural fiber composites. Negligible enhancement (typically 10%) is observed for hybrid synthetic/synthetic composites relative to synthetic fiber composites. Additionally, glass/carbon, glass/flax, and carbon/flax composites are potential alternatives to present glass laminates in WTBs. This review is novel as it is the first attempt to identify suitable interlayer hybrid fiber composites for WTBs. Full article

With the advancement of aero-engine thrust-to-weight ratios, turbine blades now incorporate complex hollow structures fabricated using ceramic cores. The emergence of light-curing 3D printing technology for ceramic cores offers a viable solution to producing such complex structural components. To avoid the breakage of the core when removing the support after the printing of the general paste, we used a rheological additive, organic bentonite, to prepare a light-curing 3D-printed silicon-based ceramic core paste that can allow for unsupported printing. This study pursues two primary research objectives: Firstly, the effect of organic bentonite on the rheological behavior and stability properties of silicon-based ceramic was investigated. Secondly, we conducted a comprehensive analysis of how organic bentonite modification influences the performance of silicon-based ceramics. The results show that, firstly, the addition of organic bentonite dramatically improves the rheology and stability of silicon-based ceramic paste, and that the optimal content is between 1 and 2 wt.% for the best effect. Second, after the primary sintering process (1250 °C), partial bentonite can produce a small amount of cordierite phase and promote the generation of cristobalite. The room-temperature performance of the ceramic core can be improved. However, organic bentonite, after secondary sintering at 1550 °C, completely forms cordierite and reduces the amount of square quartz produced. Then, it negatively affects the high-temperature performance of the ceramic core. Therefore, when the content of organic bentonite is 1 wt.%, the ceramic paste has superior rheology and stability, making unsupported printing possible. Our study revealed an apparent porosity of 32.43%, a bulk density of 1.64 g/cm³, a sintering shrinkage value of 2.94%, a room-temperature flexural strength of 24.7 MPa, a high-temperature (1550 °C) flexural strength of 10.1 MPa and a high-temperature deflection of 1.24 mm, which meet the requirements of core printing. Full article

In the rice-wheat system, using straw for soil incorporation provides better soil health and improves agricultural production. The experiment was performed in Babaiqiao town, Jiangsu Province, China’s Luhe District, Nanjing City, in June 2024 using a Shichao TG-500 tractor equipped with a Qingxuan 1GKN-180 rotary cultivator. The impacts of the three tillage practices, deep rotary tiller with straw (DRTS), shallow rotary tiller with straw (SRTS), and no-tillage with straw return (NTSR), on the level of soil disturbance were observed in the single-factor and two-factor interaction experiments. Based on the profilometry analysis, it was observed that DRTS had the highest value of soil disturbance while SRTS had a moderate disturbance value and NTSR minimized disturbance. The effects of working depths, forward speed, and rotation speed on the straw return rate have been evaluated by further investigations. The results showed that enhancing straw return rates was significantly impacted by changing the tilling depths and the rotation speeds, especially when using deeper tillage and moderate to high rotary speeds. The investigation found that the forward speed, blade rotation speed, and tillage depth explained the overall rates of straw return, soil breaking, and soil flatness. In the research, the response surface design employed was the Box–Behnken Design (BBD). The optimal operating parameters were 14.23 cm of plowing depth, 297.6 rpm for the rotary blades, and 3.23 km/h for forward speed. Achieved were the following parameters: 94.766% soil breakage rate, 84.97% straw return rates, and 16.36 mm soil flatness. The findings demonstrate the potential to implement strategies through operational parameters to significantly enhance agricultural practices. Full article

The Francis runner is a critical component of the Francis turbine generator unit, playing a central role in converting water energy into rotating mechanical energy that drives the generator in hydropower stations. In-depth analyses of the flow characteristics of the Francis runner under various operating conditions and avoiding fatigue damage of the Francis runner are crucial to the reliability and efficiency of hydropower operation. In this paper, the flow dynamics of a large Francis turbine runner are analyzed under three representative loading conditions—low partial load, high partial load, and full load—and the flow-induced stress of the runner is analyzed under these loading conditions. It was found that the maximum static and dynamics stresses of the runner at three representative loading conditions are located at the chamfered surface where the blade trailing edge connects to the runner crown. The maximum static stresses of the Francis runner are 284 MPa, 352 MPa, and 381 MPa at low partial load, high partial load, and full load, respectively, and they are above the allowable stress limits, as half of the yield stress of the runner material of 550 MPa. The peak-to-peak values of runner dynamic stress at low partial load, high partial load, and full load are 15 MPa, 25 MPa, and 14.6 MPa, respectively. The high stress invoked by the unsteady flow under various loading conditions in this runner was the cause of the fatigue breakage of the runner blades. The results of this investigation have important reference values for mitigating fatigue damage in similar Francis runners and optimizing unit operation. Full article

To achieve high-quality no-till seeding, a wing-shaped stubble-breaking device with excellent stubble-breaking performance was designed for maize stubble. A model of maize stubble was developed based on the Discrete Element Method (DEM) and verified through soil bin tests. The DEM model was used to optimize the design parameters of the device and to investigate the interaction between the blades and the maize stubble during the stubble-breaking process. Field experiments were conducted to evaluate the performance of the device. The results indicated that the DEM model was accurate; when the optimal design parameters of the wing-shaped stubble-breaking device were a 37° slide cutting angle, 31° pitching angle, and 50 mm wing width, the average torque was 41.26 N·m, the soil breakage rate was 85.68%, and the soil backfill rate was 71.65%; the wing-shaped stubble-breaking device could separate the inside and outside of the strip tillage area and cut maize stubbles and soil blocks twice, thus having excellent stubble-breaking performance. This study provided an effective and feasible method for designing stubble-breaking devices and studying the interaction between blades, soil, and roots, which improved soil tillage theory and was beneficial in promoting conservation tillage technology. Full article

In 2019, more than 16% of the globe’s total production of electricity was provided by hydroelectric power plants. The core of a typical hydroelectric power plant is the turbine. Turbines are subjected to high levels of pressure, vibration, high temperatures, and air gaps as water passes through them. Turbine blades weighing several tons break due to this surge, a tragic accident because of the massive damage they cause. This research aims to develop predictive models to accurately predict the status of hydroelectric power plants based on real stored data for all factors affecting the status of these plants. The importance of having a typical predictive model for the future status of these plants lies in avoiding turbine blade breakage and catastrophic accidents in power plants and the resulting damages, increasing the life of these plants, avoiding sudden shutdowns, and ensuring stability in the generation of electrical energy. In this study, artificial neural network algorithms (RNN and LSTM) are used to predict the condition of the hydropower station, identify the fault before it occurs, and avoid it. After testing, the LSTM algorithm achieved the greatest results with regard to the highest accuracy and least error. According to the findings, the LSTM model attained an accuracy of 99.55%, a mean square error (MSE) of 0.0072, and a mean absolute error (MAE) of 0.0053. Full article

To address the significant cutting resistance and fracture susceptibility of rotary blades, an innovative blade design was conceived to minimize resistance and enhance fracture resistance. By analyzing the interaction between the blade, soil, and root systems, an optimized design for the blade structure’s breakage resistance was developed. The theory of eccentric circular side cutting edges was applied to redesign the curve of the side cutting edge, and kinematic analysis was conducted to determine the optimal edge angle (26.57°). A flexible body model of corn residues was established, and cutting resistance measurements indicated a 15.1% reduction in cutting resistance. The breakage resistance of the rotary blade was validated using a discrete element method–finite element method (DEM–FEM) coupling approach. The results demonstrated the following: neck stress (−16.85%), specific strength efficiency (+9.72%), specific stiffness efficiency (+9.78%), fatigue life (+39.08%), and ultimate fracture stress (+20.16%), thereby meeting the design objectives. The comparison between field trial results and simulation data showed an error rate (<5%), confirming the simulation test’s feasibility. These findings provide theoretical references for reducing cutting resistance and enhancing breakage resistance in rotary blades. Full article

Taking a four-stage transonic compressor as the research object, the Lagrange particle tracking method was used to simulate the multiphase flow by considering the particle fragmentation, collision and evaporation models, and the influence of different inlet conditions (raindrop diameter, velocity, temperature and flow rate) on the compressor’s performance and stable working range was studied. The results show that inlet rain absorption can weaken the clearance leakage vortex make the shock wave move downstream, thus increasing the inlet flow rate, resulting in a decrease in stability margin and the highest efficiency point moving in the direction of flow increase. With the decrease in raindrop diameter, the pressure ratio and wet compression efficiency increase, and the stability margin decreases. With the increase in inlet raindrop velocity, the degree of pneumatic breakage increases and the raindrop diameter becomes smaller, which leads to the decrease in pressure ratio and efficiency. The influence of the mass flow rate of imported raindrops on the stable working range is significant. When the mass flow rate of imported raindrops accounts for 5% of the design flow, the stable working range can be reduced by more than half. Rain absorption increases the reaction force of the compressor and increases the load of the rotor blade. Full article

Silicon carbide particle-reinforced aluminum matrix (SiCp/Al) composites are significant lightweight metal matrix composites extensively utilized in precision instruments and aerospace sectors. Nevertheless, the inclusion of rigid SiC particles exacerbates tool wear in mechanical machining, resulting in a decline in the quality of surface finishes. This work undertakes a comprehensive investigation into the problem of tool wear in SiCp/Al composite materials throughout the machining process. Initially, a comprehensive investigation was conducted to analyze the effects of cutting velocity v_c, feed per tooth f_z, milling depth a_p, and milling width a_e on tool wear during high-speed milling under SCCO₂-MQL (Supercritical Carbon Dioxide Minimum Quantity Lubrication) ultrasonic vibration conditions. The results show that under the condition of SCCO₂-MQL ultrasonic vibration, proper control of milling parameters can significantly reduce tool wear, extend tool service life, improve machining quality, and effectively reduce blade breakage and spalling damage to the tool, reduce abrasive wear and adhesive wear, and thus significantly improve the durability of the tool. Furthermore, a prediction model for tool wear was developed by employing the orthogonal test method and multiple linear regression. The model’s relevance and accuracy were confirmed using F-tests and t-tests. The results show that the model can effectively predict tool wear, among which cutting velocity v_c and feed rate f_z are the key parameters affecting the prediction accuracy. Finally, a genetic algorithm was used to optimize the milling parameters, and the optimal parameter combination (v_c = 60.00 m/min, f_z = 0.08 mm/z, a_p = 0.20 mm) was determined, and the optimized milling parameters were tested. Empirical findings suggest that the careful selection of milling parameters can significantly mitigate tool wear, extend the lifespan of the tool, and enhance the quality of the surface. This work serves as a significant point of reference for the processing of SiCp/Al composite materials. Full article

This study aimed to develop a practical semi-mechanistic modeling framework to predict particle size evolution during wet bead milling of pharmaceutical nanosuspensions over a wide range of process conditions and milling scales. The model incorporates process parameters, formulation parameters, and equipment-specific parameters such as rotor speed, bead type, bead size, bead loading, active pharmaceutical ingredient (API) mass, temperature, API loading, maximum bead volume, blade diameter, distance between blade and wall, and an efficiency parameter. The characteristic particle size quantiles, i.e., x₁₀, x₅₀, and x₉₀, were transformed to obtain a linear relationship with time, while the general functional form of the apparent breakage rate constant of this relationship was derived based on three models with different complexity levels. Model A, the most complex and general model, was derived directly from microhydrodynamics. Model B is a simpler model based on a power-law function of process parameters. Model C is the simplest model, which is the pre-calibrated version of Model B based on data collected from different mills across scales, formulations, and drug products. Being simple and computationally convenient, Model C is expected to reduce the amount of experimentation needed to develop and optimize the wet bead milling process and streamline scale-up and/or scale-out. Full article

The study presented in this paper was undertaken in response to two instances of unexpected blade breakage in the cutting blade used in a Carton Wrap machine (CW). Failure of the Al7075 alloy blade occurred at an indentation during typical operational loading conditions. Subsequent metallographic examinations of the fractured samples confirmed that both cases were attributed to fatigue failure. The main objective of this study is to investigate potential causes of fatigue failure in the CW blade using simplified linear elastic static numerical simulations through Finite Element Analysis (FEA). In this research, we employed the well-established Theory of Critical Distance (TCD), and this case study provided a contextualization at an industrial level. Furthermore, the analysis focused on a second key aspect: proposing a new blade geometry aimed at mitigating the identified issues and eliminating possible causes of failure. In this context, the actual stress concentration at the indentation was determined using the TCD with Line Method (LM). The results from the numerical simulations indicated that the new blade geometry significantly reduced stress concentration, resulting in a risk factor reduction of approximately four compared to the original blade design, even under non-optimal operating conditions. Overall, in conjunction with simple linear static FEA, the proposed numerical approach provided substantial support for designers, especially in fault analysis and when comparing different industrial solutions. Full article

A military helicopter is easily attacked by bullets in a battlefield environment. The composite blade is the main lifting surface and control surface of the helicopter. Its ballistic performance directly determines the vulnerability and survivability of the helicopter in the battlefield environment. To study the ballistic performance of the composite helicopter blade, the damage characteristics of the impacted composite rotor blade are obtained by experiments. A numerical simulation model is established by applying Abaqus software to predict the blade ballistic damage. The three-dimensional progressive damage failure model is used to analyze the ballistic damage under the experimental conditions. The effectiveness and accuracy of the numerical simulation model are verified through a comparison with the experimental results. The ballistic damage of composite blades under three experimental conditions was investigated. The results show that the ballistic damage type of composite blade mainly includes delamination, fiber breakage, and foam collapse. The damage to the composite material at the position of bullet incidence is mainly local shear fracture, while the damage to the composite material at the exit position is mainly fiber tensile fracture. The ballistic damage size of the composite blade is closely related to the ballistic position, incident angle, and structure characteristics along the ballistic path. The larger the incident angle, the smaller the ballistic damage size of the blade. The greater the structural stiffness of the structure near the exit, the greater the damage size of the exit. The numerical simulation model presented in this paper can provide a reference for research on the ballistic performance of composite helicopter blades. Full article

The precise identification of faults in centrifugal pumps is crucial for ensuring their safe and stable operation, given their significance as vital industrial equipment. This article aims to rigorously examine and analyze the flow characteristics of centrifugal pumps under two specific conditions: normal blade operation and a single blade breakage fault. Through systematic comparison and in-depth study, this article sheds light on distinguishing flow patterns exhibited by these pumps under both normal and fault scenarios. Utilizing validated numerical simulation methods, a thorough analysis is conducted to explore the flow condition and energy characteristics of the impeller channel following the breakage of a single blade. Additionally, the article investigates changes in the pressure pulsation characteristics of the pump volute as a result. The numerical simulation results reveal that the head of the centrifugal pump decreases at all flow points when a single blade breaks. However, there is no significant change in efficiency at small flow points. As the flow rate exceeds 0.9Q_d, efficiency experiences a substantial decrease. Furthermore, the efficiency decline becomes even more pronounced as the flow rate continues to increase. At 1.5Q_d, efficiency plummets by 14.33%. The flow pattern undergoes significant changes as well. The breakage of the blade induces noteworthy secondary flow in adjacent impeller channels, resulting in heightened turbulence dissipation. Additionally, it was observed that blade fracture causes alterations in the main frequency of pressure pulsation within the volute. This is characterized by an increase in shaft passing frequency and a decrease in blade passing frequency. Notably, near the tongue monitoring point, the shaft frequency escalates by over 20 times. Full article

To study the influence law of the overburden rotating plate mechanism on the fragmentation and separation of potato soil agglomerates, a single-factor test and a response surface test simulation analysis of the soil fragmentation process were conducted in EDEM 2022 software. The results of the single-factor test show that the triangular rack blade of the overburdened rotating plate mechanism has the best effect on soil fragmentation and separation. With the increase in the lower blade speed, the upper lift chain bar line speed, and the tilt angle of the mechanism, the effect on the fragmentation and separation of potato soil agglomerates decreases. The response surface test results show that the debris removal rate decreases with the increase in blade speed and tilt angle, the percentage of bond breakage between potato soil particles declines with the rise of blade speed and lift chain bar line speed, and the percentage of bond breakage between soil particles increases with the increase in blade speed and lift chain bar line speed. The optimal solution was obtained by using the optimization function in Design-Expert 13 software, which was adjusted as follows: the blade rack type was triangular, the lift chain bar line speed was 0.307 m/s, the blade speed was 0.4 m/s, and the tilt angle was 40°. The research methods and results provide a reference for the simulation of potato soil crushing and separation motion in a sandy loam soil cultivation area. Full article