Search Results (325)

Complex mechanical systems, such as agricultural combine harvesters, are subjected to dynamic excitations from multiple coupled sources, compromising structural integrity and operational reliability. Disentangling these vibrations to identify dominant sources and quantify their transmission paths remains a significant engineering challenge. This study proposes a robust diagnostic framework to address this issue. We employed a multi-condition vibration test with sequential source activation and an improved Operational Transfer Path Analysis (OTPA) method. Applied to a harvester chassis, the results revealed that vibration energy is predominantly concentrated in the 0–200 Hz frequency band. Path contribution analysis quantified that the “cutting header → conveyor trough → hydraulic cylinder → chassis frame” path is the most critical contributor to vertical vibration, with a vibration acceleration level of 117.6 dB. Further analysis identified the engine (29.3 Hz) as the primary source for vertical vibration, while lateral vibration was mainly attributed to a coupled resonance between the threshing cylinder (58 Hz) and the engine’s second-order harmonic. This study’s theoretical contribution lies in validating a powerful methodology for vibration source apportionment in complex systems. Practically, the findings provide direct, actionable insights for targeted structural optimization and vibration suppression. Full article

The paper provides an analysis of the energy efficiency of the swing drive system of hydraulic excavators, which integrally includes a hydraulic motor and a planetary reducer. The indicator of the drive’s energy efficiency is determined based on the efficiency of the hydraulic motor and the planetary reducer. The efficiency of the hydraulic motor is defined as a function of the specific flow, pressure, and the number of revolutions of the hydraulic motor. The efficiency of the reducer is determined using structural analysis of planetary gearboxes and the moment method. As an example, the results of a comparative analysis of the energy efficiency of the swing drive of a tracked hydraulic excavator, weighing 16,000 kg and having a bucket volume of 0.6 m³, are presented. From the set of possible generated variant solutions of the drive, obtained through the synthesis process based on the required torque and platform rotation speed, two extreme drive variants were selected for the analysis. In the first configuration, a hydraulic motor characterized by a low specific flow is combined with a three-stage reduction gear featuring a higher overall transmission ratio, whereas the second configuration integrates a high-specific-flow hydraulic motor with a two-stage reduction gear of a lower transmission ratio. The obtained results of the comparative analysis of the drive’s energy efficiency are presented depending on the change in the required torque and the rotational speed of the platform. Full article

As the core component of modern mechanical transmission, the precision rotary motion mechanism and its drive system have wide applications in aerospace, robotics, and other fields. This article systematically reviews the design principles, performance characteristics, and research progress of various rotational motion mechanisms and their driving technologies. The working principles, advantages, disadvantages, and applicable scenarios of gears, drive belts, sprockets, camshafts, ratchet claw mechanisms, and linkage mechanisms were analyzed in terms of traditional mechanisms. In terms of new mechanisms, we focused on exploring the innovative design and application potential of intermittent indexing mechanisms, magnetic gears, 3D-printed spherical gears, and multi-link mechanisms. In addition, the paper compared the performance differences of electric, hydraulic, pneumatic, and piezoelectric drive methods. Research has shown that through material innovation, structural optimization, and intelligent control, there is still significant room for improvement in the load capacity, accuracy, and reliability of precision rotary motion mechanisms, providing theoretical support and practical reference for innovative design and engineering applications of future mechanical transmission technologies. Full article

The work presented in this paper discusses the steps taken to design, implement, and test a mechatronic test stand that uses historical wind power data to generate thermal power that could be used by small-to-medium consumers. The work also pertains to usage in areas where large wind turbines could not be installed due to space restrictions, such as highly populated areas. A rotor flux control (RFC) speed-controlled 2.2 kW AC motor was used to simulate the action of a wind turbine on a 6 cm³ hydraulic pump. The setup allows for a small form factor and a much lighter turbine to be installed. The paper describes the schematic, installation, usage, and initial results obtained using a hydraulic test stand developed by the authors. The initial work allowed us to obtain different temperatures of the hydraulic oil, up to 60 °C, over a period of 30 min, for various pressures and flow rates, thus confirming that the system is functional overall. Further work will elaborate on the effect of different wind patterns on the setup, as well as provide an in-depth study on a use case for the system. Full article

An electro-hydraulic servo system based on network control technology has the advantages of remote control, modularisation, and resource sharing. However, the electro-hydraulic servo system itself has the characteristics of strong nonlinearity and parameter uncertainty, combined with the limited communication bandwidth of the network control system, which leads to a poor control effect and limits its application. To solve the above problems, an event-triggered mechanism is introduced to filter redundant data and conserve the communication bandwidth, while a backstepping sliding mode control strategy integrating this event-triggered mechanism with a jamming observer is proposed. A model-based disturbance observer is designed to mitigate external interference effects on system control performance while enhancing robustness and disturbance response capabilities. The global stability of the closed-loop system is analysed using Lyapunov stability theory. The experimental results show that the system displacement tracking error of the controller designed in this paper can reach ±0.001 rad, and the system can reach stability in about 0.5 s. At the same time, it can significantly reduce the amount of data transmission, which effectively solves the problem of the network bandwidth limitation. Full article

This paper presents a comparison of some different configurations of electro-hydrostatic actuators (EHA). The gear pump EHA has a simpler mechanical configuration, but the electronic power command circuits and the electric motor are in high demand due to the very frequent speed variations. The variable piston pump EHA has a more complicated mechanical configuration, but the electronic power command circuits and the main electric motor are less loaded due to the constant speed of the electric motor. The variable displacement pump control can be made either using an electric motor and mechanical transmission, or an additional hydraulic circuit, to modify the swash plate angle. In total, four EHA configurations are studied in this paper (one with a gear pump and three with variable axial piston pumps). The paper aims to advantages and disadvantages of each type of EHA, using numerical simulations. Full article

A continuously variable transmission can improve the energy efficiency of actuators with rotary output by providing an optimum transmission ratio. A continuously variable transmission based on circumferentially arranged disks (CAD CVT) is a new type of CVT that is highly beneficial for applications requiring large torques, like heavy road transport. However, its major drawback is that its efficiency drops in the low torque region. To overcome this problem, the current paper proposes an improved mechanical design in which the force on traction disks is changed according to the instantaneous torque requirement, thus resulting in improved efficiency in low torque regions. Furthermore, a hydraulic-actuation-based control system has been designed to ensure the optimum control of the improved mechanical design. The improved mechanical design of the CAD CVT is named CAD CVT-II, which is highly beneficial for variable torque applications such as road transport and wind turbines. Full article

Hydrostatic transmissions are essential in applications demanding variable torque and speed, such as mining and agricultural machinery, due to their compact design, high power-to-weight ratio, and efficient variable speed control. Despite these advantages, their inherent nonlinearities and susceptibility to parametric uncertainties pose significant challenges for precise motion control. This study presents a comparative analysis of classical PID and robust H-infinity controllers for regulating the speed of hydraulic motors under varying torsional loads. A linearized uncertain system model is developed using upper Linear Fractional Transformations (LFTs) to capture key parametric uncertainties. A simplified H-infinity controller is designed to robustly manage system dynamics, particularly addressing phase lags induced by uncertain loads. Simulation results demonstrate that the H-infinity controller offers superior performance over the PID controller in terms of stability, disturbance rejection, and robustness to load fluctuations. This work contributes a practically viable robust control solution for improving the reliability and precision of electro-hydraulic systems, particularly in demanding, real-world environments. Full article

TRIP duplex stainless steels, characterized by high strength and high plasticity, can achieve light-weighting and contribute to reducing fuel consumption and emissions. To further promote the development and application of lightweight metastable duplex stainless steels, the martensitic transformation and the microscopic mechanism of Mn-N alloyed TRIP duplex stainless steel under cyclic loading were investigated. An in situ measurement platform for martensitic transformation under cyclic loading was constructed using an INSTRON 8801 series servo-hydraulic testing machine (Shanghai Instron Test Equipment Trading Co., Ltd., Shanghai, China) and an FMP30 ferrite measuring instrument (Nantong Fischer Testing Instrument Co., Ltd., Nantong, China). The volume fraction of martensitic transformation under symmetrical cyclic loading for different cycles, with strain amplitudes of 0.5%, 0.7%, 0.9%, 1.1%, and 1.3%, was measured. The transformation law of martensite under cyclic loading was analyzed, and a kinetics model for martensitic transformation under cyclic loading was established. Furthermore, the martensitic transformation law, the influence of austenite grain orientation on martensitic transformation, and the microscopic mechanism of martensitic transformation under cyclic loading were analyzed by means of electron back-scattering diffraction (EBSD) and transmission electron microscopy (TEM). Full article

In this paper, a double-mode self-calibration tension system is proposed, which adopts the conversion of hydraulic meter tension and the monitoring of standard force sensors. According to the material characteristics of the jack and the viscosity and temperature characteristics of the hydraulic oil, the differential model of heat conduction in the hydraulic cylinder and the mathematical model of oil film friction heat generation are established, and the internal thermodynamic characteristics of the jack are theoretically analyzed, which provides theoretical support for the temperature compensation of the hydraulic oil pressure gauge of the jack. A simulation analysis was conducted on the thermodynamic characteristics of the hydraulic jack, and the distribution patterns of the temperature field, thermal stress field, and thermal strain field inside the hydraulic cylinder during normal operation were determined by measuring the temperature changes in five different parts of the jack at different times (t = 200 s, 2600 s, 5000 s, 7400 s, and 10,000 s). For the issue of heat generation due to oil film friction in the hydraulic jack, a simulation calculation model is developed by integrating Computational Fluid Dynamics (CFD) techniques with dynamic grid and slip grid methods. By simulating and analyzing frictional heating under conditions where the inlet pressures are 0.1 MPa, 0.3 MPa, 0.5 MPa, 0.7 MPa, and 0.9 MPa, respectively, we can obtain the temperature distribution on the jack, determine the frictional resistance, and subsequently conduct a theoretical analysis of the simulation results. Using the high-precision standard force sensor after data processing and the hydraulic oil gauge after temperature compensation, the online self-calibration of the tensioning system is carried out, and the regression equation of the tensioning system under different oil temperatures is obtained. The double-mode self-calibration tensioning system with temperature compensation is used to verify the compensation accuracy of the proposed double-mode self-calibration tensioning system. Full article

Reducing the water content in soft soil is crucial for improving its load-bearing capacity. However, traditional vacuum preloading demonstrates limited effectiveness for dredged sludge due to its high water content and low permeability, resulting in inadequate consolidation and long treatment durations. To address these limitations, this study proposes a new improvement approach that combines pressurized air injection with a polyacrylamide (PAM) addition to enhance vacuum consolidation. Experimental results demonstrated that cationic polyacrylamide (CPAM) exhibited superior performance in improving water discharge efficiency, which promoted the aggregation of fine soil particles and reduced the clogging of drainage channels through adsorption bridging. The incorporation of pressurized air injection further enhanced consolidation efficiency by increasing hydraulic gradients and inducing micro-fractures in soil, thereby improving soil permeability and vacuum pressure transmission. However, excessive CPAM addition or high-pressure air injection was found to compromise the effectiveness of the vacuum preloading treatment due to drainage channel clogging and extensive soil fracturing. The appropriate consolidation performance was achieved with a 0.075% CPAM addition and 20 kPa air pressure injection, demonstrating a 24.5% increase in water discharge mass and a 30.9% improvement in soil shear strength compared to traditional methods. Microstructural analysis revealed a more compacted soil matrix with reduced porosity and enhanced interparticle interactions. These findings provide valuable insights for improving the treatment efficiency of dredged sludge in coastal regions, particularly in the Nansha District of Guangzhou. Full article

The Bi-directional Evolutionary Structural Optimization (BESO) method, owing to its algorithmic simplicity and strong scalability, has emerged as one of the most prevalent topology optimization methodologies in current research and industrial applications. To overcome the limitations of existing commercial finite element software (e.g., ABAQUS), particularly regarding the closed architecture of topology optimization modules and low efficiency in 3D complex structure optimization, this study proposes an ABAQUS–MATLAB cooperative framework. This innovative approach implements direct read/write operations via Python scripts on CAE/ODB model databases, coupled with MATLAB-based master control programs for sensitivity analysis, mesh filtering, and design variable updating. Compared with conventional integration methods employing INP/FIL file interactions, the proposed framework reduces computational time through MATLAB’s advanced matrix operations while maintaining solution accuracy. Validation cases including 2D cantilever beams and 3D wheel hubs demonstrate the method’s precision and computational efficiency. Practical applications in lightweight design of a hydraulic transmission test bench adapter support achieved 31% volume reduction while satisfying strength and stiffness requirements, significantly lowering material costs. The developed cooperative framework provides an extensible solution for high-efficiency topology optimization of complex engineering structures, balancing algorithmic transparency with practical applicability. Full article

This study presents a novel approach that integrates the Kalman filter and genetic algorithms to obtain the hydraulic parameters of a confined aquifer with precision, eliminating noise that is not normally considered in traditional procedures; these parameters are necessary for the design of wells, the calculation of water balances and the numerical modeling of aquifers. The Theis solution for horizontal radial groundwater flow to an extraction well within a confined aquifer is implemented in the Kalman filter to calibrate the hydraulic transmissivity and the storage coefficient, minimizing the differences between drawdown estimates and the Theis solution by means of genetic algorithms. The estimate error variances provided by the method allowed for the quantification of an approximate average drawdown measurement error of 0.12 m and 0.02 m, respectively, during the execution of two pumping tests. Full article

The use of supercritical carbon dioxide (SC-CO₂) coiled tubing drilling technology for developing heavy oil and other special reservoirs offers significant advantages, including non-pollution of oil layers, prevention of clay swelling, avoidance of reservoir damage, compact footprint, and enhanced oil recovery, making it a highly promising innovative drilling technology. The thermo-hydraulic coupling characteristics of SC-CO₂ in helical coiled tubes are critical to the design of SC-CO₂ coiled tubing drilling systems. However, existing models often neglect thermal conduction, variable thermophysical properties, and friction-compression coupling effects, leading to significant deviations in the prediction of temperature and pressure variations. Considering heat transmission and fluid dynamics, a coiled tube heat-transfer model which considers varying properties of both pressure and temperature has been developed based on an optimized convective heat-transfer coefficient. Then, the physical parameters of the carbon dioxide in the helical coiled tubing were researched. Results indicated that the temperature change of carbon dioxide in helical coiled tubing was small due to the low temperature difference between the carbon dioxide and the air as well as the existence of an air interlayer and low natural convective heat-transfer efficiency. The drop in pressure of the carbon dioxide increased with increasing coiled tubing length, and the pressure was half that of the conventional drilling fluid in the same condition due to its low viscosity. The density of carbon dioxide in the helical coiled tubing changed from 1078 kg/m³ to 1047 kg/m³ with increasing coiled tubing length under the conditions stated herein, and the carbon dioxide remained liquid throughout the whole process. Full article

The hydraulic energy storage component (HESC) is the core component of hydraulic energy regeneration (HER) technologies in construction equipment, directly influencing the overall energy efficiency of the system. However, under complex practical operating conditions, the performance of traditional HESCs has become a critical factor limiting the broader application of HER technologies. This paper proposes a novel hydraulic energy storage component (NHESC) that integrates hybrid energy storage through the use of compressed air and electric energy. The system configuration of the NHESC is first designed, followed by the modeling of key components and analysis of working states. Second, based on the working state of energy absorption and release in the NHESC, a corresponding determination strategy is formulated. Third, a simulation model of the boom potential energy regeneration (PER) system based on the NHESC is developed, with partial experimental validation to verify its reliability. Finally, the recovery, reuse, and regeneration efficiencies in state pair B-E of the NHESC mode and the accumulator mode are compared, followed by an analysis of energy losses in the hydraulic components. The analysis results, based on simulation, indicate that the regeneration efficiency of the NHESC is 55.1%, which is better than the 41.1% of the traditional hydraulic accumulator. The NHESC combines the advantages of compressed gas energy storage and electric energy storage, effectively resolving issues of passive operation and uncontrollability while demonstrating superior energy regeneration capabilities. Full article