Search Results (63)

The use of aerial robots for inspection and maintenance in industrial settings demands high maneuverability, precise control, and reliable measurements. This study explores the development of a fully customized unmanned aerial manipulator (UAM), composed of a tilting drone and an articulated robotic arm, designed to perform non-destructive in-contact inspections of iron structures. The system is intended to operate in complex and potentially hazardous environments, where autonomous execution is supported by shared-control strategies that include human supervision. A parallel force–impedance control framework is implemented to enable smooth and repeatable contact between a sensor for ultrasonic testing (UT) and the inspected surface. During interaction, the arm applies a controlled push to create a vacuum seal, allowing accurate thickness measurements. The control strategy is validated through repeated trials in both indoor and outdoor scenarios, demonstrating consistency and robustness. The paper also addresses the mechanical and control integration of the complex robotic system, highlighting the challenges and solutions in achieving a responsive and reliable aerial platform. The combination of semi-autonomous control and human-in-the-loop operation significantly improves the effectiveness of inspection tasks in hard-to-reach environments, enhancing both human safety and task performance. Full article

Aimed at hydrogen turbines, this research employs advanced noncontact cylindrical sealing and optimizes its sealing structure to enhance efficiency. Therefore, this paper considers the variable density and viscosity cylindrical sealing model with actual gas effects and explores the impact of groove parameters on load capacity, leakage, and friction force under two different temperature and pressure conditions. A multivariate linear regression analysis model is established. Subsequently, the NSGAII algorithm is used to perform multi-objective optimization design under operational conditions. The TOPSIS methods are applied to select the optimal parameters. This study shows that the groove depth of the spiral groove has the most significant impact on sealing performance when the groove depth is 2 μm. Full article

Labyrinth seals, extensively used in aerospace and turbomachinery as non-contact sealing devices, undergo accelerated wear and enhanced leakage due to repeated rub-impact between rotating shafts and sealing rings. To address the problem of increased leakage under rub-impact conditions, this research integrates experimental and numerical methods to investigate the deformation mechanisms and leakage characteristics of thermoplastic labyrinth seals. A custom designed rub-impact test rig was constructed to measure dynamic forces and validate finite element analysis (FEA) models with an error of 5.1% in predicting tooth height under mild interference (0.25 mm). Computational fluid dynamics (CFD) simulations further demonstrated that thermoplastic materials, such as PAI and PEEK, displayed superior resilience (with rebound ratios of 57% and 70.3%, respectively). Their post-impact clearances were 4.8–18.3% smaller than those of PTFE and F500. Leakage rates were predominantly correlated with interference, causing a substantial increase compared to the original state; at 0.25 mm interference (reverse flow), increases ranged from 151% (PAI) to 217% (PTFE), highlighting material-dependent performance degradation. Meanwhile, tooth orientation modulated leakage by 0.5–3% through the vena contracta effect. Based on these insights, two optimized inclined-tooth geometries were designed, reducing leakage by 28.2% (Opt1) and 28.1% (Opt2) under rub-impact. These findings contribute to the development of high-performance labyrinth seals suitable for extreme operational environments. Full article

In recent years, underground hydrogen storage (UHS) has become a hot topic in the field of deep energy storage. Green hydrogen, produced using surplus electricity during peak production, can be injected and stored in underground reservoirs and extracted during periods of high demand. A profound understanding of the mechanisms of the gas–water two-phase flow at the pore scale is of great significance for evaluating the sealing integrity of UHS reservoirs and optimizing injection, as well as the storage space. The pore structure of rocks, as the storage space and flow channels for fluids, has a significant impact on fluid injection, production, and storage processes. This paper systematically summarizes the methods for characterizing the micro-pore structure of reservoir rocks. The applicability of different techniques was evaluated and compared. A detailed comparative analysis was made of the advantages and disadvantages of various numerical simulation methods in tracking two-phase flow interfaces, along with an assessment of their suitability. Subsequently, the microscopic visualization seepage experimental techniques, including microfluidics, NMR-based, and CT scanning-based methods, were reviewed and discussed in terms of the microscopic dynamic mechanisms of complex fluid transport behaviors. Due to the high resolution, non-contact, and non-destructive, as well as the scalable in situ high-temperature and high-pressure experimental conditions, CT scanning-based visualization technology has received increasing attention. The research presented in this paper can provide theoretical guidance for further understanding the characterization of the micro-pore structure of reservoir rocks and the mechanisms of two-phase flow at the pore scale. Full article

Addressing the challenge of manual dependency and the difficulty in automating the online detection of height discrepancies following engine oil seal assembly, this paper proposes a composite vision-based method for the post-assembly size inspection of engine oil seals. The proposed method enables non-contact, online three-dimensional measurement of oil seals already installed on the engine. To achieve accurate positioning of the inner and outer ring regions of the oil seals, the process begins with obtaining the center point and the major and minor axes through ellipse fitting, which is performed using progressive template matching and the least squares method. After scaling the ellipse along its axes, the preprocessed image is segmented using the peak–valley thresholding method to generate an annular ROI (region of interest) mask, thereby reducing the complexity of the image. By integrating three-frequency four-step phase-shifting profilometry with an improved RANSAC (random sample consensus)-based plane fitting algorithm, the height difference between the inner and outer rings as well as the press-in depth are accurately calculated, effectively eliminating interference from non-target regions. Experimental results demonstrate that the proposed method significantly outperforms traditional manual measurement in terms of speed, with the relative deviations of the height difference and press-in depth confined within 0.33% and 1.45%, respectively, and a detection success rate of 96.35% over 1415 samples. Compared with existing methods, the proposed approach not only enhances detection accuracy and efficiency but also provides a practical and reliable solution for real-time monitoring of engine oil seal assembly dimensions, highlighting its substantial industrial application potential. Full article

In the cold chamber high pressure die casting process (CC-HPDC) for light alloys, the piston lubricants play a key role in protecting the piston tip from wearing and ensure adequate seal with the shot sleeve. However, during the production process, the pouring of overheated aluminum alloy melt into the shot sleeve would lead to evaporation and burning of the lubricants once in contact with the piston tip. The burning products, however, would form gas and non-metallic inclusions in the melt which would be transported and injected into the die area and finally trapped in the castings, all of which would affect the mechanical properties of the as-cast samples and deteriorate the product quality. To further investigate this issue, a pilot scale HPDC machine is used and the lubricant burning issue is studied based on material characterization and numerical modelling. The chemical composition, size, and morphology of the burned products are observed using scanning electron microscope (SEM) and energy dispersive spectrometer (EDS). In order to better explore the issue of lubricant combustion discovered in the experiment, a finite element model describing the entire HPDC process is established and the burning, motion, and trapping of the lubricant are calculated. The final distribution of the burned products such as gas and non-metallic inclusions are predicted and their influence on final solidification quality of the as-cast products under various process parameters are analyzed qualitatively. Finally, a slow shot velocity range of 0.4–0.6 m/s and an acceleration profile that ramps up to 0.3 m/s over 0–370 mm of the shot sleeve proved to be the most effective in reducing air entrainment and oxide inclusions to alleviate the burning of lubricant on final product quality. Full article

This paper reviews the current state of dynamic sealing technologies, examining the challenges faced by conventional sealing methods under complex working conditions, such as high temperature, high pressure, and corrosive environments. It also provides a concise overview of the status and developmental trends in sealing inspection technologies. From the perspective of obstruction mechanisms, this study reinterprets the concept of sealing science by redefining the classification of sealing types based on solid-phase medium obstruction, fluid hydrostatic and hydrodynamic obstruction, fluid pumping obstruction, fluid energy dissipation obstruction, and fluid impact obstruction. Comparative analyses of sealing structures across these obstruction mechanisms are presented. The sealing technology based on fluid impact medium obstruction, newly proposed by this paper, represents an innovative sealing approach. It offers distinct advantages such as zero wear, structural simplicity, and high stability, addressing longstanding issues in high-speed, large-clearance non-contact seals, including low leakage suppression efficiency, system complexity, and poor stability. Since its introduction, this novel sealing structure has garnered significant attention and recognition from both the academic and industrial sealing communities. With the potential to revolutionize the field, this groundbreaking sealing design is poised to lead the next wave of technological advancements in sealing science. Full article

Current designs of sealing systems for non-adhesive flexible pipe end-fittings primarily address short-term loading conditions, often overlooking the creep behavior of polyvinylidene fluoride (PVDF) and the material used in the sealing layer. Over time, the creep of PVDF, particularly at elevated temperatures, can lead to excessive reduction in the sealing layer’s thickness, thereby compromising the sealing performance of the end-fittings. In this study, to address the creep-related issues in the sealing layer, the compression and compression creep tests of PVDF were conducted at different temperatures to establish the material’s elastic-plastic constitutive relationship and develop a creep constitutive model based on the time hardening model. Using the pressure penetration method within ABAQUS software, a two-dimensional axisymmetric finite element model of the end-fitting sealing system was constructed, incorporating the effects of internal fluid pressure. This model was employed to analyze the sealing performance while accounting for the materials’ creep behavior across varying temperature conditions. The results demonstrate that creep in the sealing layer occurs predominantly in the early stages post-installation. Furthermore, the API 17J standard, which stipulates that reduction in sealing layer thickness should not exceed 30%, is found to be conservative at high temperatures. In these conditions, although the thickness reduction exceeds 30% before the maximum contact pressure drops below the fluid pressure, no fluid leakage is observed. Thus, in the initial phase following installation, especially at elevated temperatures, monitoring for potential leakage is critical. This research is the first to quantify the long-term impact of PVDF creep behavior on the sealing performance of flexible pipe end-fittings through comprehensive experiments and simulation analysis. The findings provide both a theoretical foundation and practical guidance for enhancing the long-term sealing performance of flexible pipe end-fittings. Full article

In hydraulics, threaded plugs are used to close various manufacturing holes and other fluid channels. They are preloaded to ensure sufficient sealing force. Since the range of recommended thread and underhead friction coefficients for preloaded threaded connections in the literature is very wide, they are not suitable for accurate determination of the preload–torque relationships of plug–valve connections. In the study, two non-standard plugs with metric threads were equipped with strain gauges and repeatedly tightened three times in valve housings under lubricated and unlubricated conditions. The preload and tightening torque were measured. (1) Although the plug–valve connections had a similar geometry with the same surface roughness of the contacting surfaces, the average overall friction coefficient (uniform thread and underhead friction coefficient) and torque coefficient differed between the two connections in the unlubricated and lubricated conditions by 16% and 18%, respectively. This indicates that even small geometrical differences can have a considerable influence on these coefficients. The overall friction and torque coefficients were between 8% and 17% higher in the unlubricated condition than in the lubricated condition (not statistically proven). (2) The overall friction and torque coefficients decreased with repeated tightening under lubricated conditions. This influence decreased with the number of tightening repetitions. (3) Consideration of the minimum and maximum thread and underhead friction coefficients given in VDI 2230 would lead to an error in the estimated preload of −15% to +86%. In conclusion, for accurate determination of the preload–torque relationship of the plug–valve connections, measurements considering repeated tightening are crucial. These should be performed for each type and size of plug–valve connection separately. To minimize the repeated tightening influence, it is recommended to re-tighten the connections several times before leaving production. Full article

Turbomachinery in gas turbines uses seals to control the leakage between regions of high and low pressure, consequently enhancing engine efficiency and performance. A film riding seal hybridizes the advantages of contact and non-contact seals, i.e., low leakage and low friction and wear. The literature focuses on the leakage performance of these seals; however, one of their fundamental characteristics, i.e., the gap between the rotor and seal surface, is scarcely presented. The seal pad levitates due to the deflection of the springs at its back under the influence of hydrodynamic forces. This study develops a test rig to measure the levitation of film riding seals. A high-speed motor rotates the rotor and gap sensors measure the levitation of the seal pads. Measurements are also compared with the predictions from a Reynolds equation-based theoretical model. Tests performed for the increasing rotor speed indicated that, initially, until a certain rotor speed, the pads adjust their position, then rub against the rotor until another rotor speed is reached, before finally starting levitating with further increased rotor speeds. Moreover, both the measured and predicted results show that pads levitated the most when located 90° clockwise from the positive horizontal axis (bottom of seal housing) compared to other circumferential positions. Full article

Gas film floating ring seals are extensively utilized in aircraft engines, and precise analysis of gas film performance is crucial for ensuring reliable seal design. For this reason, this paper proposes the Reynolds–Bernoulli small-perturbation (RBSP) model to analyze the performance of the gas film based on the conservation of mechanical energy. Through experimental verification and comparison with other analytical models, the results of the RBSP model calculations are both reliable and more broadly applicable. Analyses using the finite element method revealed that the differential pressure effect of Poiseuille flow and the dynamic pressure effect of Couette flow are the primary factors enabling the floating ring to overcome resistance and establish a non-contact seal. Additionally, an appropriate sealing clearance and an increased width of the floating ring could significantly enhance the dynamic performance of the seal. The research findings offer a dependable performance analysis method for designers of gas film floating ring seals. Full article

With the growing global demand for clean energy, new energy vehicles are a key focus in the automotive industry. This paper investigates the micro-grooved pumping seal used in such vehicles, using a custom Python computational programme to study the start-up behaviour of a non-contact oil–gas two-phase micro-grooved seal. The research explores the balance of forces during start-up, employing fractal theory for surface contact force calculations and solving the two-phase laminar Reynolds equation by the finite difference method. The results show that high-speed micro-grooved seals perform well under typical conditions for new energy vehicles. When film thickness is below a critical value, fractal dimension and characteristic length influence the initial thickness. Above the critical value, film thickness increases non-linearly with rotational speed, whereas the leakage rate decreases linearly. Critical rotational speed decreases non-linearly with the oil–gas ratio, peaking at an oil–gas ratio of 0.06. Both critical speed and leakage rate increase linearly and non-linearly with pressure and temperature, respectively. The study highlights the boundary-line where leakage transitions to pumping, providing valuable guidance for optimising seal design in new energy vehicles. Full article

To further enhance the intelligent technology, platformisation, and systematisation of coalbed methane extraction sealing technology, this paper analyses the research progress of theories, technologies, and sealing materials related to coalbed methane extraction sealing and systematically summarises the latest achievements of the basic theories, key technologies, and sealing materials of coalbed methane extraction. Considering the increasing mining depth, advancements in intelligent technology, and the evolving landscape of coalbed methane development, it is particularly important to establish a more comprehensive coalbed methane extraction borehole sealing system. Based on this, future development trends and research prospects are proposed: In terms of coalbed-methane-extraction-related theories, there should be a stronger focus on fundamental research such as on gas flow within the coal matrix. For coalbed methane extraction borehole sealing technologies and devices, efforts should be made to enhance research on intelligent, platform-based, and systematic approaches, while adapting to the application of directional long borehole sealing processes. In terms of coalbed methane extraction borehole leakage detection, non-contact measurement and non-destructive monitoring methods should be employed to achieve dynamic monitoring and early warning of methane leaks, integrating these technologies into coalbed methane extraction system platforms. For coalbed methane extraction borehole sealing materials, further development is needed for liquid sealing materials that address borehole creep and the development of fractures in surrounding rock, as well as solid sealing materials with Poisson’s ratios similar to that of the surrounding rock mass. Full article

To obtain an optimal range of structural parameters for dry-gas seals with good performance, this study employed advanced sensing technology to monitor and analyze the internal flow characteristics of dry-gas seals in real time. Additionally, the validity of the calculation program was verified through experimentation. Using steady-state performance parameters as evaluation indices, a calculation model with lubrication characteristics was developed. The results indicate that when there are 12 grooves, the gas film pressure distribution is uniform and has a high value. At pressures greater than 2 MPa, the opening force, leakage, and gas film stiffness change significantly due to enhanced dynamic pressure effects with high-pressure differences, which reduces the local contact forces and frictional forces. At a constant speed, decreasing the gas film thickness increases the pressure difference while increasing both the opening force and film stiffness; however, at higher rotational speeds where the gas flow becomes non-uniform, the stability of the gas film is affected, leading to increased frictional forces. When there are between 10 and 16 grooves with depths ranging from 5.0 to 6.0 μm, dynamic pressure effects caused by pressure gradients become apparent, resulting in good dry-gas sealing performance being achieved. This research provides a theoretical reference for optimizing the design of dry-gas seals, as well as their steady-state seal performance. Full article

There is a constant demand for higher equipment parameters, such as the pressure of a sealing medium and shaft rotation speed. However, as the parameters increase, it becomes more difficult to ensure hermetization efficiency. The rotor of a multi-stage machine rotates in non-contact seals. Seals’ parameters have a great influence on vibration characteristics. Non-contact seals are considered to be hydrostatodynamic supports that can effectively dampen rotor oscillations. The force coefficients of gap seals are determined by geometric and operational parameters. A purposeful choice of these parameters can influence the vibration state of the rotor. It is shown for the first time that the initially dynamically flexible rotor, in combination with properly designed seals, can become dynamically rigid. Analytical dependencies for the computation of the dynamic characteristics are obtained. The resulting equations make it possible to calculate the radial-angular vibrations of the rotor of a centrifugal machine in the seals and construct the amplitude–frequency characteristics. By purposefully changing the parameters of non-contact seals, an initially flexible rotor can be made rigid, and its vibration resistance increases. Due to this, the environmental safety of critical pumping equipment increases. Full article