Search Results (171)

This study investigates the influence of unsteady heat and mass transfer processes on the formation of gas composition and thermal conditions in a large cross-section (132 m²) blind-end chamber of a gypsum mine during the operation of diesel-powered mining equipment, including a front-end loader representing the LHD class and a dump truck. The modeled system considers a chamber where the LHD operates continuously, while the dump truck enters periodically to perform haulage cycles. Ventilation is provided from an adjacent panel haulage drift using a booster fan. Numerical simulations were carried out using ANSYS Fluent within the RANS framework, employing the realizable k-ε turbulence model, with consideration of thermal and gas convection. A dynamic mesh approach was applied to explicitly represent the motion of the dump truck. Both steady-state scenarios, corresponding to extreme equipment positions, and a fully transient case involving dump truck entry into the chamber followed by idling were analyzed. The results demonstrate that the movement of the dump truck generates a pronounced piston effect, which alters the jet flow structure and temporarily increases the supply of fresh air to the working face. It is shown that steady-state assumptions based on prolonged equipment presence near the face overestimate the total NO_x concentration within the large chamber and may not adequately reflect actual gas conditions over typical loading cycle durations. The analysis of unsteady processes using the dynamic mesh approach reveals significant inertia in contaminant accumulation within the chamber. This finding enables a more accurate estimation of the required airflow rate, reducing excessive safety margins compared to calculations based on the assumption of continuous equipment operation near the face. Full article

Internal combustion engines are a well-established, efficient and dispatchable solution for distributed power generation and they are widely used in various sectors including grid balancing, data centers and combined heat and power systems. Current research efforts focus on further increasing efficiency, enabling decarbonization through renewable fuels and improving responsiveness to electricity demand in the presence of variable renewable energy sources. In this context, the free-piston linear generator (FPLG) stands out as a highly promising technology, as it directly converts piston motion into electricity, offering high efficiency, reduced mechanical complexity and seamless grid integration. Initially explored for its high-efficiency potential with homogeneous charge compression ignition combustion at extreme compression ratios, opposed-piston FPLGs are now commercially available for distributed power generation, delivering global efficiencies exceeding 45%, near-zero emissions and multi-fuel capability. Building on the detailed studies conducted by Svrcek and co-authors, this work investigates the power-generation potential of low-temperature homogeneous combustion using CFD simulations with detailed chemical kinetics. First, rapid compression machine (RCM) experiments with methane were reproduced in simulations to validate the proposed methodology and to consolidate experimental findings on the maximum achievable efficiency. Subsequently, an extensive RCM simulation campaign supported the identification of optimal operating conditions in terms of air–fuel ratio using methane as fuel. The RCM results enabled the definition of a preliminary methane-fueled opposed-piston FPLG configuration. Full-cycle simulations including gas exchange, mixing and combustion demonstrated an indicated efficiency of 58% at an equivalence ratio $\varphi =0.5$ and a compression ratio of 50. The key novelties of this study are the development of a novel RCM-2 configuration that more closely reproduces the dynamic behavior of an opposed-piston FPLG including air-spring effects and the introduction of a divided intake port strategy to simultaneously reduce fuel slip and mitigate knocking behaviour through charge stratification. The simulation results for the proposed configuration confirm the potential of opposed-piston FPLGs for high-efficiency power generation and highlight key parameters affecting performance and emissions formation. 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

This paper presents a comprehensive experimental and simulation study on the stick–slip characteristics of pneumatic cylinders operating at low velocities. A pneumatic servo experimental system is constructed to systematically investigate stick–slip motion by measuring piston position, piston velocity, pressures in the two-cylinder chambers, and friction force. Extensive experiments are conducted on three pneumatic cylinders of different types and sizes to examine the influences of airflow rate, air source pressure, external load, and initial piston position on stick–slip behavior. Based on experimental observations, a complete mathematical model of the pneumatic servo system is developed. Unlike conventional approaches that simulate stick–slip motion using friction models driven solely by piston velocity, the proposed system-level model explicitly describes the entire dynamic process from valve control inputs to airflow, pressure evolution in the cylinder chambers, piston motion, and friction force. In addition, a new dynamic friction model is proposed by improving the revised LuGre friction model through the incorporation of a dwell-time-dependent static friction force, which is experimentally observed to play a critical role in governing stick–slip motion. Simulation studies are performed using both the proposed friction model and the revised LuGre friction model. The simulated results are systematically compared with experimental data for all tested cylinders. The results demonstrate that the proposed system model with the new friction formulation significantly improves the prediction of stick–slip characteristics, including the number of stick–slip cycles and the evolution of pressure and friction force, compared with conventional friction-model-based simulations. Full article

In today’s energy landscape, defined by the growing demand for sustainable energy generation technologies and the parallel need to advance internal combustion engine (ICE) architectures toward cleaner and more efficient solutions, the adoption of Free-Piston Linear Generator (FPLG) engines emerges as a highly promising approach. This innovative system enables the direct conversion of combustion-induced piston motion into electrical energy, eliminating the need for traditional crankshaft and connecting rod mechanisms. The FPLG concept facilitates efficient utilization of a broad spectrum of fuels—including methane, ethanol, LPG, gasoline, biodiesel, and hydrogen—by supporting variable compression ratio operation. This feature enhances operational flexibility and fuel adaptability, positioning the technology as a viable candidate for future energy transition scenarios. The absence of rotating mechanical components significantly reduces frictional losses, contributing to an overall increase in system efficiency. To accurately characterize and optimize engine performance, an extensive series of one-dimensional (1D) numerical simulations was performed under both free and controlled operating conditions. The resulting data enabled the development of semi-empirical models capable of predicting the dynamic behavior of the engine across a wide range of working scenarios. Finally, through a detailed parametric analysis, the optimal operating conditions were identified to maximize both net electric efficiency and electrical power output. These findings provide a solid ground for the design and implementation of FPLG engine systems in advanced power generation applications. Full article

This study reports on the design, construction, and operation of a laboratory-scale biomass gasification reactor, together with the procedures used to define and evaluate key operational and performance variables, including piston velocity, nominal biomass residence time, airflow rate, gas yield, lower heating value, and gasification efficiency. The unit is a moving-bed reactor operating in co-current gas–solid mode and reproducing key features of downdraft-like gasification, allowing the identification of the four main reaction zones: drying, pyrolysis, oxidation, and reduction. The reactor exhibits simple operation and handling and, notably, enables controlled axial displacement of the biomass bed through the reaction zone, allowing the nominal solid residence time in the heated zone to be adjusted through piston motion. In addition, the gasification of Spartina argentinensis was investigated in order to evaluate the functionality of the system and to assess reactor performance under selected operating conditions. At operating temperatures of 800–850 °C and an equivalence ratio of 0.2, gas yields exceeded 60 wt%, gasification efficiencies were above 50%, and the product gas reached heating values close to 1000 kcal Nm⁻³, indicating a favorable fuel quality of the product gas. These results confirm the potential of the proposed reactor as a useful experimental platform for the investigation of biomass gasification under controlled laboratory conditions. Full article

Contact–impact phenomena caused by joint clearances can significantly alter the dynamic response of high-speed mechanical systems, yet fewer studies combine analytical impact-force modeling, virtual prototyping, and experimental observations for multi-cylinder internal combustion engine mechanisms within a unified framework. This problem is scientifically important because the piston–connecting rod–crankshaft chain is subjected to rapid motion reversals, high transmitted loads, and local clearances that may generate shocks, force amplification, and vibration growth. The objective of this study is to evaluate the influence of mechanical impact on the dynamic response of a three-cylinder inline engine mechanism by combining analytical modeling, MSC Adams virtual prototyping, and experimental investigation. The mechanism was analyzed in two operating conditions: under load, using an experimentally derived gas pressure input, and without load at low speed imposed on the crankshaft, using a sectioned engine test bench. The loaded virtual model was studied at a crankshaft speed of 6000 rpm, with cylinder gas pressure peaks above 90 bar and engine torque oscillating around 170 Nm. A radial clearance of 0.03 mm was introduced in the connecting rod–piston joint to evaluate clearance-induced impacts. The results showed that the damping coefficient strongly influences the amplitude and harmonic content of the impact force. For the analyzed no-load case at low speed, the simulated impact force reached a maximum value of 3000 N. Experimentally, the worn connecting rod with 0.03 mm clearance exhibited markedly higher dynamic response than the clearance-free case, with the maximum longitudinal acceleration increasing from 17.77 to 48.26 m/s² at 1.341 Hz. The novelty of the study lies in the integrated analytical–virtual–experimental investigation of clearance-induced impact in a three-cylinder inline engine mechanism and in the comparative evaluation of its effects on joint forces and vibration signatures. In addition, compared to other models, the novelty lies in introducing and adapting the impact force damping component for mechanisms with rapid motion and high dynamic loads. Full article

Airborne electromagnetic detection systems are highly susceptible to low-frequency motion-induced noise, which significantly degrades the extraction of weak geological signals. Conventional signal processing methods alone are often insufficient to suppress mechanically induced vibration noise, resulting in signal distortion and reduced detection reliability. To address this limitation, this study proposes an active noise suppression strategy that integrates mechanical vibration isolation with advanced signal processing. A pneumatic vibration isolation platform based on a cable-driven parallel robot (CDPR) architecture is developed to achieve precise orientation correction and effective vibration isolation. The system employs kinematic modeling and a servo-controlled pneumatic cylinder driven by a proportional directional valve to enable accurate dynamic regulation. Numerical simulations conducted in the Advanced Modeling and Simulation Environment (AMESim), combined with proportional–integral–derivative (PID) control, demonstrate that piston displacement overshoot is constrained within 0.2 mm. Furthermore, targeted filtering techniques are applied to enhance signal quality. Experimental results show that the response time for continuous step input is 0.18–0.2 s, with a steady-state error below 0.3 mm, confirming robust control performance. The proposed framework provides an effective low-noise solution for airborne electromagnetic detection and can improve survey reliability in deep resource exploration. Full article

Reducing friction in the piston ring–cylinder liner contact is a key area for improving the efficiency of internal combustion engines. While tribological studies commonly focus on the top dead centre region using linear tribometers, the mid-stroke regime—with its higher sliding velocities—remains experimentally inaccessible to most conventional test methods. This study presents a rotating ring-on-liner tribometer that enables investigations at constant relative speed by transitioning the motion from oscillating to rotating. A cylindrical substitution geometry for the piston ring specimen is derived through a coupled elastohydrodynamic and asperity contact simulation approach to reproduce realistic load-sharing behaviour. Experimental results from starved lubrication tests demonstrate stable contact conditions with a low coefficient of variation in wear, confirming good reproducibility. Stepwise performed Stribeck tests at 40 °C and 100 °C reveal characteristic friction–velocity behaviour, including the transition from mixed to hydrodynamic lubrication. Although the test rig’s maximum sliding speed and steady-state thermal conditions differ from fired engine environments, the methodology closes an important gap between low-speed linear tribometers and complex floating-liner systems. The presented approach provides a flexible and robust platform for controlled parametric studies of ring-on-liner contacts under application-relevant lubrication regimes. 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

Legged robots inspired by animal locomotion require actuators with high power density, fast response, and robust force control, yet traditional valve-controlled hydraulic systems suffer from substantial energy losses and weak regeneration performance. Motivated by role allocation across gait phases in animal legs, where in-air positioning requires far less actuation effort than ground contact support and force modulation, this work proposes a novel gas–oil hybrid servo actuator, denoted GOhsa, for quadruped knee joints. GOhsa utilizes pre-charged high-pressure gas to pressurize hydraulic oil, converting the conventional dual-chamber pressure servo control into a single-chamber configuration while preserving the original piston stroke. This architecture enables bidirectional position–force control, enhances energy regeneration applicability, and improves operational efficiency. Theoretical modeling is conducted to analyze hydraulic stiffness and frequency-response characteristics, and a linearization-based force controller with dynamic compensation is developed to handle system nonlinearities. Experimental validation on a single-leg platform demonstrates significant energy-saving performance: under no-load conditions (simulating the swing phase), GOhsa achieves a maximum power reduction of 79.1%, with average reductions of 15.2% and 11.5% at inflation pressures of 3 MPa and 4 MPa, respectively. Under loaded conditions (simulating the stance phase), the maximum reduction reaches 28.0%, with average savings of 10.0% and 9.8%. Tracking accuracy is comparable to traditional actuators, with reduced maximum errors (13.7 mm/16.5 mm at 3 MPa; 15.0 mm/17.8 mm at 4 MPa) relative to the 16.6 mm and 18.1 mm errors of the conventional system, confirming improved motion stability under load. These results verify that GOhsa provides high control performance with markedly enhanced energy efficiency. Full article

To address the technical challenge where traditional high-pressure, large-flow emulsion pump stations cannot adapt to the drastic flow rate changes in hydraulic supports due to the fixed displacement of their quantitative pumps—leading to frequent system unloading, severe impacts, and damage—this study proposes an intelligent flow control method based on the digital flow distribution principle for actively perceiving and matching support demands. Building on this method, a compact, electro-hydraulically separated prototype with stepless flow regulation was developed. The system integrates high-speed switching solenoid valves, a piston push rod, a plunger pump, sensors, and a controller. By monitoring piston position in real time, the controller employs an optimized combined regulation strategy that integrates adjustable duty cycles across single, dual, and multiple cycles. This dynamically adjusts the switching timing of the pilot solenoid valve, thereby precisely controlling the closure of the inlet valve. As a result, part of the fluid can return to the suction line during the compression phase, fundamentally achieving accurate and smooth matching between the pump output flow and support demand, while significantly reducing system fluctuations and impacts. This research adopts a combined approach of co-simulation and experimental validation to deeply investigate the dynamic coupling relationship between the piston’s extreme position and delayed valve closure. It further establishes a comprehensive dynamic coupling model covering the response of the pilot valve, actuator motion, and backflow control characteristics. By analyzing key parameters such as reset spring stiffness, piston cylinder diameter, and actuator load, the system reliability is optimized. Evaluation of the backflow strategy and delay phase verifies the effectiveness of the multi-mode composite regulation strategy based on digital displacement pump technology, which extends the effective flow range of the pump to 20–100% of its rated flow. Experimental results show that the system achieves a flow regulation range of 83% under load and 57% without load, with energy efficiency improved by 15–20% due to a significant reduction in overflow losses. Compared with traditional unloading methods, this approach demonstrates markedly higher control precision and stability, with substantial reductions in both flow root mean square error (53.4 L/min vs. 357.2 L/min) and fluctuation amplitude (±3.5 L/min vs. ±12.8 L/min). The system can intelligently respond to support conditions, providing high pressure with small flow during the lowering stage and low pressure with large flow during the lifting stage, effectively achieving on-demand and precise supply of dynamic flow and pressure. The proposed “demand feedforward–flow coordination” control architecture, the innovative electro-hydraulically separated structure, and the multi-cycle optimized regulation strategy collectively provide a practical and feasible solution for upgrading the fluid supply system in fully mechanized mining faces toward fast response, high energy efficiency, and intelligent operation. Full article

The diesel substitution ratio is a key parameter influencing the combustion characteristics and energy conversion efficiency of hydrogen diesel dual-fuel free-piston engines. This study develops a thermodynamic hydrodynamic coupled model for a dual-fuel free engine to investigate the effects of five substitution ratios (15%, 20%, 25%, 30%, and 35%) on in-cylinder mixture formation, combustion characteristics, and emission performance. The key novelty of this work lies in employing this fully coupled combustion-dynamics model to systematically optimize the hydrogen–diesel substitution ratio, which explicitly captures the critical feedback between combustion and the piston’s unique motion. The cumulative heat release served as the key quantitative metric. The analyzed parameters included the gas mixture fraction, turbulent kinetic energy, flow trajectories, in-cylinder pressure and temperature, combustion reaction rate, unburned equivalent ratio, cumulative heat release and its rate, heat release rate, and emission mass. The results demonstrate that the engine’s overall performance is optimal at a substitution ratio of 25%. At this ratio, a peak volumetric mixture fraction of 0.0088 was achieved with a broad distribution range, indicating significantly improved spatial fuel uniformity. The flow field exhibited organized swirl patterns that enhanced fuel dispersion. The peak in-cylinder pressure reached 7.2 MPa, which was 0.044 MPa higher than that of the 20% group. The combustion temperature remained stable, with a peak value of 1606 K, exceeding the 20% and 30% groups by 7 K and 16 K, respectively. The heat release phase was well-synchronized with the piston motion, ensuring a high proportion of premixed combustion for thorough fuel oxidation. Although nitrogen oxide (NOx) emissions were slightly higher, the reduction in soot was substantially greater than in the 20% group, leading to overall superior performance compared to the other substitution ratios. This study develops a thermodynamic hydrodynamic coupled model for a dual-fuel free-piston engine by leveraging the interaction between piston motion and combustion. This paper presents a novel strategy for optimizing the substitution ratio in a free piston engine via a fully coupled combustion-dynamics model. Full article