Search Results (5)

Tunnel boring machine (TBM) hydraulic cylinders operate under pronounced start–stop shocks and load uncertainties, making it difficult to simultaneously achieve smooth start-up and high-precision tracking. This paper proposes a two-phase switching adaptive sliding mode control (ASMC) strategy for TBM hydraulic actuation. Phase I targets a soft start by introducing smooth gating and a ramped start-up mechanism into the sliding surface and equivalent control, thereby suppressing pressure spikes and displacement overshoot induced by oil compressibility and load transients. Phase II targets precise tracking, combining adaptive laws with a forgetting factor design to maintain robustness while reducing chattering and steady-state error. We construct a state-space model that incorporates oil compressibility, internal/external leakage, and pump/valve dynamics, and provide a Lyapunov-based stability analysis proving bounded stability and error convergence under external disturbances. Comparative simulations under representative TBM conditions show that, relative to conventional PID Controller and single ASMC Controller, the proposed method markedly reduces start-up pressure/velocity peaks, overshoot, and settling time, while preserving tracking accuracy and robustness over wide load variations. The results indicate that the strategy can achieve the unity of smooth start and high-precision trajectory of TBM hydraulic cylinder without additional sensing configuration, offering a practical path for high-performance control of TBM hydraulic actuators in complex operating environments. Full article

This paper presents a genetic algorithm (GA) approach to optimize key structural parameters of the torque motor used in a direct-drive slide knife gate valve. The optimization aims at enhancing the performance of the torque motor by improving the output torque, minimizing the overshoot, and reducing the response time. A mathematical model based on these performance indicators is formulated to guide the optimization process. Compared to the original design, the optimized design is shown to achieve a 26.4% increase in output torque, a 0.14 ms reduction in response time, and a 9% decrease in overshoot. Additionally, AMESim simulations confirm that the optimized motor significantly improves valve control accuracy, dynamic response, and flow stability, while also decreasing sensitivity to pressure fluctuations under high-current conditions. Finally, experimental results are provided to corroborate the simulation findings, validating the accuracy and effectiveness of the proposed optimization methodology. This study provides novel theoretical insights and practical guidance for the design of high-performance torque motors used in direct-drive electro-hydraulic servo valves within aerospace applications. Full article

This work studies how the sliding-gate valve (SGV) modifies the features and the dynamic behavior of the outlet jets for flat-bottom and well-bottom bifurcated submerged entry nozzles (SENs) used in continuous casting machines. Three conditions for the SGV were studied: no obstruction, moderate obstruction, and severe obstruction. The experimental study used a scaled model, employing cold water as the working fluid. A high-frequency analysis of the flow inside the SEN’s bore arriving at the outlet ports was performed by employing the particle image velocimetry (PIV) technique. Low-frequency measurements of the volumetric flow at the exit port were obtained by splitting the exit jet into four quadrants and employing digital flowmeters. It was observed that reducing the SGV clearance increases the turbulence of the flow inside the SEN bore, but the flow displays ordered rather than erratic fluctuations. Flowmeter measurements showed that, regardless of the level of obstruction in the SGV, the outlet jets on flat-bottom and the well-bottom SENs have dynamic behaviors and features with significant differences. This finding is relevant because the flow distribution inside the outlet ports is directly related to the jet’s wideness, affecting the recirculation pattern inside the mold and, therefore, the quality of the finished steel slab. Full article

Subtractive manufacturing processes are usually accompanied by the occurrence of tiny flakes and swarf, which later on cause severe wear and damage, especially in moving components such as rolling or sliding bearings, pistons, etc. However, up until now, such detrimental effects have hardly been investigated. One reason is the lack of a definition of a typical design of debris particle. Therefore, the main goal of the project described in this paper was to elaborate a draft that defines standardized test particles. It had to be evaluated whether test particles could be adequately reproduced and whether they would reveal significant damage potential. Taking into account future mass fabrication, Micro Powder Injection Molding (MicroPIM) was chosen as a production method. Five different 3D designs of geometrically defined test particles were developed. The maximum size of each design was 1167 mm in green state; however, all samples shrank in size during sintering. Specially tailored feedstocks containing 42CrMo4 steel powders were used and the related molding, debinding and sintering procedures were developed. All particle geometries and related mold inserts were developed using a commercial software routine for the layout of runner systems, gate locations and ejector positions. The damage potential of the test particles was evaluated based on trials using journal bearing and shift valve test rigs. Although only a moderate degree of damage potential could be ascertained up until now, it can be expected that the artificial swarf will enable standardized wear test procedures to be developed. Full article

The characterization of the turbulent flow of liquid steel in a slab mold using a commercial nozzle was carried out through physical experiments and mathematical models. Six ultrasonic sensors were located at each side of the nozzle to obtain real-time plotting of the bath levels during the experimental time. An ultrasonic transducer located in the mold, 20 mm below the meniscus, determines the velocities and the turbulent variables along with the distance from the narrow face to the position of the nozzle’s outer wall. These data, together with the mathematical simulations, demonstrated a high correlation of bath level oscillations and the time-dependent behavior of the discharging jets. The flow inside the mold shows low-frequency non-symmetric patterns without a severe turbulent in the meniscus. The source of this instability is the partial opening of the slide valve gate used to control the mass flow of liquid. Full article