FE Study for Reducing Forming Forces and Flat End Areas of Cylindrical Shapes Obtained by the Roll-Bending Process

A roll-bending process that minimizes the flat areas on the leading and trailing ends of formed plates will produce more accurate and easier assemble final shapes. There are several methods of minimizing flat areas, but they are costly or difficult to apply for thick plates. This study proposes a new, simple approach that reduces these flat areas. This approach includes moving the bottom roll slightly along the feeding direction and adjusting the bottom roll location. Sensitivity analyses were performed using a developed 3D dynamic FE （finite element） model of an asymmetrical roll-bending process in the Ansys/LS-Dyna software package. Simulations were validated by experiments run on an instrumented roll-bending machine. The FE results indicate that this new approach not only minimizes the flat areas but also reduces the forming forces.     

Redundant Hydraulic Secondary Flight Control Systems Behavior in Failure Conditions

The flight control systems, designed in order to assure the necessary safety level even in failure conditions, are generally characterized by a proper redundant layout. The redundancies must be designed in order to assure an adequate system behavior when some failures are present; in fact an incorrect layout may cause serious shortcomings concerning the response when some component is not operational. Therefore the usual correct design activities request the complete analysis of the system behavior in failure condition. The work analyses the response of a redundant secondary flight control hydraulic servo-mechanism equipped with some proper equalization devices, when some of the most probable and representative failures are present. It must be noted that the redundancy layout, designed in order to assure the necessary safety level even in failure conditions, may behave improperly during normal operations, if the system architecture is unsuitable, when manufacturing defects are present. The improper behavior, generally consisting of force fighting or speed fighting caused by different offsets or asymmetries between the two sections of the system, may be usually overcome by means of a suitable equalization device. Therefore, the system behavior during and following the failure transient greatly depends on both its redundancy architecture and related equalization device. The above mentioned problems have been studied by means of an appropriate physical-mathematical model of a typical electro-hydraulic servo-mechanism prepared to the purpose, performing a certain number of simulations of representative actuations in which different types of failures are accurately modeled. In the opinion of the authors, this paper concerns a topic quite neglected but important in the technical literature. At the best of the authors＇ knowledge, no specific scientific work in this field is available, excepting some industrial technical reports.     

Stabilizing Mechanism and Running Behavior of Couplers on Heavy Haul Trains

Published studies in regard to coupler systems have been mainly focused on the manufacturing process or coupler strength issues. With the ever increasing of tonnage and length of heavy haul trains, lateral in-train forces generated by longitudinal in-train forces and coupler rotations have become a more and more significant safety issue for heavy haul train operations. Derailments caused by excessive lateral in-train forces are frequently reported. This article studies two typical coupler systems used on heavy haul locomotives. Their structures and stabilizing mechanism are analyzed before the corresponding models are developed. Coupler systems models are featured by two distinct stabilizing mechanism models and draft gear models with hysteresis considered. A model set which consists of four locomotives and three coupler systems is developed to study the rotational behavior of different coupler systems and their implications for locomotive dynamics. Simulated results indicate that when the locomotives are equipped with the type B coupler system, locomotives can meet the dynamics standard on tangent tracks; while the dynamics performance on curved tracks is very poor. The maximum longitudinal in-train force for locomotives equipped with the type B coupler system is 2000 kN. Simulations revealed a distinct trend for the type A coupler system. Locomotive dynamics are poorer for the type A case when locomotives are running on tangent tracks, while the dynamics are better for the type A case when locomotives are running on curved tracks. Theoretical studies and simulations carried out in this article suggest that a combination of the two types of stabilizing mechanism can result in a good design which can significantly decrease the relevant derailments.     

液压鹅颈挂车转弯建模与轨迹动态仿真研究

液压鹅颈挂车是装运大件产品的新型运输车辆,为确保大件产品公路运输的安全,针对液压鹅颈挂车运输过程中弯道通过能力差的问题,在分析液压鹅颈挂车的装载静态结构属性和车组动态转弯过程的基础上,构建了液压鹅颈挂车的转弯模型,提出了关键物理量坐标的迭代算法并实现了液压鹅颈挂车弯道轨迹的动态模拟仿真,为其在运输过程中顺利通过复杂弯道提供了工程指导。     

Identification Method of Dynamic Coefficients of Fluid Film Bearings for HDD Spindle Motors

Fluid film bearings are widely used as support elements of rotating shaft for HDD （hard disk drive） spindle motors. Recently, the opportunity for the HDD spindle motors exposed to external vibration has been increasing because the HDDs are used for various information related equipments such as mobile PCs, car navigation systems. Hence, the rotating shaft has a possibility to come in contact with the bearing and it causes wear or seizure to the bearing surface. In order to avoid the problems, it is extremely important to enhance the dynamic characteristics of the fluid film bearings for spindles. However, verification from both theory and experiment of dynamic characteristics such as spring coefficients and damping coefficients is rare and few. In this paper, the bearing vibration characteristics when the HDD spindle is oscillated are investigated theoretically and experimentally. And then the identification method ofoil film coefficients of fluid film bearing spindles is described.     

Design of preview controllers for active roll stabilization

This paper presents design methods of H_∞ and sliding mode preview controllers for active roll stabilization. A lateral acceleration of the preceding vehicle is transmitted through vehicle-to-vehicle (V2V) communication. A preview controller can be designed for active roll stabilization considering the lateral acceleration to be a previewed disturbance. In order to design a preview controller, H_∞ and sliding mode control methodologies are adopted. The designed preview controllers are compared to LQ optimal one through simulation conducted on vehicle simulation package, CarSim.

     

Fully Integrated Machine Control for Ultra Precision Machining

To meet the demands for highly advanced components with ultra precise contour accuracy and optical surface quality arising in the fields of photonics and optics, automotive, medical applications and biotechnology, consumer electronics and renewable energy, more advanced production machines and processes have to be developed. As the complexity of machine tools rises steadily, the automation of manufacture increases rapidly, processes become more integrated and cycle times have to be reduced significantly, challenges of engineering efficient machine tools with respect to these demands expand every day. Especially the manufacture of freeform geometries with non-continuous and asymmetric surfaces requires advanced diamond machining strategies involving highly dynamic axes movements with a high bandwidth and position accuracy. Ultra precision lathes additionally equipped with Slow Tool and Fast Tool systems can be regarded as state-of-the-art machines achieving the objectives of high quality optical components. The mechanical design of such ultra precision machine tools as well as the mechanical integration of additional highly dynamic axes are very well understood today. In contrast to that, neither advanced control strategies for ultra precision machining nor the control integration of additional Fast Tool systems have been sufficiently developed yet. Considering a complex machine setup as a mechatronic system, it becomes obvious that enhancements to further increase the achievable form accuracy and surface quality and at the same time decrease cycle times and error sensitivity can only be accomplished by innovative, integrated control systems. At the Fraunhofer Institute for Production Technology IPT a novel, fully integrated control approach has been developed to overcome the drawbacks of state-of-the-art machine controls for ultra precision processes. Current control systems are often realized as decentralized solutions consisting of various computational hardware components for setpoint generation, machine control, HMI （human machine interface）, Slow Tool control and Fast Tool control. While implementing such a distributed control strategy, many disadvantages arise in terms of complex communication interfaces, discontinuous safety structures, synchronization of cycle times and the machining accuracy as a whole. The novel control approach has been developed as a fully integrated machine control including standard CNC （computer numerical control） and PLC （programmable logic controller） functionality, advanced setpoint generation methods, an extended HMI as well as an FPGA （field programmable gate array）-based controller for a voice coil driven Slow Tool and a piezo driven Fast Tool axis. As the new control system has been implemented as a fully integrated platform using digital communication via EtherCAT, a continuous safety strategy could be realized, the error sensitivity and EMC susceptibility could be significantly decreased and the overall process accuracy from setpoint generation over path interpolation to axes movements could be enhanced. The novel control at the same time offers additional possibilities of automation, process integration, online data acquisition and evaluation as well as error compensation methods.     

Development of a Stabilized Pan/Tilt Platform and the State of the Art

In the context of this paper, a small scale, medium precision, stabilized pan/tilt platform is developed as a prototype, which is used to compare various stabilization algorithms experimentally. The overall performance of the system depends on rigid body dynamics, structural dynamics, servo control loops, stabilization control algorithm, sensor fusion algorithm and sensory feedback such as from the IMU （inertial measurement unit）. In the case that the response bandwidth of the overall system is high enough, the same hardware can also achieve active vibration isolation. All of these design aspects are investigated in the paper via numerical models and with their experimental verification.     

Unsteady flow simulations in a three-lobe positive displacement blower

To improve the performance of the positive displacement blower, it is imperative to understand the detailed internal flow characteristics or enable a visualization of flow status. However, the existing two-dimensional unsteady, three-dimensional steady or quasi-unsteady numerical simulation and theoretical analysis cannot provide the detailed flow information, which is unfavorable to improve the performance of positive displacement blower. Therefore, the unsteady flow characteristics in a three-lobe positive displacement blower are numerically investigated by solving the three-dimensional, unsteady, compressible Navier-Stokes equations coupled with RNG k-e turbulent model. In the numerical simulation, the dynamic mesh technique and overset mesh updating method are adopted. Due to the air being compressed in the process of the rotors rotating, the variation of the temperature field in the positive displacement blower is considered. By comparing the experimental measurements and the numerical results on the variation of flow rate with the outlet pressure, the maximum relative error of the flow rate is less than 2.15% even at the maximum outlet pressure condition, which means that the calculation model and numerical computational method used are effective. The numerical results show that in the intake region, the fluctuations of the inlet flow are greatly affected by the direction of the velocity vectors. In the exhaust region, the temperature changes significantly, which leads to the increase of the airflow pulsation. Through analysis on the velocity, pressure and temperature fields obtained from the numerical simulations, three-dimensional unsteady flow characteristics in the positive displacement blower are revealed. The studied results will provide useful reference for improving the performance and empirical correction in the design of the positive displacement blower.     

基于ADAMS的铰接轮式重型拖拉机振动特性分析

为分析铰接轮式重型拖拉机的振动特性,利用ADAMS虚拟样机技术,采用GB/T 10910—2004中规定的35 m较粗糙人工试验跑道对其整机振动进行了仿真分析。建立方向器转角开度为0时转向液压简化系统,与整机铰接和摆动机构组成了空间机械-液压偶合的仿真系统。通过仿真,得到了拖拉机在该工况下的各构件载荷和振动频率,总结了铰接轮式重型拖拉机的振动规律。文中主要研究拖拉机铰接结构特性对拖拉机振动的影响,可为铰接轮式重型拖拉机关键部件的减振器设计提供理论依据。     

Real Time Math Simulation of Contact Interaction during Spacecraft Docking and Berthing

Contact reactions of guide surfaces of assembly interfaces lead to the decreasing of theirs lateral and angular misalignments. The focus of this paper is the development of algorithms for computation of guide surfaces contact forces with acceptable engineering accuracy for real time simulation of assembly operations. Therefore, each complex guide surface is described as a set of contacting elements. Each contacting element for one＇s part can be represented by a finite set of geometric primitives which geometry is described by low order algebraic equations. So contact conditions and geometric parameters for all pairs of primitives are determined by analytical expressions. Math models are developed for two classes of contact interaction. The first class includes all cases when each contacting surface has several degrees of freedom of motion. Therefore, contact reactions introduced into differential equations of motion are calculated by using contacting elements penetrations, stiffness and damping parameters. The second class corresponds to all cases when one of contacting surfaces has insignificant inertia and only one degree of freedom of relative displacement counteracted by a spring. Here contact reactions are calculated from spring tension with any practical accuracy. This is very useful in some practical applications. Presented algorithms provide real time simulation together with some approaches for reduction of redundant comnutations.     

HYDRAULIC ACTIVE GUIDE ROLLER SYSTEM FOR HIGH-SPEED ELEVATOR BASED ON FUZZY CONTROLLER

Increase of elevator speed brings about amplified vibrations of high-speed elevator. In order to reduce the horizontal vibrations of high-speed elevator, a new type of hydraulic active guide roller system based on fuzzy logic controller is developed. First the working principle of the hydraulic guide system is introduced, then the dynamic model of the horizontal vibrations for elevator cage with active guide roller system and the mathematical model of the hydraulic system are given. A fuzzy logic controller for the hydraulic system is designed to control the hydraulic actuator. To improve the control performance, preview compensation for the controller is provided. Finally, simulation and experiments are executed to verify the hydraulic active guide roller system and the control strategy. Both the simulation and experimental results indicate that the hydraulic active guide roller system can reduce the horizontal vibrations of the elevator effectively and has better effects than the passive one, and the fuzzy logic controller with preview compensation can give superior control performance.     

Dynamic Control of a Flexible Shaft Mounted in Adaptive or Active Bearing

The dynamic behavior of rotors is highly influenced by bearing characteristics. In previous works, the authors have shown that it may be beneficial to adapt the bearing behavior to the shaft behavior. Several adaptive and active components will be developed in this paper in order to control the shaft dynamical amplitude. Different models of hydrodynamic bearings behavior are described. The Reynolds equation resolution may be done by numerical or analytical solutions. A physical analysis of the equation of thin films will identify the most sensitive parameters. The shaft flexibility is taking into account by a modal approach. The fluid-structure coupling process is a simulation, step by step, of the rotor behavior. At each step, the nonlinear fluid force is numerically calculated to obtain the unbalanced shaft response. The results, presented in this paper, concern the dynamic response of unbalanced shaft mounted in adaptive or active bearings： bearings with variable clearance, variable viscosity or variable housing speed. It is shown that the fluid bearing parameters must be adapted to the rotor speed （in particular near or far a critical speed）. Then, the paper presents a new kind of active bearing. It works with a mechanical control of the housing position. Several parameters are tested and compared. The robustness of the dynamic control parameters is presented. In conclusion, the bearing adaptation could be very useful to control the shaft dynamic. This limits the effect of the critical speed, in particular by diminishing the shaft amplitude and the dynamic forces transmitted to the housing.     

Investigation of CFD calculation method of a centrifugal pump with unshrouded impeller

Currently, relatively large errors are found in numerical results in some low-specific-speed centrifugal pumps with unshrouded impeller because the effect of clearances and holes are not accurately modeled. Establishing an accurate analytical model to improve performance prediction accuracy is therefore necessary. In this paper, a three-dimensional numerical simulation is conducted to predict the performance of a low-specific-speed centrifugal pump, and the modeling, numerical scheme, and turbulent selection methods are discussed. The pump performance is tested in a model pump test bench, and flow rate, head, power and efficiency of the pump are obtained. The effect of taking into consideration the back-out vane passage, clearance, and balance holes is analyzed by comparing it with experimental results, and the performance prediction methods are validated by experiments. The analysis results show that the pump performance can be accurately predicted by the improved method. Ignoring the back-out vane passage in the calculation model of unshrouded impeller is found to generate better numerical results. Further, the calculation model with the clearances and balance holes can obviously enhance the numerical accuracy. The application of disconnect interface can reduce meshing difficulty but increase the calculation error at the off-design operating point at the same time. Compared with the standard k-ε, renormalization group k-ε, and Spalart-Allmars models, the Realizable k-ε model demonstrates the fastest convergent speed and the highest precision for the unshrouded impeller flow simulation. The proposed modeling and numerical simulation methods can improve the performance prediction accuracy of the low-specific-speed centrifugal pumps, and the modeling method is especially suitable for the centrifugal pump with unshrouded impeller.     

汽车驾驶员自适应模糊PID控制模型

汽车动力学控制系统具有强非线性特性,在人-车-路闭环系统中采用基于传递函数的传统方法难以建立精确的驾驶员模型.在"预瞄最优曲率模型"的基础上,对驾驶员校正环节采用模糊PID控制,对包括"魔术公式"轮胎模型在内的汽车模型,建立加速度反馈自适应模糊PID控制驾驶员模型.该模型通过模糊控制器在线实时调整PID的3个参数.仿真结果表明,所建立的自适应模糊PID控制驾驶员模型很好地描述了驾驶员的方向控制行为,为人-车-路闭环系统的进一步研究和智能车辆自动驾驶控制提供了可行的途径.     

Numerical Simulation of New Friction Welded Joints

In developing the new friction welding technology, the thermal elastic-plastic stress analysis by the finite element method was carried out to seek the suitable welding conditions such as the friction pressure, the friction speed and the upset pressure. The results obtained are as follows： Heat transfer to the specimens and the intermediate material during friction process was made clear; The operational conditions such as the rotation number of the intermediate material and the friction pressure to reach the liquidus in the interface could be estimated; Further, as the overhang length near the interface is well related to the joint efficiency, we tried to obtain the operational conditions by numerical analysis to acquire a certain length of the overhang length near the interface.     

Kinematics and Path Following Control of an Articulated Drum Roller

Automatic navigation of an articulated drum roller, which is an articulated steering type vehicle widely used in the construction industry, is highly expected for operation cost reduction and improvement of work efficiency. In order to achieve the path following control,considering that its steering system is articulated steering and two frames are articulated by an active revolute joint, a kinematic model and an error dynamic state-space equation of an articulated drum roller are proposed. Besides, a statefeedback control law based on Lyapunov stability theory is also designed, which can be proved to achieve the purpose of control by the analysis of stability. What's more, to evaluate the performance of the proposed method, simulation under the MATLAB/Simulink and experiments using positioning algorithm and errors correction at the uneven construction site are performed, with initial displacement error(-1.5 m), heading error(-0.11 rad) and steering angle(-0.19 rad). Finally, simulation and experimental results show that the errors and steering angle can decrease gradually, and converge to zero with time.Meanwhile, the control input is not saturated. An articulated drum roller can lock into a desired path with the proposed method in uneven fields.     

半挂牵引车车架模态分析

建立了以板壳单元为基本单元的半挂牵引车车架有限元分析模型，应用NASTRAN有限元分析软件对车架进行了模态分析。计算了该车架在自由状态下的模态参数，并分析了其振动特性和对整车性能的影响。计算结果与试验结果对比分析表明，所建立的有限元模型和分析方法是可行的，可为车架结构的进一步改进提供依据。     

超长型半挂车转向机构优化设计

从半挂汽车转向运动学关系出发，解决了重型汽车改型为超长半挂车的转向机构设计问题。首先对牵引车的转向机构进行优化设计，优化目标是最大程度地减少轮胎的磨损。同时分析了半挂汽车转弯时的运动学特征并确定了半挂车轴距的长度，以保证整个半挂汽车的稳定行驶。     

基于主动悬架系统车辆的道路友好性

为分析悬架系统对车辆道路友好性的影响,设计出可提高道路友好性的主动悬架系统最优控制器,及可分析基于最优控制策略的主动悬架系统,以及被动悬架系统的道路友好性动态仿真模型,仿真分析得出车辆在两种典型的A、B级路面行驶时,基于最优控制策略的主动悬架系统及被动悬架系统车辆对路面造成的动载荷.利用动态载荷系数、动态载荷应力因子及95百分位综合四次幂力三种典型道路友好性评价指标对两种悬架系统的道路友好性进行分析比较.结果表明,采用动态载荷系数、动态载荷应力因子对悬架系统的道路友好性进行评价时,在A级路面上,主动悬架系统的道路友好性分别是被动悬架系统的1.5、1.6倍;在B级路面上主动悬架系统的道路友好性是被动悬架系统的1.5、2.5倍;采用95百分位综合四次幂力指标评价两种悬架系统的道路友好性时,在A级路面上,两种悬架系统的道路友好性相差无几;在B级路面上主动悬架系统的道路友好性比被动悬架系统提高2.5倍.因此,具有合理控制参数的基于最优控制策略的主动悬架系统可提高重型车辆的道路友好性.