Digital twin-based analysis of volumetric error mapping procedures

The evaluation of the volumetric accuracy of a machine tool is an open challenge in the industry, and a wide variety of technical solutions are available in the market and at research level. All solutions have advantages and disadvantages concerning which errors can be measured, the achievable uncertainty, the ease of implementation, possibility of machine integration and automation, the equipment cost and the machine occupation time, and it is not always straightforward which option to choose for each application. The need to ensure accuracy during the whole lifetime of the machine and the availability of monitoring systems developed following the Industry 4.0 trend are pushing the development of measurement systems that can be integrated in the machine to perform semi-automatic verification procedures that can be performed frequently by the machine user to monitor the condition of the machine. Calibrated artefact based calibration and verification solutions have an advantage in this field over laser based solutions in terms of cost and feasibility of machine integration, but they need to be optimized for each machine and customer requirements to achieve the required calibration uncertainty and minimize machine occupation time.This paper introduces a digital twin-based methodology to simulate all relevant effects in an artefact-based machine tool calibration procedure, from the machine itself with its expected error ranges, to the artefact geometry and uncertainty, artefact positions in the workspace, probe uncertainty, compensation model, etc. By parameterizing all relevant variables in the design of the calibration procedure, this simulation methodology can be used to analyse the effect of each design variable on the error mapping uncertainty, which is of great help in adapting the procedure to each specific machine and user requirements. The simulation methodology and the analysis possibilities are illustrated by applying it on a 3-axis milling machine tool.     

Generation,validation and application of dynamic load profiles in flow measurement using cavitating Herschel–Venturi nozzles

Today, utility meters for water are tested for measurement behavior at stable operating conditions at specified flow rates as part of the approval process. The measurement error that occurs during start and stop or when changing between flow rates may not be taken into account. In addition, there are new technologies whose measuring behavior under real-world conditions is only known to a limited extend. To take these facts into account, a new method has been developed and tested to determine the measurement behavior of water meters under dynamic load profiles as they occur in the real application. For this purpose, a test rig for flow rate measurement was extended by a cavitation nozzle apparatus and the generation of dynamic load profiles was validated. For the cavitation nozzles used, possible factors influencing the flow rate, such as temperature and purity of the water as well as the upstream pressure were investigated. Using different types of domestic water meters, the applicability of the dynamic test procedure was demonstrated and the measurement behavior of the meters was characterised.     

Influence of temperature on acoustic emission source location accuracy in underground structure

An acoustic emission (AE) experiment was carried out to explore the AE location accuracy influenced by temperature. A hollow hemispherical specimen was used to simulate common underground structures. In the process of heating with the flame, the pulse signal of constant frequency was stimulated as an AE source. Then AE signals received by each sensor were collected and used for comparing localization accuracy at different temperatures. Results show that location errors of AE keep the same phenomenon in the early and middle heating stages. In the later stage of heating, location errors of AE increase sharply due to the appearance of cracks. This provides some beneficial suggestions on decreasing location errors of structural cracks caused by temperature and improves the ability of underground structure disaster prevention and control.     

Trade-off study between risk and benefit in safety devices for hydrogen refueling stations using a dynamic physical model

As hydrogen refueling stations become increasingly common, it is clear that a high level of economic efficiency and safety is crucial to promoting their use. One way to reduce costs is to use a simple orifice instead of an excess flow valve, which Japanese safety regulations have identified as a safety device. However, there is concern about its effect on refueling time and on risk due to hydrogen leakage. To clarify the effect, we did a study of model-based refueling time evaluation and quantitative risk assessment for a typical refueling station. This study showed that an orifice is an effective alternative safety device. The increase in refueling time was less than 10%, based on simulations using a dynamic physical model of the station. Neither was there a significant difference in the risk between a configuration with excess flow valves and one with an orifice.     

Temperature adaptability of the soluble lead flow battery using different solutions of fluoborate,perchlorate, methanesulfonate and trifluoromethanesulfonate

The evaluation of cell's weatherability is of practical interest. To further improve the soluble lead flow battery's weatherability, physiochemical properties of electrolytes containing fluoborate, perchlorate, methanesulfonate and trifluoromethanesulfonate are investigated from ?60 to 50 °C. Activities of CF₃SO₃H and HClO₄ are poor in trifluoromethanesulfonate and perchlorate solutions due to common anion effect. The solubility of lead salt can be improved by increasing temperature, but worsened by increasing acid's content. With the temperature increasing, the conductivity is enhanced, and the viscosity is lowered for four solutions. The same results have been found by increasing acid's content except for CF₃SO₃H. The high energy efficiency can be achieved for cells over ?40–0 °C using fluoborate and perchlorate solutions, 73.2% at ?40 °C and 78.1% at ?30 °C respectively. Over the temperature range of 20–50 °C, the cells with methanesulfonate and trifluoromethanesulfonate solutions have good performance, 77.4% and 73.7% at 50 °C respectively.     

Generation expansion planning in electricity markets: A novel framework based on dynamic stochastic MPEC

This paper presents a novel framework for generation expansion planning (GEP) of restructured power systems under uncertainty in a multi-period horizon, which includes generation investment from a price maker perspective. The investment problem is modeled as a bi-level optimization problem. The first level problem includes decisions related to investment in order to maximize total profit in the planning horizon. The second level problem consists of maximizing social welfare where the power market is cleared. Rival uncertainties on offering and investment are modeled using sets of scenarios. The bi-level optimization problem is then converted to a dynamic stochastic MPEC and represented as a mixed integer linear program (MILP) after linearization. The proposed framework is examined on a typical six-bus power network, MAZANDARAN regional electric company (MREC) transmission network as an area of IRAN interconnected power system and IEEE RTS 24-bus network. Simulation results confirm that the proposed framework can be a useful tool for analyzing the behavior of investments in electricity markets.     

Study on the non-uniform contact during ELID groove grinding

This paper introduces the potential feasibility that ELID (electrolytic in-process dressing) grinding replaces superfinishing in bearing manufacturing, but ELID grinding will bring new challenges. Different regions present distinguish surface profile due to the non-uniform contact in ELID groove grinding. However, few reports explaining the non-uniform contact are available. This article explores the mechanisms of the non-uniform contact during ELID groove grinding. Experiments on the non-uniform contact between bearing raceway and grinding wheel have been carried out under different conditions. The results show that non-uniform contact exists in ELID groove grinding process and it exerts influence on the profile of the raceway surface. Non-uniform contact influences the Rsk and Rku value all the time, but it influences the Ra value occasionally. Improvement strategies of eliminating the non-uniform contact are also discussed based on the experimental study.     

Effect of strain rate on the dynamic compressive mechanical behaviors of rock material subjected to high temperatures

Strain rate is not only an important measure to characterize the deformation property, but also an important parameter to analyze the dynamic mechanical properties of rock materials. In this paper, by using the SHPB test system improved with high temperature device, the dynamic compressive tests of sandstone at seven temperatures in the range of room temperature to 1000 °C and five impact velocities in the range of 11.0–15.0 m/s were conducted. Investigations were carried out on the influences of strain rate on dynamic compressive mechanical behaviors of sandstone. The results of the study indicate that the enhancement effects of strain rates on dynamic compressive strength, peak strain, energy absorption ratio of sandstone under high temperatures still exist. However, the increase ratios of dynamic compressive strength, peak strain, and energy absorption ratio of rock under high temperature compared to room temperature have no obvious strain rate effects. The temperatures at which the strain rates affect dynamic compressive strength and peak strain most, are 800, and 1000 °C, respectively. The temperatures at which the strain rates affect dynamic compressive strength and peak strain weakest, are 1000 °C, and room temperature, respectively. At 200 and 800 °C, the strain rate effect on energy absorption ratio are most significant, while at 1000 °C, it is weakest. There are no obvious strain rate effects on elastic modulus and increase ratio of elastic modulus under high temperatures. According to test results, the relationship formula of strain rate with high temperature and impact load was derived by internalizing fitting parameters. Compared with the strain rate effect at room temperature condition, essential differences have occurred in the strain rate effect of rock material under the influence of high temperature.     

A Global Maximum Error Controller Based Nonlinearity Aware TPWL Method for Reducing Nonlinear Systems

Abstract

Model order reduction is a common practice to reduce large order systems so that their simulation and control become easy. Nonlinearity aware trajectory piecewise linear is a variation of trajectory piecewise linearization technique of order reduction that is used to reduce nonlinear systems. With this scheme, the reduced approximation of the system is generated by weighted sum of the linearized and reduced sub-models obtained at certain linearization points on the system trajectory. This scheme uses dynamically inspired weight assignment that makes the approximation nonlinearity aware. Just as weight assignment, the process of linearization points selection is also important for generating faithful approximations. This article uses a global maximum error controller based linearization points selection scheme according to which a state is chosen as a linearization point if the error between a current reduced model and the full order nonlinear system reaches a maximum value. A combination that not only selects linearization points based on an error controller but also assigns dynamic inspired weights is shown in this article. The proposed scheme generates approximations with higher accuracies. This is demonstrated by applying the proposed method to some benchmark nonlinear circuits including RC ladder network and inverter chain circuit and comparing the results with the conventional schemes.     

Effects of apparent image velocity and complexity on the dynamic visual field using a high-speed train driving simulator

Train driving is a highly visual task. The visual capabilities of the train driver affects driving safety and driving performance. Understanding the effects of train speed and background image complexity on the visual behavior of the high-speed train driver is essential for optimizing performance and safety. This study investigated the role of the apparent image velocity and complexity on the dynamic visual field of drivers. Participants in a repeated-measures experiment drove a train at nine different speeds in a state-of-the-art high-speed train simulator. Eye movement analysis indicated that the effect of image velocity on the dynamic visual field of high-speed train driver was significant while image complexity had no effect on it. The fixation range was increasingly concentrated on the middle of the track as the speed increased, meanwhile there was a logarithmic decline in fixation range for areas surrounding the track. The extent of the visual search field decreased gradually, both vertically and horizontally, as the speed of train increased, and the rate of decrease was more rapid in the vertical direction. A model is proposed that predicts the extent of this tunnel vision phenomenon as a function of the train speed.Relevance to industryThis finding can be used as a basis for the design of high-speed railway system and as a foundation for improving the operational procedures of high-speed train driver for safety.