Machines

20 pages, 7621 KiB

Open AccessArticle

Enhancing Photovoltaic-Powered DC Shunt Motor Performance for Water Pumping through Fuzzy Logic Optimization

by Abdulaziz Alkuhayli, Abdullah M. Noman, Abdullrahman A. Al-Shamma’a, Akram M. Abdurraqeeb, Mohammed Alharbi, Hassan M. Hussein Farh and Affaq Qamar

Machines 2024, 12(7), 442; https://0-doi-org.brum.beds.ac.uk/10.3390/machines12070442 (registering DOI) - 27 Jun 2024

Abstract

This paper addresses the critical challenge of optimizing the maximum power point (MPP) tracking of photovoltaic (PV) modules under varying load and environmental conditions. A novel fuzzy logic controller design has been proposed to enhance the precision and adaptability of MPP monitoring and [...] Read more.

This paper addresses the critical challenge of optimizing the maximum power point (MPP) tracking of photovoltaic (PV) modules under varying load and environmental conditions. A novel fuzzy logic controller design has been proposed to enhance the precision and adaptability of MPP monitoring and adjustment. The research objective is to improve the efficiency and responsiveness of PV systems by leveraging voltage and power as input parameters to generate an optimized duty cycle for a buck-boost converter. This system is tested through both simulation and experimental validation, comparing its performance against the conventional perturb and observe (P&O) method. Our methodology includes rigorous testing under diverse conditions, such as temperature fluctuations, irradiance variations, and sudden load changes. The fuzzy logic technique is implemented to adjust the reference voltage every 100 µs, ensuring continuous optimization of the PV module’s operation. The results revealed that the proposed fuzzy logic controller achieves a tracking efficiency of approximately 99.43%, compared to 97.83% for the conventional P&O method, demonstrating its superior performance. For experimental validation, a 150 W prototype converter controlled by a dSPACE DS1104 integrated solution was used. Real-world testing involved both a resistive static load and a dynamic load represented by a DC shunt motor. The experimental results confirmed the robustness and reliability of the fuzzy logic controller in maintaining optimal MPP operation, significantly outperforming traditional methods. In brief, this research introduces and validates an innovative fuzzy logic control strategy for MPP tracking, contributing to the advancement of PV system efficiency. The findings highlight the effectiveness of the proposed approach in consistently optimizing PV module performance across various testing scenarios. Full article

(This article belongs to the Special Issue Performance-Explainable Fault Diagnosis and Advanced Control Techniques for Industrial Dynamic Systems)

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22 pages, 7161 KiB

Open AccessArticle

Experiment and Simulation of Liquid Film Flow Driving Abrasive Particle Dispersion on the Surface of a Rotating Disk

by Qiong Fu, Weibin Shi, Nian Duan, Hui Huang and Yong Zhang

Machines 2024, 12(7), 441; https://0-doi-org.brum.beds.ac.uk/10.3390/machines12070441 (registering DOI) - 27 Jun 2024

Abstract

Controlling the distribution of the abrasive grains on the surface of the grinding tools in an appropriate way is important for improving the quality of grinding processing and meeting the workpiece precision requirements. In the present study, a novel method for the orderly [...] Read more.

Controlling the distribution of the abrasive grains on the surface of the grinding tools in an appropriate way is important for improving the quality of grinding processing and meeting the workpiece precision requirements. In the present study, a novel method for the orderly arrangement of abrasive particles is proposed by using the liquid film flow on the surface of the rotating disk as the driving and controlling means for the uniform dispersion and position arrangement of abrasive particles. Computational fluid dynamics (CFD) simulations have been performed to clearly illustrate the trajectories of abrasive particles under the strong influence of liquid film flow on the rotating disk and reveal the effects of fluid flow, disk rotational motion, and the mixture viscosity on the particle distribution. A new abrasive grain arrangement device is designed and fabricated using this novel method. The operating parameters such as liquid volume flow rate, disk rotational speed, and liquid viscosity are adjusted to control the placement of abrasive grains on the surface of the grinding tool. An image processing tool is used to examine and analyze the arrangement results. The experimental results indicated that the application of the liquid film flow on a rotating disk to the abrasive grain arrangement can improve the arrangement of abrasive grains and get rid of the dependence on the template. Full article

(This article belongs to the Topic Advanced Manufacturing and Surface Technology)

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12 pages, 5734 KiB

Open AccessArticle

A Conceptual Framework Based on Current Directives to Design Lithium-Ion Battery Industrial Repurposing Models

by Akash Basia, Zineb Simeu-Abazi, Eric Gascard and Peggy Zwolinski

Machines 2024, 12(7), 440; https://0-doi-org.brum.beds.ac.uk/10.3390/machines12070440 (registering DOI) - 27 Jun 2024

Abstract

The global market for End of Life Lithium-Ion Batteries is growing exponentially to satisfy the needs of electric mobility and clean energy technologies. Reusing or repurposing these batteries could ensure sustainability and keep the excessive demands of raw materials in check. However, a [...] Read more.

The global market for End of Life Lithium-Ion Batteries is growing exponentially to satisfy the needs of electric mobility and clean energy technologies. Reusing or repurposing these batteries could ensure sustainability and keep the excessive demands of raw materials in check. However, a strong commitment and trust from the various stakeholders is necessary to build such circular industrial systems. In this paper, a thorough analysis of practices and regulations allowed us to highlight the actors and processes involved in the life cycle of repurposed Lithium-Ion Batteries (LIBs). This led us to propose a conceptual framework describing a generic organization for LIB repurposing. LIB State of Health and diagnosis estimations, which can be carried out with data from LIB passports, are also underlined as essential for the functioning of the organization. This was discussed and implemented on a real case of LIBs used as a power source for electric heaters after their first life in a mobility application. Full article

(This article belongs to the Special Issue Evaluation of State of Health of Equipment for Predictive Maintenance and Circular Economy)

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14 pages, 1126 KiB

Open AccessArticle

Response Surface Methodology for Kinematic Design of Soft Pneumatic Joints: An Application to a Bio-Inspired Scorpion-Tail-Actuator

by Michele Gabrio Antonelli, Pierluigi Beomonte Zobel and Nicola Stampone

Machines 2024, 12(7), 439; https://0-doi-org.brum.beds.ac.uk/10.3390/machines12070439 (registering DOI) - 26 Jun 2024

Abstract

In soft robotics, the most used actuators are soft pneumatic actuators because of their simplicity, cost-effectiveness, and safety. However, pneumatic actuation is also disadvantageous because of the strong non-linearities associated with using a compressible fluid. The identification of analytical models is often complex, [...] Read more.

In soft robotics, the most used actuators are soft pneumatic actuators because of their simplicity, cost-effectiveness, and safety. However, pneumatic actuation is also disadvantageous because of the strong non-linearities associated with using a compressible fluid. The identification of analytical models is often complex, and finite element analyses are preferred to evaluate deformation and tension states, which are computationally onerous. Alternatively, artificial intelligence algorithms can be used to follow model-free and data-driven approaches to avoid modeling complexity. In this work, however, the response surface methodology was adopted to identify a predictive model of the bending angle for soft pneumatic joints through geometric and functional parameters. The factorial plan was scheduled based on the design of the experiment, minimizing the number of tests needed and saving materials and time. Finally, a bio-inspired application of the identified model is proposed by designing the soft joints and making an actuator that replicates the movements of the scorpion’s tail in the attack position. The model was validated with two external reinforcements to achieve the same final deformation at different feeding pressures. The average absolute errors between predicted and experimental bending angles for I and II reinforcement allowed the identified model to be verified. Full article

(This article belongs to the Special Issue Intelligent Bio-Inspired Robots: New Trends and Future Perspectives)

27 pages, 7945 KiB

Open AccessArticle

Prediction of Drilling Efficiency for Rotary Drilling Rig Based on an Improved Back Propagation Neural Network Algorithm

by Cunde Jia, Junyong Zhang, Xiangdong Kong, Hongyu Xu, Wenguang Jiang, Shengbin Li, Yunhong Jiang and Chao Ai

Machines 2024, 12(7), 438; https://0-doi-org.brum.beds.ac.uk/10.3390/machines12070438 - 26 Jun 2024

Viewed by 94

Abstract

Accurately predicting the drilling efficiency of rotary drilling is the key to achieving intelligent construction. The current types of principle analysis (based on traditional interactive experimental methods) and efficiency prediction (based on simulation models) cannot meet the requirements needed for the efficient, real-time, [...] Read more.

Accurately predicting the drilling efficiency of rotary drilling is the key to achieving intelligent construction. The current types of principle analysis (based on traditional interactive experimental methods) and efficiency prediction (based on simulation models) cannot meet the requirements needed for the efficient, real-time, and accurate drilling efficiency predictions of rotary drilling rigs. Therefore, we adopted a method based on machine learning to predict drilling efficiency. The extremely complex rock fragmentation process in drilling conditions also brings challenges to predicting drilling efficiency. Therefore, this article went through a combination of mechanism and data analysis to conduct correlation analysis and to clarify the drilling characteristic parameters that are highly correlated with drilling efficiency, and it then used them as inputs for machine learning models. We propose a rotary drilling rig drilling efficiency prediction model based on the GA-BP neural network to construct an accurate and efficient drilling efficiency prediction model. Compared with traditional BP neural networks, it utilizes the global optimization ability of a genetic algorithm to obtain the initial weights and thresholds of a BP neural network in order to avoid the defect of ordinary BP neural networks, i.e., that they easily fall into local optimal solutions during the training process. The average prediction accuracy of the GA-BP neural network is 93.6%, which is 3.1% higher than the traditional BP neural network. Full article

(This article belongs to the Section Machine Design and Theory)

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13 pages, 2979 KiB

Open AccessArticle

Optimization of the Surface Roughness and Chip Compression Ratio of Duplex Stainless Steel in a Wet Turning Process Using the Taguchi Method

by Virginija Gyliene, Algimantas Brasas, Antanas Ciuplys and Janina Jablonskyte

Machines 2024, 12(7), 437; https://0-doi-org.brum.beds.ac.uk/10.3390/machines12070437 - 26 Jun 2024

Viewed by 98

Abstract

Duplex stainless steels (DSSs) are used in many applications due to their properties, such as high mechanical strength, good corrosion resistance, and relatively low cost. Nevertheless, DSS belongs to the materials group that is difficult to machine. The demand for a total increase [...] Read more.

Duplex stainless steels (DSSs) are used in many applications due to their properties, such as high mechanical strength, good corrosion resistance, and relatively low cost. Nevertheless, DSS belongs to the materials group that is difficult to machine. The demand for a total increase in the production requires the optimization of cutting conditions. This paper examines the influence of cutting parameters, namely cutting velocity, feed, and the depth of cut on the surface roughness and chip compression ratio (CCR) after the DSS wet turning process. The study employed Taguchi optimization to determine the ideal cutting parameters for wet turning finishing operations on steel 1.4462. Using the Taguchi design, experiments focused on surface roughness (Ra) and CCR. Utilizing a TiAlN/TiN-PVD coating insert with a 0.4 mm nose radius, cutting velocity of 200 m/min, feed rates of 0.05 mm/rev, and cutting depths of 1 mm yielded the lowest R_a at 0.433 μm. Meanwhile, a cutting velocity of 200 m/min, feed rate of 0.15 mm/rev, and cutting depth of 0.5 mm resulted in the smallest CCR at 1.39, indicating minimal plastic deformation. The inclusion of additional cooling proved beneficial for surface roughness compared to dry and wet turning methods. The experimental data holds value for training and validating artificial intelligence models, preventing overfitting by ensuring sufficient data collection. Full article

15 pages, 17757 KiB

Open AccessArticle

A Study on the Machinability and Environmental Effects of Milling AISI 5140 Steel in Sustainable Cutting Environments

by Tufan Zerooğlu, Ünal Değirmenci and Serhat Şap

Machines 2024, 12(7), 436; https://0-doi-org.brum.beds.ac.uk/10.3390/machines12070436 - 26 Jun 2024

Viewed by 99

Abstract

AISI 5140 steel is an alloy frequently used in the manufacturing and automotive industries. This steel alloy is shaped using different manufacturing methods and cooling is required during this process. This research study included the milling of AISI 5140 steel utilizing various cutting [...] Read more.

AISI 5140 steel is an alloy frequently used in the manufacturing and automotive industries. This steel alloy is shaped using different manufacturing methods and cooling is required during this process. This research study included the milling of AISI 5140 steel utilizing various cutting settings and cooling/lubrication procedures. For this purpose, two cutting speeds (75–100 m/min), two feed rates (0.075–0.100 mm/rev), and four cooling media (dry, MQL, flood, nanofluid) were used. Then, 5% Mo nanoparticles were added to the nanofluid cutting fluid. Machinability and power consumption analyses were carried out using the input parameters selected in light of the manufacturer’s recommendations and studies in the literature. The effects of sustainable cutting fluids and their parameters on machinability and power consumption were investigated through experiments. This study concluded that the use of nanofluid led to improvements in surface roughness, flank wear, and power consumption characteristics. It was determined that the flood environment is the most effective in reducing the cutting temperature. As a result, it is predicted that nanofluid cutting fluids can be used during machining. Full article

(This article belongs to the Special Issue Recent Advances in Surface Integrity with Machining and Milling)

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14 pages, 29667 KiB

Open AccessArticle

An Accurate and Rapid Docking Algorithm for Four-Way Shuttle in High-Density 3D Warehousing Environment

by Xiangpeng Liu, Xun Liu, Yaqing Song, Yu Hu, Liuchen Zhou and Xiaonong Xu

Machines 2024, 12(7), 435; https://0-doi-org.brum.beds.ac.uk/10.3390/machines12070435 - 25 Jun 2024

Viewed by 140

Abstract

High-density 3D warehousing is the future cornerstone of modern logistics storage. It aims to efficiently manage and store various types of goods by utilizing 3D space and automation technology. The accurate and fast docking algorithm of the four-way shuttles, as a core method [...] Read more.

High-density 3D warehousing is the future cornerstone of modern logistics storage. It aims to efficiently manage and store various types of goods by utilizing 3D space and automation technology. The accurate and fast docking algorithm of the four-way shuttles, as a core method of carrying the goods in high-density 3D warehousing, has become an increasingly important technical challenge. Inaccurate docking will result in a failure to change direction, while long docking time will affect the operation efficiency of the four-way shuttle. To overcome these obstacles, this paper presents an accurate and rapid docking algorithm for four-way shuttles. Firstly, the deceleration and jerk of a four-way shuttle in the braking stage are initialized according to the motion parameter set calculated by the docking motion model. Then, the four-way shuttle starts to move until the stop signal has been detected. If the system fails to detect the stop signal, the distance compensation is needed to ensure that the four-way shuttle can arrive at the stop point. Finally, the four-way shuttle stops immediately by way of amplifying the deceleration when reaching the stop point. The result shows that the accuracy of rapid docking is superior to that of direct docking. Compared with crawling docking, rapid docking reduces the braking time by 3.99s and stops at a speed lower than the crawling speed. The rapid docking algorithm not only enhances the throughput of high-density 3D warehousing but also improves the service life of four-way shuttles. Full article

(This article belongs to the Section Industrial Systems)

16 pages, 6146 KiB

Open AccessArticle

Investigation of Valve Seat Cone Angle on Small Opening Direct-Acting Relief Valve Cavitation Noise

by Tiechao Qiu, Liu Yang, Jiannan Zhang, Zhanqi Wang, Yanhe Song and Chao Ai

Machines 2024, 12(7), 434; https://0-doi-org.brum.beds.ac.uk/10.3390/machines12070434 - 25 Jun 2024

Viewed by 128

Abstract

Direct-acting relief valves are important pressure-control components in hydraulic systems; however, noise problems are now common. This study aimed to reduce and numerically analyze the valve cavitation and noise using the Zwart–Gerber–Belamri (ZBG) model with the Ffowcs Williams and Hawkings (FW–H) model to [...] Read more.

Direct-acting relief valves are important pressure-control components in hydraulic systems; however, noise problems are now common. This study aimed to reduce and numerically analyze the valve cavitation and noise using the Zwart–Gerber–Belamri (ZBG) model with the Ffowcs Williams and Hawkings (FW–H) model to optimize the design based on the sound field perspective. First, a direct-acting relief valve flow field model was established to determine the relationship between the seat structure and the degree of cavitation through a CFD (Computational Fluid Dynamics) simulation. Second, sound field analysis was conducted based on the cavitation and non-cavitation flow fields, respectively, and the resulting noise levels were compared. Finally, prototypes of the relief valve were manufactured, and noise levels between the original and optimized valves were compared. The results revealed that cavitation within the relief valve generated noise while optimizing the valve seat cone angle suppressed this phenomenon, thereby reducing the noise emitted by the optimized valve by 18.2 dB compared to the original valve. These findings can serve as a guide for designing and optimizing direct-acting relief valves. Full article

(This article belongs to the Special Issue Components of Hydrostatic Drive Systems)

18 pages, 1221 KiB

Open AccessArticle

Adaptive Control for Suspension System of In-Wheel Motor Vehicle with Magnetorheological Damper

by Dal-Seong Yoon and Seung-Bok Choi

Machines 2024, 12(7), 433; https://0-doi-org.brum.beds.ac.uk/10.3390/machines12070433 - 25 Jun 2024

Viewed by 129

Abstract

This study proposes two adaptive controllers and applies them to the vibration control of an in-wheel motor vehicle’s (electric vehicle) suspension system, in which a semi-active magnetorheological (MR) damper is installed as an actuator. As a suspension model, a nonlinear quarter car is [...] Read more.

This study proposes two adaptive controllers and applies them to the vibration control of an in-wheel motor vehicle’s (electric vehicle) suspension system, in which a semi-active magnetorheological (MR) damper is installed as an actuator. As a suspension model, a nonlinear quarter car is used, providing greater practical feasibility than linear models. In the synthesis of the controller design, the values of the sprung mass, damping coefficient and suspension stiffness are treated as bounded uncertainties. To take into account the uncertainties, both direct and indirect adaptive sliding mode controllers are designed, in which the principal control parameters for the adaptation law are updated using the auto-tune method. To reflect the practical implementation of the proposed controller, only two accelerometers are used, and the rest of the state values are estimated using a Kalman observer. The designed controller is applied to a quarter car suspension model of an in-wheel motor vehicle featuring an MR damper, followed by a performance evaluation considering factors such as ride comfort and road holding. It is demonstrated in this comparative work that the proposed adaptive controllers show superior control performance to the conventional proportional–integral–derivative (PID) controller by reducing the vibration magnitude by 50% and 70% for the first and second modes, respectively. In addition, it is identified that the second mode (wheel mode) of the in-wheel motor vehicle is more sensitive than the first body mode depending on the mass ratio between the sprung and unsprung mass. Full article

(This article belongs to the Special Issue Adaptive Control Using Magnetorheological Technology)

23 pages, 7155 KiB

Open AccessArticle

Variable Layer Heights in Wire Arc Additive Manufacturing and WAAM Information Models

by Ethan Kerber, Heinrich Knitt, Jan Luca Fahrendholz-Heiermann, Emre Ergin, Sigrid Brell-Cokcan, Peter Dewald, Rahul Sharma and Uwe Reisgen

Machines 2024, 12(7), 432; https://0-doi-org.brum.beds.ac.uk/10.3390/machines12070432 - 25 Jun 2024

Viewed by 165

Abstract

In Wire Arc Additive Manufacturing (WAAM), variable layer heights enable the non-parallel or non-planar slicing of parts. In researching variable layer heights, this paper documents printing strategies for a reference geometry whose key features are non-orthogonal growth and unsupported overhangs. The complexity of [...] Read more.

In Wire Arc Additive Manufacturing (WAAM), variable layer heights enable the non-parallel or non-planar slicing of parts. In researching variable layer heights, this paper documents printing strategies for a reference geometry whose key features are non-orthogonal growth and unsupported overhangs. The complexity of 3D printing with welding requires parameter optimization to control the deposition of molten material. Thus, 3D printing with welding requires the precise deposition of molten material. Currently, there is no standard solution for the customization of process parameters and intelligent collection of data from sensors. To address this gap in technology, this research develops an Internet of Things (IoT)-enabled, distributed communication protocol to control process parameters, synchronize commands, and integrate device data. To intelligently collect sensor information, this research creates a query-able database during pre-planning and production. This contributes to fundamental research in WAAM by documenting strategies for printing variable layer heights, the customization of control parameters, and the collection of data through a WAAM Information Model (WIM). Full article

(This article belongs to the Special Issue Intelligent Welding)

18 pages, 3622 KiB

Open AccessArticle

Experimental Evidence of Efficient Phononic-Based Vibration Isolators for Mechanical Applications

by Hugo Policarpo, Raquel A. B. Almeida, Miguel M. Neves and Nuno M. M. Maia

Machines 2024, 12(7), 431; https://0-doi-org.brum.beds.ac.uk/10.3390/machines12070431 - 24 Jun 2024

Viewed by 171

Abstract

Even though the design of vibration isolators is well-established for many engineering applications, their efficiency in wide and multiple frequency ranges is still a challenge. In these cases, the use of Phononic-Based Vibration Isolators (PBVIs) may be advantageous as they present different Attenuation [...] Read more.

Even though the design of vibration isolators is well-established for many engineering applications, their efficiency in wide and multiple frequency ranges is still a challenge. In these cases, the use of Phononic-Based Vibration Isolators (PBVIs) may be advantageous as they present different Attenuation Regions (ARs) in which the elastic waves are strongly attenuated. Therefore, the present paper is devoted to the experimental evaluation, in terms of force transmissibility, of different types of supporting devices tested on a load mass and a motor of a Hermetic Compressor (HC). Those devices are the original Helical Coil Spring (HS) that equips the HC, the PBVI, and the Combined Structure (CS) which is composed of a PBVI combined in series with the HS. Results evidentiate the capability of the CSs to isolate vibrations, where the PBVI contributes with its ARs, thus operating as a “filter” in specific frequency ranges, while the HSs maintain the flexibility of the CSs, which is advantageous for impact-loads and/or transient-case scenarios. Hence, the capability, relevance and impact that these PBVIs present for force transmissibility reduction applications is highlighted here, which should capture the attention of and motivate the industry, e.g., producers of isolation systems, since it has wide-ranging engineering applications. Full article

(This article belongs to the Special Issue Creative Mechanism Design in Applied Mechanics)

17 pages, 8573 KiB

Open AccessArticle

A Robust Online Diagnostic Strategy of Inverter Open-Circuit Faults for Robotic Joint BLDC Motors

by Mohamed Y. Metwly, Victor M. Logan, Charles L. Clark, Jiangbiao He and Biyun Xie

Machines 2024, 12(7), 430; https://0-doi-org.brum.beds.ac.uk/10.3390/machines12070430 - 24 Jun 2024

Viewed by 182

Abstract

As robots are increasingly used in remote, safety-critical, and hazardous applications, the reliability of robots is becoming more important than ever before. Robotic arm joint motor-drive systems are vulnerable to hardware failures due to harsh operating environment in many scenarios, which may yield [...] Read more.

As robots are increasingly used in remote, safety-critical, and hazardous applications, the reliability of robots is becoming more important than ever before. Robotic arm joint motor-drive systems are vulnerable to hardware failures due to harsh operating environment in many scenarios, which may yield various joint failures and result in significant downtime costs. Targeting the most common robotic joint brushless DC (BLDC) motor-drive systems, this paper proposes a robust online diagnostic method for semiconductor faults for BLDC motor drives. The proposed fault diagnostic technique is based on the stator current signature analysis. Specifically, this paper investigates the performance of the BLDC joint motors under open-circuit faults of the inverter switches using finite element co-simulation tools. Furthermore, the proposed methodology is not only capable of detecting any open-circuit faults but also identifying faulty switches based on a knowledge table by considering various fault conditions. The robustness of the proposed technique was verified through extensive simulations under different speed and load conditions. Moreover, simulations have been carried out on a Kinova Gen-3 robot arm to verify the theoretical findings, highlighting the impacts of locked joints on the robot’s end-effector locations. Finally, experimental results are presented to corroborate the performance of the proposed fault diagnostic strategy. Full article

(This article belongs to the Special Issue Towards Electric Motors and Drives: Condition Monitoring, Performance Prediction and Fault Diagnosis)

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19 pages, 5174 KiB

Open AccessArticle

Finite Speed-Set Model Reference Adaptive System Based on Sensorless Control of Permanent Magnet Synchronous Generators for Wind Turbines

by Mohammed A. Hassan, Mahmoud M. Adel, Ahmed Farhan and Amr A. Saleh

Machines 2024, 12(7), 429; https://0-doi-org.brum.beds.ac.uk/10.3390/machines12070429 - 24 Jun 2024

Viewed by 187

Abstract

This paper proposes a novel finite speed-set model reference adaptive system (FSS-MRAS) based on the current predictive control (CPC) of a permanent magnet synchronous generator (PMSG) in wind energy turbine systems (WETSs). The mathematical models of wind energy systems (WESs) coupled with a [...] Read more.

This paper proposes a novel finite speed-set model reference adaptive system (FSS-MRAS) based on the current predictive control (CPC) of a permanent magnet synchronous generator (PMSG) in wind energy turbine systems (WETSs). The mathematical models of wind energy systems (WESs) coupled with a permanent magnet synchronous generator (PMSG) are presented in addition to the implementation of the CPC of PMSGs. The proposed FSS-MRAS is based on eliminating the tuning burden of the conventional MRAS by using a limited set of speeds of the PMSG rotor that are employed to predict the rotor speed of the generator. Consequently, the optimal speed of the rotor is the one resulting from the optimization of a proposed new cost function. Accordingly, the conventional MRAS controller is eliminated and the main disadvantage represented in the tuning burden of the constant-gain proportional-integral (PI) controller has been overcome. The proposed FSS-MRAS observer is validated using MATLAB/Simulink (R2023b) at different operating conditions. The results of the proposed FSS-MRAS have been compared with those of the conventional MRAS, which proved the high robustness and reliability of the proposed observer. Full article

(This article belongs to the Section Electrical Machines and Drives)

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14 pages, 7885 KiB

Open AccessArticle

Fault Identification of Direct-Shift Gearbox Using Variational Mode Decomposition and Convolutional Neural Network

by Rishikesh Kumar, Prabhat Kumar, Govind Vashishtha, Sumika Chauhan, Radoslaw Zimroz, Surinder Kumar, Rajesh Kumar, Munish Kumar Gupta and Nimel Sworna Ross

Machines 2024, 12(7), 428; https://0-doi-org.brum.beds.ac.uk/10.3390/machines12070428 - 24 Jun 2024

Viewed by 228

Abstract

The direct-shift gearbox is widely used in many applications, such as automotive and aerospace, due to its large transmission ratio and high transmission efficiency. Rough and heavy-duty working conditions induce various faults, such as scratches, fatigue cracks, pitting, and missing teeth due to [...] Read more.

The direct-shift gearbox is widely used in many applications, such as automotive and aerospace, due to its large transmission ratio and high transmission efficiency. Rough and heavy-duty working conditions induce various faults, such as scratches, fatigue cracks, pitting, and missing teeth due to breakage. These defects may lead to the failure of one or more components attached to an automatic transmission system. A fault identification scheme for the direct-shift gearbox has been developed, making use of variational mode decomposition (VMD) and convolutional neural network (CNN). The acquired raw signal from the gearbox under different health conditions (healthy, pitting, and chipping) is decomposed into different modes using VMD. The prominent mode is selected based on kurtosis, which is utilized to obtain scalograms. An image matrix is formed utilizing scalograms. Such matrices from different scalograms are divided into training and testing matrices. The training matrices train the CNN model, whereas the testing matrices validate the efficacy of the built CNN model. The proposed scheme identifies faults with 100% accuracy. The proposed scheme has also been compared with other neural networks. These results suggest that the proposed scheme outperforms other networks. Full article

(This article belongs to the Special Issue Application of Sensing Measurement in Machining)

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20 pages, 1186 KiB

Open AccessArticle

A Coordinated Mode Switch Control Strategy for a Two-Gear Power-Split Hybrid System

by Qinpeng Sun, Xueliang Li, Xinlei Liu and Wei Wu

Machines 2024, 12(7), 427; https://0-doi-org.brum.beds.ac.uk/10.3390/machines12070427 - 21 Jun 2024

Viewed by 274

Abstract

The hybrid system can extend the range of special vehicles and meet the electrical requirements of on-board equipment. In this paper, the driving force plummet problem of a new two-gear power-split hybrid system was studied during gear switches in a hybrid mode. The [...] Read more.

The hybrid system can extend the range of special vehicles and meet the electrical requirements of on-board equipment. In this paper, the driving force plummet problem of a new two-gear power-split hybrid system was studied during gear switches in a hybrid mode. The dynamic model of a hybrid electric system was established, and the effects of the engine angular acceleration and angular jerk on vehicle power and ride performance were obtained. The optimal ratio of the torque change rate of the motor and engine in the mode switch process was proposed. Considering the battery limitation and the external characteristics of the engine, the method of determining the target speed of the engine during shifting was proposed. Considering the response characteristics of each power source, the dynamic coordinated control strategy of multiple power sources in the mode switch process was proposed. The vehicle dynamics model was established based on the Matlab/Simulink 2020b and verified by simulation and a hardware-in-the-loop (HIL) test. The results show that the dynamic coordinated control strategy can reduce the peak impact by 80.33%, effectively improve the vehicle power and ride performance, and prevent the occurrence of high-current battery charging. Full article

(This article belongs to the Topic Vehicle Dynamics and Control)

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Machines, Volume 12, Issue 7 (July 2024) – 16 articles

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