Recent Patents on Mechanical Engineering - Volume 17, Issue 5, 2024

Background: Hospitals account for the most proportion of energy consumption in the public building sector. Chillers usually account for most of the overall energy consumption of the cold source system. Objective: To solve the problem of chillers' large energy consumption problem, novel technologies were developed, and achievements were patented. Methods: The operating characteristics influencing factors of the magnetic suspension centrifugal chiller (MSCC) and variable frequency screw chiller (VFSC) of a hospital in Shanghai were analyzed and discussed by actual measurements. Then, based on the operating characteristics of the chiller obtained from the analysis of the measured data, the cooling capacity was classified by the K-Means clustering method to obtain the startup strategy of the chillers. Results: The effects of the supply chilled water temperature, the supply cooling water temperature and variable cooling water flow rate on the maximum cooling capacity and coefficient of performance (COP) of both chillers were explored. The load distribution scheme was discussed based on the chillers' startup strategy. Conclusion: The average part load ratio operation scheme was the preferred chiller distribution scheme. A chiller's maximum allowable part load ratio should not exceed 80% during the low-load operation period and should not be less than 60% during the conventional operation period. It provided a reference for optimizing the chiller operation strategy to reduce system energy consumption.

Background: Railroad transportation in the actual operation process, there are also many dangerous accidents caused by resonance, which greatly affect the safety of railroad transportation. A comprehensive examination of the operational dynamics within the power branch of a traction substation is imperative for sustaining system equilibrium. Discrepancies between these facets pose a potential threat to the safety of railway transport. Thus, a meticulous analysis of highfrequency resonance characteristics and the formulation of effective suppression techniques become paramount. Objective: Harmonics from grid-side locomotive traction braking are scrutinized under different operational scenarios and different train runs. The aim is to develop an effective harmonic management strategy to normalize the THD and thus maintain the traction power supply system to become more stable. Methods: This study investigates the high-frequency harmonic resonance characteristics using a control variable approach. Harmonics and negative sequences generated during locomotive traction braking under different operating conditions are investigated by means of extensive analysis. These challenges require the implementation of a harmonic management method. This method uses a combination of two monotonic filters and a C filter in parallel. This method applies to different operating conditions and can dynamically adapt harmonics to changes in the number of trains, which is related to the actual dynamics of the traction power system closely. Results: A comparative evaluation of seven operating conditions shows that the filter in this patent exceeds the efficiency of existing methods. The filter reduces the fluctuations during spectral changes, and the voltage distortion rate decreases from the previous 2.33% to 0.55%, making it more adaptable and promising effective harmonic management in high voltage and high current situations. Conclusion: Through multiple simulation tests, a synergistic configuration involving the C-type filter and two single-tuned parallel connections under regenerative braking conditions emerges. This refined, patented filter design not only mitigates the impact of negative sequence during the filtration process but also substantially diminishes high harmonics and THD.

Background: The substantial cutting force and elevated cutting temperature during the machining of hardened steel GCr15 exacerbate tool wear. Objective: In this study, the influence of cutting parameters on cutting force and cutting temperature in the process of hard-cutting GCr15 was studied, the cutting parameters were optimized, and the cutting force and cutting temperature were predicted. Methods: The cutting simulation model was constructed using ABAQUS software, and the cutting force and cutting temperature were investigated under various cutting parameters through range analysis, variance analysis, and signal-to-noise ratio transformation analysis. Results: The simulation and experimental results demonstrated that the cutting force could be optimized by utilizing cutting speed vc=140 m/min, feed rate f=0.1 mm/r, and cutting depth ap=0.1 mm. Under these conditions, the cutting force in the x-direction was measured as 78.560N, while the cutting force in the y-direction was 32.423N. Moreover, for achieving the optimal cutting temperature, the recommended cutting parameters were cutting speed vc=120 m/min, feed rate f=0.1 mm/r, and cutting depth ap=0.4 mm. Conclusion: Compared to the conventional analytical method, which is burdened with high costs and low efficiency, the patent leverages finite element simulation technology to replicate the hardcutting process and its underlying cutting mechanism. This innovation simplifies the otherwise complex and laborious experimental and measurement procedures. By studying cutting force and cutting temperature, the optimization of cutting parameters can be achieved, thus offering valuable theoretical insights for practical production.

Background: Compaction in the powder metallurgy process typically involves using a die and punch, applying high pressure to mixed powder to achieve product quality, such as geometry, density, and porosity. This step is critical in the powder metallurgy process. Objective: This study aims to systematically design and manufacture a die and punch for compacting an Alumina-based matrix composite. Specimens were selected according to ASTM C 1421-10 guidelines, and the die and punch were constructed using AISI D3 tool steel alloy. Methods: To ensure satisfactory compaction, the design underwent virtual testing using Finite Element Analysis (FEA) with compaction loads ranging from 2.5 to 20 tons in 2.5-ton increments. The simulation results were validated through experimental testing. Results: The die parts were analyzed for three-dimensional stress and deformation during compaction. Maximum stress distribution was observed in the Alumina powder, followed by the punch, plate, and die. Additionally, compaction behavior and density tests confirmed that a compaction pressure of 548 MPa or more results in high relative density in the Alumina-based matrix composite powder during the compaction process. Conclusion: Both simulation and experimental results indicate that a compaction pressure of 548 MPa or more is necessary to achieve satisfactory compaction of the Alumina-based matrix composite. These findings offer practical implications for optimizing the powder metallurgy compaction process and reducing costs.

Background: The efficient and accurate calculation of working chamber volume can greatly contribute to the optimized design efficiency of the combined profile scroll compressor, but current papers and patents lack research on the method of calculating the working chamber volume of a combined profile scroll compressor. Objective: A method of using digital image processing is proposed to efficiently calculate the working chamber volume of a combined scroll compressor. Methods: This method discretizes and reconstructs the scroll profile that forms the working chamber into a coordinate sequence with equal involute angle intervals. By calculating the relationship between the coordinate sequence and the rotation angle, a general coordinate sequence that forms the working chamber profile is obtained. The real-time changes in the projection image of the working chamber during all the suction, compression and discharge processes can be accurately depicted. The digital image is processed to obtain the actual projection area of the working chamber, and thus, the volume of the working chamber is accurately calculated. Results: The digital image method can accurately calculate the volume change of the working chamber of the combined profile scroll compressor by selecting the appropriate involute angle interval and digital image size, with a mean relative error of less than 1%. At the beginning of suction and the end of discharge, the calculated volume has been found to have poor accuracy, with a maximum relative error higher than 10%. Conclusion: The digital image method has been found to have high accuracy, greatly reduce the difficulty of the analysis of the working chamber volume, and promote the design optimization of the combined profile scroll compressor, thus broadening the idea for the calculation method of the working chamber volume of the scroll compressor.

Background: Low-frequency resonance is one of the common issues encountered during the variable-frequency operation of condensate water pumps. There have been numerous patents and papers proposing solutions to address the low-frequency resonance problem in condensate water pumps. However, the solutions for resonance problems often need to be tailored to specific circumstances. Methods: Based on the acoustic method, the dynamic model of the rotor and inner cylinder of Jiangsu Guohua Chenjiagang Power Plant 2B condensate pump is established to compare the difference between dry modal and fluid-structure coupling modal, the influence of perpendicularity, concentricity and bearing wear on the natural frequency of rotor is studied. Results: The rotor is rigid under normal conditions. When the bearing is worn, the frequency of the rotor will be greatly reduced and may fall into the frequency conversion operation range to excite resonance. The deviation of perpendicularity and concentricity will not directly lead to the decrease of rotor modal but will lead to the increase of bearing stress, aggravate bearing wear, and then affect the rotor modal. As the inner cylinder only relies on the fixed support at the top, the structure stiffness is low, which may lead to low-frequency resonance. By adding two support structures at the guide vane, the first-order modal frequency of the inner cylinder can be increased from 3.29 Hz to 28.88 Hz, effectively avoiding the operating frequency range of the system. Conclusion: This study can guide the optimization of similar pump structures.