I-SA Algorithm Based Optimization Design and Mode-Switching Strategy for a Novel 3-Axis-Simpson Dual-Motor Coupling Drive System of PEV

Pure electric vehicle (PEV) equipped with a dual-motor coupling drive system can make full use of the high efficiency working range of the motor in order to improve vehicle efficiency. In order to further expand the application range of the system and to improve its practical application, this paper designs and proposes a new dynamic coupling drive system of three axis-double working modes, which is based on the Simpson planetary gear train. The new system adopts two planetary gears (P1 and P2), and the two sun gears of double rows, planetary carrier of P1 and gear ring of P2 are bunded. The power output of the P1 gear ring (mode 1) and P2 planetary carrier (mode 2) is realized by a controlling wet clutch. This paper adopts the linear interpolation method, least square method and 5-fold CV cross validation method to establish the full load speed characteristics and efficiency characteristics models of two motors (13 and 30 kW). This paper proposes an optimization design method based on an improved simulated annealing (I-SA) algorithm for new system parameter matching and working mode switching strategy determination. The results show that the modeling accuracy of the two motors is high, and the mean value of MAPE is 4.337%. The proposed optimization design method achieves the demand goal of PEV effectively. The I-SA algorithm has good effectiveness and fast convergence, the mean efficiency of the optimized PEV is 83.91% under all working conditions, the maximum speed is 142.56 km/h and the power utilization rate of the dual-motor is 100%. This study proposes a new hardware system and a design optimization method on software and provides a direct reference for the research of PEV drive systems by combining hardware with software.

TOOTH LEG EXCESSIVE UNDERCUT ELIMINATION IN HELICAL CYLINDRICAL GEARS WITH PROTUBERANCE OF HOBBING CUTTER BASED ON GRAPHIC RUN-IN

In the paper there are considered procedures for designing a transition curved tooth leg of helical cylindrical gears. A significant parameter of a transition curve is a diameter of boundary points. The boundary point diameter belongs to a bottom point of the involute profile of the teeth side surface of a gear ring. The boundary point position must be lower of the design end point of the involute profile defined by the designer of gearing. A diameter value depends upon a great number of production factors: a profile and wear of a grinding disk, setting up parameters, teeth machining modes of a gear ring, but it is impossible to ensure the specified values of the diameter of boundary points without a correct design solution in the course of the form choice of milling cutter protuberance. The solution on protuberance acceptable parameters of a gear-cutting tool is made by the designer of a cutter during graphic run-in fulfillment. In the paper there are revealed conditions under which arise mistakes in the course of graphic run-in fulfillment within the limits of one teeth pitch of a milling cutter. There are shown recommendations for the fulfillment ensuring the diameter dimension of boundary points of the transition curve specified by the designer of gearing. The data on the design parameter impact of the hob protuberance upon the continuance of cutting edge interaction are shown. There are recommendations given to prevent undercut arising caused by the fulfillment of graphic two-dimensional run-ins of cylindrical helical gears. The work purpose: the elimination of tooth leg excessive undercut in helical cylindrical gears with the protuberance of a worm milling cutter at the expense of the fulfillment of graphic run-in conditions. The investigation methods: the graphical modeling of a run-in process. The investigation results and novelty: there are defined conditions of arising an excessive undercut in the tooth leg of helical cylindrical gears during the fulfillment of graphic run-ins of a tool rack. The conclusions: for mistake prevention in the calculations of the protuberance geometrical parameters of the helical milling cutter the graphic run-in must be carried out not less than on the 1.5 pitch of the milling cutter.

Adjustment of parameters of precision stamping of gear wheels on results of modeling of physical processes at their chemical and thermal processing

The surface layer after chemical-thermal treatment in structure and physico-mechanical properties differs sharply from the inner layers of the product, which leads to significant internal stresses that cause deformation and warping, i.e. resizing and shape. Prediction of the phase composition, depth of carbon saturation of the layer, microhardness and deformation of the surface of the product elements after chemical-thermal treatment based on modeling in the application package allows even at the stage of technological preparation for the production of precision hot die forging to make adjustments to the geometry of the die tool to increase dimensional accuracy, and accordingly, the durability of the gear ring gears. The input data for modeling the processes of chemical-thermal treatment is a 3D model of the product with a finite element grid and the fixation scheme of the product, temperature and time modes (heating temperature, heating and cooling rate, holding time, number of cycles), type of carburizing cooling medium and its temperature, material details.

Study on the influencing factors of the deformation in the process of gear shaping

Ring gear is an important part of high-power transmission system. Because of its thin wall and low stiffness, it is easy to produce deformation in the process of gear shaping, which affects its accuracy. In order to ensure the machining quality of gear shaper, this research focuses on the typical material 42CrMo, which is used in the gear ring of automobile gearbox. Through the finite element simulation and actual test, the influence of gear shaper cutting parameters on the deformation of gear ring is studied. The results show that the influence of the main cutting parameters on the deformation of the ring gear is in the order of radial feed, circumferential feed, stroke speed and cutting depth. In the actual gear shaping process, the cutting parameters can be adjusted according to the deformation law of 42CrMo workpiece in the gear shaping process, so as to control the deformation of gear ring.

Analysis of ring operation from south Andaman Fish Landing Centres (FLC)

A study was carried out during 2014-2018 to find out the major fish catches through the Gear Ring net at the coast of Andaman Islands. The data were collected from four major Fish Landing Centres (FLC) viz Junglighat, Dugnabad, Guptapara and Wandoor which are located at South Andaman. Altogether 1097 FLC visits have been carried out during the study period at all four FLC with an average of 219 visits / year. Altogether 1379 operations of Ring net were observed from two FLC i.e. Junglighat (1322) and Dugnabad (57) amongst four FLC. The total fishes captured were 1609 tons from the two FLCs, i.e. 1594 tons from Junglighat FLC and 15 tons from Dugnabad FLC respectively. The contribution of gear the Ring net was 41.5 % amongst the other gears operated from all four FLCs. The major fish catch by ring net were Scombrids (52.3%), followed by Sardines (22.4%), Carangids (21.3%), Anchovies (2.7%) and others (1.2%). 39 ring net fishing ground identified during the period around the coast of Andaman Islands. The maximum fish catch occurred at around the coast of Havelock Island (15.5%) followed by Rutland (10.5%), Chidiatappu (8 %), Shoal Bay (7.6%), Baratang (7 %), Carbyns cove (6 %), Burmanallah (5.2%), Madhuban (5.2%), Out-drum Island (4.7%), Mayabunder (4 %), Colinpur (3.3%), Long Island (3.3%), Wandoor (2.1%) etc and minimum fish catch was observed at the coast of Pachim Sagar (0.02%) . PFZ forecast disseminated to the Ring netters and validated during the study period. Forty nine operations of gear the ring net were observed at PFZ with an average of 9.8 operations /year. The fishes captured from the PFZ were 91.1 tons with an average of 18.2± 5.6 tons / year. Similarly 49 operations of ring net were also observed at Non-PFZ with an average of 9.8 operations /year. The fishes captured from the Non PFZ were 23.77 tons with an average of 4.5±1.5 tons / year. The Length-weight measurements of the pelagic fishes viz Atule mate, Decapterus russelli, Sardinella albella, Sardinella sirm, Herklotsichthys quadrimaculatus and Rastrelliger kanagurta caught from both the zones have been done. 12 Class Intervals with respect to length were observed from the catch of all the fishes i.e. 81-100 mm, 101-120, 141-160 mm,........301- 320 mm. In the Class Intervals, the length category 121-140 mm was the most representating class for Atule mate with 128 specimens (19.1%) at PFZ and 159 specimens (23.7%) at Non-PFZ respectively. It has been observed for other fishes i.e. for Decapterus russelli, Sardinella albella, Sardinella sirm, Herklotsichthys quadrimaculatus and Rastrelliger kanagurta which collected from the PFZ were class 161-180 mm with 172 specimens (48.6%), 141-160 mm with 195 specimens (53.1%), 221- 240 mm with 177 specimens (48.2%), 121-140 mm with 189 specimens (47.7%) and 261-280 with 199 specimens (30.9%) respectively. The same species were collected at the Non-PFZ were 141-160 with 173 specimen (49.0%), 121-140 with 194 specimens (53.3%), 221-240 with 159 (45.4%), 101-120 with 173 (49.4%) and 201-220 with 144 specimens (23%) respectively. The water samples have been collected during day time from various sites of PFZ and Non-PFZ during the study period and analysed. The average visibility at PFZ and Non-PFZ were 15.49±0.28 m and 16.74 ± 0.25 respectively. The average dissolved oxygen (DO) at PFZ and Non-PFZ were 6.30±0.05 mg/lit and 5.94 ±0.06 mg/lit respectively. Due to density of phytoplankton and Eddies the dissolved oxygen increased at PFZ than Non-PFZ. Alkalinity was at PFZ 111.16±1.09 ml/lit and Non PFZ 113.68 ± 1.28 ml/lit respectively.

Potential of gear-ring turbulator in three-dimensional heat exchanger tube from second law of thermodynamic viewpoint

PurposeThis paper aims to use the second law of thermodynamic to evaluate the potential of gear-ring turbulator in a three-dimensional heat exchanger tube. Accordingly, a numerical simulation is performed to obtain the irreversibilities in a three-dimensional heat exchanger tube equipped with some gear-ring turbulators for turbulence regime.Design/methodology/approachA numerical simulation is performed to obtain the irreversibilities in a three-dimensional heat exchanger tube equipped with some gear-ring turbulators for turbulence regime. The analysis is carried out based on shear stress transport (SST) k-ω turbulent model. The influences of different parameters containing tooth number, free-space length ratios and Reynolds number on frictional and thermal irreversibilities and Bejan number are discussed.FindingsThe results indicated that the thermal irreversibility reduces by decreasing the tooth number. For example, the thermal entropy generation decreases about 25.81 per cent by decreasing the tooth number in the range of 24 to 0 at Re = 6,000. Moreover, the frictional entropy generation decreases by increasing the tooth number as the gear with more tooth number causes a lower flow disturbance.Originality/valueThe present study arranged a numerical work to study the potential of a gear-ring turbulator in a heat exchanger tube from first and second laws of thermodynamic viewpoint. The turbulent flow is considered for this problem. The literature review showed that the usage of a gear-ring turbulator in a heat exchanger tube is not investigated from the second law of thermodynamic viewpoint by previous studies. As a result, the influences of different parameters containing tooth number, free-space length ratios and Reynolds number on frictional and thermal irreversibilities and Bejan number are discussed.

GRANULATION OF RAW MATERIALS DURING THE DIELECTRIC HEATING PROCESS

The aim of the work is to develop and justify the parameters of the installation for the granulation of non-food waste of animal and vegetable origin in the process of dielectric heating. Objectives of the study: to develop microwave installations with volumetric resonators of different configurations, providing high electric field strength and continuity of the process of granulating raw materials; calculate the parameters of the electrodynamic system of the generator (electric field strength, the intrinsic Q factor of the resonator) and visualize the distribution pattern of the electromagnetic field in the resonators of different configurations. The studies were based on the dielectric heating theory and the theory of forming granules from multicomponent raw materials. The parameters of the electrodynamic system of the microwave generator were studied in the CST Microwave Studio program. The structural performance of volume resonators is analyzed from the point of view of the implementation of the requirements imposed by microwave devices and granulators intended for use in farms. Analyzed devices with a toroidal resonator and a disk matrix and with ellipsoid resonators and gear ring matrices are analyzed. The electromagnetic field distributions are visualized in the developed design versions of resonators combined with the working chamber of granulators. The values of the self-quality of the resonators and the electric field strength in them are calculated.

Torsionsfestigkeit von umformgefügten Zahnrädern*/Torsional Strength of Multi-Component Gears – static and dynamic torsional strength of gears manufactured by lateral extrusion

Im Rahmen des Verbundprojekts „massiverLeichtbau“ (AiF-KZ47M4712) wurde als Beitrag zur Gewichtsreduktion von Antriebsstrangkomponenten am Institut für Umformtechnik (IFU) in Stuttgart und an der Forschungsstelle für Zahnräder und Getriebebau (FZG) in München das Verfahrenskonzept zur umformtechnischen Herstellung von „gebauten“ Zahnrädern mittels Querfließpressen in Mehrkomponentenbauweise entwickelt und dessen Leichtbaupotenzial untersucht. Dieses Verfahren erlaubt das form- und/oder reibschlüssige Fügen von Zahnkranz, Zahnradkörper und Welle und erlaubt so eine kompakte, gewichtsoptimierte Bauweise solcher Zahnräder. Zur Quantifizierung des Anwendungspotenzials von gebauten Zahnrädern mittels Umformfügen wurden die Einflüsse des Werkstoffs, des Umformschmierstoffs und der Zahnkranzinnengeometrie auf das übertragbare Drehmoment gezeigt. Das Ziel der experimentellen Untersuchungen lag einerseits in der Ermittlung der Versagensart unter Torsionslast und schließlich in der Bestimmung einer optimalen Kombination aus Werkstoff, Umformschmierstoff und Zahnkranzinnenprofil zur Übertragung möglichst hoher Drehmomente. Die hier dargestellten Ergebnisse sowie einzelne Textpassagen stammen aus dem AiF-Abschlussbericht sowie einer vorangehenden Veröffentlichung [12].   In order to reduce the weight of powertrain components, the manufacturing process concept for joining by forming of „built“ gears using lateral extrusion in multi-component design is being developed and the lightweight potential is being investigated. This paper deals with the manufacturing of an assembled gearwheel using cold forging and simultaneously joining the gearwheel body with a gear ring. The aim of this publication is to demonstrate the influence of the material, the lubricant and the geometry of the inner gear ring on the transmittable torsional load based on built gears manufactured by joining by forming. The aim of the experimental investigations was on the one hand to determine the type of failure under torsional load and finally to determine an optimal configuration of material, lubricant and internal gear ring profile for the transmission of preferably high torques. The here presented results and individual text passages originate from the AiF final report [14] and a prior publication [12].

A GENERALIZED METHOD FOR PREDICTING CONTACT STRENGTH, WEAR, AND THE LIFE OF INVOLUTE CONICAL SPUR AND HELICAL GEARS: PART 1. SPUR GEARS

The paper presents the results of research undertaken to determine maximum contact pressures, wear, and the life of involute conical spur gear, taking into account gear height correction, tooth engagement, and weargenerated changes in the curvature of their involute profile. Moreover, we have established the following: (a) the initial contact pressures are higher in the internal section with double-single-double tooth engagement; (b) the highest values can be observed at the entry of single tooth engagement; (c) the maximal tooth wear of the wheels in the frontal section will be less than half of that in the internal section; (d) profile shift coefficients have an optimum at which the highest gear life is possible; and (e) gear life in the internal section will be less than half of that the frontal section. The calculations were made for a reduced cylindrical gear using a method developed by the authors. The effect of applied conditions of tooth engagement in the frontal and internal sections of a cylindrical gear ring is shown graphically. In addition, optimal correction coefficients ensuring the longest possible gear life are determined.