A Dual Closed-Loop Digital Twin Construction Method for Optimizing the Copper Disc Casting Process

The copper disc casting machine is core equipment for producing copper anode plates in the copper metallurgy industry.The copper disc casting machine casting package motion curve(CPMC) is significant for precise casting and efficient production.However,the lack of exact casting modeling and real-time simulation information severely restricts dynamic CPMC optimization.To this end,a liquid copper droplet model describes the casting package copper flow pattern in the casting process.Furthermore,a CPMC optimization model is proposed for the first time.On top of this,a digital twin dual closed-loop self-optimization application framework(DT-DCS) is constructed for optimizing the copper disc casting process to achieve self-optimization of the CPMC and closed-loop feedback of manufacturing information during the casting process.Finally,a case study is carried out based on the proposed methods in the industrial field.

An Experimental Analysis of Gas-Liquid Flow Breakdown in a T-Junction

When a gas-liquid two-phase flow(GLTPF)enters a parallel separator through a T-junction,it generally splits unevenly.This phenomenon can seriously affect the operation efficiency and safety of the equipment located downstream.In order to investigate these aspects and,more specifically,the so-called bias phenomenon(all gas and liquid flowing to one pipe,while the other pipe is a liquid column that fluctuates up and down),laboratory experiments were carried out by using a T-junction connected to two parallel vertical pipes.Moreover,a GLTPF prediction model based on the principle of minimum potential energy was introduced.The research results indicate that this model can accurately predict the GLTPF state in parallel risers.The boundary of the slug flow and the churn flow in the opposite pipe can be predicted.Overall,according to the results,the pressure drop curves of the two-phase flow in the parallel risers are basically the same when there is no bias phenomenon,but the pressure drop in the parallel riser displays a large deviation when there is a slug flow-churn flow.Only when the parallel riser is in a state of asymmetric flow and one of the risers produces churn flow,the two-phase flow is prone to produce the bias phenomenon.

Air-drying Models for New-built Offshore Gas Pipelines

Drying （conditioning） is an important procedure to prevent hydrate formation during gas pipeline gas-up and to protect pipelines against corrosion. The air-drying method is preferred in offshore gas pipelines pre-commissioning. The air-drying process of gas pipelines commonly includes two steps, air purging and soak test. The mass conservation and the phase equilibrium theory are applied to setting up the mathematical models of air purging, which can be used to simulate dry airflow rate and drying time. Fick diffusion law is applied to setting up the mathematical model of soak test, which can predict the water vapor concentration distribution. The results calculated from the purging model and the soak test model are in good agreement with the experimental data in the DF 1-1 offshore production pipeline conditioning. The models are verified to be available for the air-drying project design of offshore gas pipelines. Some proposals for airdrying engineering and operational procedures are put forward by analyzing the air-drying process of DFI-1 gasexporting pipelines.

Two-dimensional Numerical Modeling Research on Continent Subduction Dynamics

Continent subduction is one of the hot research problems in geoscience. New models presented here have been set up and two-dimensional numerical modeling research on the possibility of continental subduction has been made with the finite element software, ANSYS, based on documentary evidence and reasonable assumptions that the subduction of oceanic crust has occurred, the subduction of continental crust can take place and the process can be simplified to a discontinuous plane strain theory model. The modeling results show that it is completely possible for continental crust to be subducted to a depth of 120 km under certain circumstances and conditions. At the same time, the simulations of continental subduction under a single dynamical factor have also been made, including the pull force of the subducted oceanic lithosphere, the drag force connected with mantle convection and the push force of the mid-ocean ridge. These experiments show that the drag force connected with mantle convection is critical for continent subduction.

Test selection and optimization for PHM based on failure evolution mechanism model

The test selection and optimization （TSO） can improve the abilities of fault diagnosis, prognosis and health-state evalua- tion for prognostics and health management （PHM） systems. Traditionally, TSO mainly focuses on fault detection and isolation, but they cannot provide an effective guide for the design for testability （DFT） to improve the PHM performance level. To solve the problem, a model of TSO for PHM systems is proposed. Firstly, through integrating the characteristics of fault severity and propa- gation time, and analyzing the test timing and sensitivity, a testability model based on failure evolution mechanism model （FEMM） for PHM systems is built up. This model describes the fault evolution- test dependency using the fault-symptom parameter matrix and symptom parameter-test matrix. Secondly, a novel method of in- herent testability analysis for PHM systems is developed based on the above information. Having completed the analysis, a TSO model, whose objective is to maximize fault trackability and mini- mize the test cost, is proposed through inherent testability analysis results, and an adaptive simulated annealing genetic algorithm （ASAGA） is introduced to solve the TSO problem. Finally, a case of a centrifugal pump system is used to verify the feasibility and effectiveness of the proposed models and methods. The results show that the proposed technology is important for PHM systems to select and optimize the test set in order to improve their performance level.

Modeling mechanism and extension of GM (1,1)

Firstly, the research progress of grey model GM （1,1） is summarized, which is divided into three development stages： assimilation, alienation and melting stages. Then, the matrix analysis theory is used to study the modeling mechanism of GM （1,1）, which decomposes the modeling data matrix into raw data transformation matrix, accumulated generating operation matrix and background value selection matrix. The changes of these three matrices are the essential reasons affecting the modeling and the accuracy of GM （1,1）. Finally, the paper proposes a generalization grey model GGM （1,1）, which is a extended form of GM （1,1） and also a unified form of model GM （1,1）, model GM （1,1,α）, stage grey model, hopping grey model, generalized accumulated model, strengthening operator model, weakening operator model and unequal interval model. And the theory and practical significance of the extended model is analyzed.

Universal Mechanism Modeling Method in Virtual Assembly Environment

Motion simulation and performance analysis of mechanism are important methods for analyzing assembly quality after finishing assembly simulation in virtual assembly environment. However, most simulation systems have no function of mechanism motion simulation due to the randomicity of mechanism and lack of universal mechanism modeling method. In order to realize the simulation of any mechanism after finishing assembly simulation in a virtual environment, a new universal mechanism modeling method is presented. Two main models are contained in the mechanism model： information model and mathematical model. Firstly, the information model of mechanism is proposed to describe the data structure of mechanism which contains bottom geometry data, information of constraint, link, kinematic pair and physical data. Because the object of mechanism simulation is the assembly, which is assembled during the process of assembly simulation, the information of mechanism can be obtained automatically through mechanism automatic search method. Secondly, mathematical model of mechanism is presented. The mathematical model uses mathematical method to express the mechanism. In order to realize the automatic expression of any random mechanism, basic constraint library is presented, consequently random mechanism can be described based on the basic constraint library. Finally, two examples are introduced to validate the method in the prototype system named VAPP（Virtual Assembly Process Planning）. The validation result shows that the mechanism modeling provides a universal modeling method for mechanism motion simulation in virtual assembly environment. This research has important effect on the development both of mechanism motion simulation and virtual assembly.

An Initial Residual Stress Inference Method by Incorporating Monitoring Data and Mechanism Model

Initial residual stress is the main reason causing machining deformation of the workpiece,which has been deemed as one of the most important aspects of machining quality issues.The inference of the distribution of initial residual stress inside the blank has significant meaning for machining deformation control.Due to the principle error of existing residual stress detection methods,there are still challenges in practical applications.Aiming at the detection problem of the initial residual stress field,an initial residual stress inference method by incorporating monitoring data and mechanism model is proposed in this paper.Monitoring data during machining process is used to represent the macroscopic characterization of the unbalanced residual stress,and the finite element numerical model is used as the mechanism model so as to solve the problem that the analytic mechanism model is difficult to establish;the policy gradient approach is introduced to solve the gradient descent problem of the combination of learning model and mechanism model.Finally,the initial residual stress field is obtained through iterative calculation based on the fusing method of monitoring data and mechanism model.Verification results show that the proposed inference method of initial residual stress field can accurately and effectively reflect the machining deformation in the actual machining process.

Prediction model of slurry pH based on mechanism and error compensation for mineral flotation process

A suitable pH value of the slurry is a key to efficient mineral flotation. Considering the control delay problem of pH value caused by offline pH measurement, an integrated prediction model for pH value in bauxite froth flotation is proposed, which considers the effect of ore compositions on pH value. Firstly, a regression model is obtained for alkali(Na_2CO_3) consumed by the reaction between ore and alkali. According to the first-order hydrolysis of the remaining alkali, a mechanism-based prediction model is presented for the pH value. Then, considering the complexity of the flotation mechanism, an error prediction model which uses time series of the error of the mechanism model as inputs is presented based on autoregressive moving average(ARMA) method to compensate the mechanism model. Finally, expert rules are established to correct the error compensation direction, which could reflect the dynamic changes during the process accurately and effectively. Simulation results using industrial data show that the presented model meets the needs of the industrial process, which laid the foundation for predictive control of pH regulator.

Modeling mechanism of a novel fractional grey mode based on matrix analysis

To fully display the modeling mechanism of the novelfractional order grey model （FGM （q,1））, this paper decomposesthe data matrix of the model into the mean generation matrix, theaccumulative generation matrix and the raw data matrix, whichare consistent with the fractional order accumulative grey model（FAGM （1,1））. Following this, this paper decomposes the accumulativedata difference matrix into the accumulative generationmatrix, the q-order reductive accumulative matrix and the rawdata matrix, and then combines the least square method, findingthat the differential order affects the model parameters only byaffecting the formation of differential sequences. This paper thensummarizes matrix decomposition of some special sequences,such as the sequence generated by the strengthening and weakeningoperators, the jumping sequence, and the non-equidistancesequence. Finally, this paper expresses the influences of the rawdata transformation, the accumulation sequence transformation,and the differential matrix transformation on the model parametersas matrices, and takes the non-equidistance sequence as an exampleto show the modeling mechanism.

MODELING METHOD FOR PRODUCT STRUCTURE MAPPING BASED ON REVERSE SOLVING OF LOCUS AND MOTION

Aiming at the problem of structure design in reverse-design of mechanism, a structure mapping method based on reverse solving of locus and motion （RSLM） is presented. The mechanism scheme meeting the requirements of geometric and structural features is obtained through RSLM. The element instance subsets related to component are established based on the element type mapping, pair structure type mapping and design knowledge mapping between components and elements layer by layer. The assembly position mapping of elements is established based on the topological structure information of mechanism scheme, and the product modeling of structure mapping is realized. The algorithm program and prototype system of product structure mapping based on RSLM are developed. Application samples show that the method implements the integration of scheme design, assembly design and structure design, and modeling for product structure mapping based on RSLM. The feasibility of assembly is analyzed in scheme design that contributes to reducing the design error, and raising the design efficiency and quality.

Dynamic model and performance analysis of landing buffer for bionic locust mechanism

The landing buffer is an important problem in the research on bionic locust jumping robots, and the different modes of landing and buffering can affect the dynamic performance of the buffering process significantly. Based on an experimental observation, the different modes of landing and buffering are determined, which include the different numbers of landing legs and different motion modes of legs in the buffering process. Then a bionic locust mechanism is established, and the springs are used to replace the leg muscles to achieve a buffering effect. To reveal the dynamic performance in the buffering process of the bionic locust mechanism, a dynamic model is established with different modes of landing and buffering. In particular, to analyze the buffering process conveniently, an equivalent vibration dynamic model of the bionic locust mechanism is proposed.Given the support forces of the ground to the leg links, which can be obtained from the dynamic model, the spring forces of the legs and the impact resistance of each leg are the important parameters affecting buffering performance, and evaluation principles for buffering performance are proposed according to the aforementioned parameters. Based on the dynamic model and these evaluation principles, the buffering performances are analyzed and compared in different modes of landing and buffering on a horizontal plane and an inclined plane. The results show that the mechanism with the ends of the legs sliding can obtain a better dynamic performance. This study offers primary theories for buffering dynamics and an evaluation of landing buffer performance,and it establishes a theoretical basis for studies and engineering applications.

MODELING AND IMPLEMENTATION OF SPEED GOVERNOR FOR THE HYBRID ELECTRIC VEHICLE ENGINE

A speed control analysis for an in-line gasoline fueled internal combustion （IC） engine is presented for the purpose of alleviation of high frequency oscillations in engine revolutions. A dynamic cylinder-by-cylinder model is proposed, base on slider-crank mechanism, which is extended to develop a digital governor providing a high fidelity estimation of rotary speed oscillation for hybrid vehicle engines. A modified PID controller that P and I gain is placed in feedback path is also described for hybrid electric vehicle （HEV） engine speed regulation, By comparison between measured and estimated signals, it is demonstrated that a good agreement has been achieved and the governor behaves an excellent damping speed ripple.

Simulating the Effect of Propylene Promoter on Product Yield with FCC Mechanism Model

A FCC mechanism model was used to predict the effects of propylene promoter in a 3.0 Mt/a FCCU. The FCC mechanism model was developed based on one set of commercial FCC data without using the promoter, and was modified by using another set of commercial FCC data with 3m% promoter in the catalyst inventory, and the calculations by means of this simulation model were performed to predict the data of the FCC unit containing 4m% promoter in the catalyst inventory. The test results showed that the calculated values agreed well with the data obtained from the commercial FCC unit, in which the deviations of calculated product yields versus the actual product yields at the commercial FCC unit were equal to 1.74 percentage points for gasoline, 2.59 percentage points for diesel, 1.50 percentage points for dry gas and LPG, and 0.28 percentage points for coke. The proposed method regarding the development of a simulation model and modifications to the model for commercial FCC unit was feasible.

Study on Residual Oil HDS Process with Mechanism Model and ANN Model

Based on the Residual Oil Hydrodesulfurization Treatment Unit (S-RHT), the n-order reaction kinetic model for residual oil HDS reactions and artificial neural network (ANN) model were developed to determine the sulfur content of hydrogenated residual oil. The established ANN model covered 4 input variables, 1 output variable and 1 hidden layer with 15 neurons. The comparison between the results of two models was listed. The results showed that the predicted mean relative errors of the two models with three different sample data were less than 5% and both the two models had good predictive precision and extrapolative feature for the HDS process. The mean relative error of 5 sets of testing data of the ANN model was 1.62%—3.23%, all of which were smaller than that of the common mechanism model (3.47%— 4.13%). It showed that the ANN model was better than the mechanism model both in terms of fitting results and fitting difficulty. The models could be easily applied in practice and could also provide a reference for the further research of residual oil HDS process.

A hybrid model of a subminiature helicopter in horizontal turn

A hybrid model of a subminiature helicopter in horizontal turn is presented. This model is based on a mechanism model and its compensated neural network （NN）. First, the nonlinear dynamics of a sub-miniature helicopter is established. Through the linearization of the nonlinear dynamics on a trim point, the linear time-invariant mechanism model in horizontal turn is obtained. Then a diagonal recursive neural network is used to compensate the model error between the mechanism model and the nonlinear model, thus the hybrid model of a subminiature helicopter in horizontal turn is achieved. Simulation results show that the hybrid model has higher accuracy than the mechanism model and the obtained compensated-NN has good generalization capability.

Kinetic modelling of NO+CO reaction on Pt/MoO_x/Al_2O_3 catalyst

A mathematical model has been developed to describe the dynamic behaviours of NO+CO reaction on supported Pt MO catalyst. The ignited state kinetics can be fit quantitatively using directly a Langmuir Henshelwood bimolecular rate expression with a heat of adsorption of NO of 32 4 kJ/mol and of CO of 106 7 kJ/mol, respectively.

CHARACTERISTICS AND DEVELOPMENT MODEL OF DUNE ROCKS ON SOUTH CHINA COASTS

Dune riocks are aeolian sands cemented ty calcium carbonate under subaerial conditions. They have been found in many of the coastal belts of Fujian, Guangdong and Hainan Provinces in South China. The grain composition of the dune rocks is mainly quartz sands and shell fragments. The quartz sands are medium and fine sized, relatively well sorted and positively skewed. Their surface texture formed in aeolian environments is characterized ty dishshaped depressions, meniscus depressions and V-shaped depressions with rounded edges. The most common bedding type of the rocks is larg (thickness>1.5m), steeply dipping (32--40°) with cross strata tolaner and convex upward). Mg and Sr contents are very low in the rock chemical composition which is classified into low Mg and low Sr category. The typical species of microfossils in the dune rocks are mainly freshwater ones and lack of typical saltwaer or semi-saltwater ones with incomplete assemblage of marine species. The cement minerals in the rocks are mainly low-Mg calcite and the common cement fabrics are meniscus cement and gravitational cement in response to impermanent water in vadose zones. Therefore, the dune rocks may be apparently distinguished from the beach rocks.

Application of diffusive transport model for better insight into retardation mechanisms involved in ion-imprinted membrane transport

Heavy metal removal from water is a great concern for environmentalists and engineers. Ion-imprinted membranes are among the state of the art technologies for selective adsorption of heavy metals from aqueous environment. Dialysis permeation of nickel ions through Ni(II)-imprinted membranes has been thermodynamically studied in our prior work. In current study, the diffusive transport model was developed and then applied for better insight into the retardation mechanisms involved in the ion-imprinted membrane transport. The Sips isotherm model was coupled with the transport model to obtain the governing equation. Chemisorption and physical interactions(bulk diffusion and pore-clogging) were the most probable retardation mechanisms according to the modeling results. Relative retardation factor(η) was also defined as; transport-rate controlled by chemical adsorption to that controlled by physical interactions. With the help of the retardation factor, it was understood that the membrane behavior gradually changes from chemisorption to facilitated transport during permeation time. Effect of important operating parameters such as time, temperature and concentration on transport behavior was also investigated. Results indicated that chemisorption rate is rather higher at lower concentrations, early permeation times and reduced temperatures. In addition, η tabulated greater values for Ni(II) compared to Co(II) due to the imprinting effect.

MODELLING OF MECHANICAL MECHANISM OF CHROMATOGRAPHIC SYSTEM AND THEORETICAL EQUATIONS SHOWING DYNAMICAL CHARACTERISTICS OF CHROMATOGRAPHY

A simple model of chromatographic mechanical mechanism is present, and then a scrics of theoretical chromatographic equations and fundamental Formulae are derived. These theoretical equations and formulae not only reserve thermodynamic characteristics in the current fundamental chromatographic formulae, but also introduce one or more kinetic parameter, so it is possible to make the macroscopic-control on the effect of kinetic characteristics on chromatographic system.