Expert Experience and Data-Driven Based Hybrid Fault Diagnosis for High-SpeedWire Rod Finishing Mills

The reliable operation of high-speed wire rod finishing mills is crucial in the steel production enterprise.As complex system-level equipment,it is difficult for high-speed wire rod finishing mills to realize fault location and real-time monitoring.To solve the above problems,an expert experience and data-driven-based hybrid fault diagnosis method for high-speed wire rod finishing mills is proposed in this paper.First,based on its mechanical structure,time and frequency domain analysis are improved in fault feature extraction.The approach of combining virtual value,peak value with kurtosis value index,is adopted in time domain analysis.Speed adjustment and side frequency analysis are proposed in frequency domain analysis to obtain accurate component characteristic frequency and its corresponding sideband.Then,according to time and frequency domain characteristics,fault location based on expert experience is proposed to get an accurate fault result.Finally,the proposed method is implemented in the equipment intelligent diagnosis system.By taking an equipment fault on site,for example,the effectiveness of the proposed method is illustrated in the system.

EXPERIMENTAL STUDY ON HIGH-SPEED CENTRIFUGAL PUMPS WITH DIFFERENT IMPELLERS

The experimental study is carried out on high-speed centrifugal pumps withthree different impellers. The experimental results and analysis show that high-speed centrifugalpumps with a closed complex impeller can achieve the highest efficiency and the lowest headcoefficient followed by those with half-open impeller and open-impeller, and can obtain much easilystable head-capacity characrastic curve, while those with a half-open complex impeller can't. Thecharacteristic curve with a open impeller is almost constant horizontal line before droppingsharply. The results also show that the axial clearance between pump casing and impeller caninfluence greatly on the performance of centrifugal pumps.

Numerical and experimental investigation on snow accumulation on bogies of high-speed trains

This paper reviews the current status of investigation on snow accumulation on the bogies of high-speed trains(HSTs) running in snowy region. First, the background of the snow issue occurring to the HST and the contra-measures for the snow issue proposed in the past decades are provided by reviewing previous studies. Next, the methodology for investigating the snow issue developed by High-Speed Train Research Center of Central South University is introduced, including the numerical simulation research platform and the experimental devices for two-phase flow wind tunnel tests. Then, effective anti-snow flow control schemes for guiding the underbody airflow and their impact on the motion and accretion of snow in the installation region of the bogies are presented. Finally, the remaining investigating challenge for the snow issue of HST and the future research with respect to the challenge are provided from an engineering application viewpoint.

NUMERICAL AND EXPERIMENTAL INVESTIGATION OF WAVE DYNAMIC PROCESSES IN HIGH-SPEED TRAIN/TUNNELS

Numerical and experimental investigation on wave dynamic processes induced by high-speed trains entering railway tunnels are presented. Experiments were conducted by using a 1:250 scaled train-tunnel simulator. Numerical simulations were carried out by solving the axisymmetric Euler equations with the dispersion-controlled scheme implemented with moving boundary conditions. Pressure histories at various positions inside the train-tunnel simulator at different distance measured from the entrance of the simulator are recorded both numerically and experimentally, and then compared with each other for two train speeds. After the validation of nonlinear wave phenomena, detailed numerical simulations were then conducted to account for the generation of compression waves near the entrance, the propagation of these waves along the train tunnel, and their gradual development into a weak shock wave. Four wave dynamic processes observed are interpreted by combining numerical results with experiments. They are: high-speed trains moving over a free terrain before entering railway tunnels; the abrupt-entering of high-speed trains into railway tunnels; the abrupt-entering of the tail of high-speed trains into railway tunnels; and the interaction of compression and expansion waves ahead of high-speed trains. The effects of train-tunnel configuration, such as the train length and the train-tunnel blockage ratio, on these wave processes have been investigated as well.

Experimental study on failure evolution mechanism of clastic rock considering cementation and intermediate principal stress

The study of clastic rock failure evolution under true triaxial stress is an important research topic;however,it is rarely studied systematically due to the limitation of monitoring technology.In this study,true triaxial compression tests were conducted on clastic rock specimens to investigate the effect of cementation and intermediate principal stress(s2)on the failure mechanism.The complete stressestrain curves were obtained,while the acoustic emission(AE)was monitored to indirectly evaluate the evo-lution of tensile and shear cracks,and crack evolution under true triaxial compression was imaged in real time by a high-speed camera.The results showed that the deformation and failure characteristics of clastic rock were closely related to the cementation type and intermediate principal stress.On the basis of the distribution characteristics of the ratio of rise time to amplitude(RA)and the average frequency(AF)of AE signals,tensile cracks of the contact cementation specimen propagated preferentially.Meanwhile,the enhancement of specimen cementation promoted the evolution of shear cracks,and the increase inσ_(2)promoted the evolution of tensile cracks.Moreover,the mesoscale cracking mechanism of clastic rock caused by cementation andσ_(2)under true triaxial compression was analyzed.The failure patterns of clastic rock under true triaxial compression were divided into three modes:structure-induced,structure-stress-induced and stress-induced failures.This study confirms the feasibility of high-speed camera technology in true triaxial testing,and has important implications for elucidating the disaster mechanism of deep tunnels in weak rocks.

The Calibration of High-Speed Camera Imaging System for ELMs Observation on EAST Tokamak

A tangential fast visible camera has been set up in EAST tokamak for the study of edge MHD instabilities such as ELM. To determine the 3-D information from CCD images, Tsai＇s two-stage technique was utilized to calibrate the high-speed camera imaging system for ELM study. By applying tiles of the passive stabilizers in the tokamak device as the calibration pattern, transformation parameters for transforming from a 3-D world coordinate system to a 2-D image coordinate system were obtained, including the rotation matrix, the translation vector, the focal length and the lens distortion. The calibration errors were estimated and the results indicate the reliability of the method used for the camera imaging system. Through the calibration, some information about ELM filaments, such as positions and velocities were obtained from images of H-mode CCD videos.

Investigation of condition-induced bubble size and distribution in electroflotation using a high-speed camera

In the flotation process, bubble is a key factor in studying bubble-particle interaction and fine particle flo- tation. Knowledge on size distribution of bubbles in a flotation system is highly important. In this study, bubble distributions in different reagent concentrations, electrolyte concentrations, cathode apertures, and current densities in electroflotation are determined using a high-speed camera. Average bubble sizes under different conditions are calculated using Image-Pro@ Plus （Media Cybernetics@, MD, USA） and SigmaScan@ Pro （Systat Software, CA, USA） software. Results indicate that the average sizes of bubbles, which were generated through 38, 50, 74, 150, 250, 420, and 1000 μm cathode apertures, are 20.2, 29.5, 44.6, 59.2, 68.7, 78.5, and 88.8 μm, respectively. The optimal current density in electroflotation is 20 A/m2. Reagent and electrolyte concentrations, current density, and cathode aperture are important factors in controlling bubble size and nucleation. These factors also contribute to the control of fine- Particle flotation.

FLOW STRESS MODELING FOR AERONAUTICAL ALUMINUM ALLOY 7050-T7451 IN HIGH-SPEED CUTTING

The high temperature split Hopkinson pressure bar （SHPB） compression experiment is conducted to obtain the data relationship among strain, strain rate and flow stress from room temperature to 550 C for aeronautical aluminum alloy 7050-T7451. Combined high-speed orthogonal cutting experiments with the cutting process simulations, the data relationship of high temperature, high strain rate and large strain in high-speed cutting is modified. The Johnson-Cook empirical model considering the effects of strain hardening, strain rate hardening and thermal softening is selected to describe the data relationship in high-speed cutting, and the material constants of flow stress constitutive model for aluminum alloy 7050-T7451 are determined. Finally, the constitutive model of aluminum alloy 7050-T7451 is established through experiment and simulation verification in high-speed cutting. The model is proved to be reasonable by matching the measured values of the cutting force with the estimated results from FEM simulations.

CUTTING FORCES FOR HIGH-SPEED DRILLING OF COMPOSITES

The thrust and the torque of various carbide drills are studied for the high-speed drilling of fiber reinforced epoxy composites. The orthogonal experiment is carried out with different feed speeds at high rotation speed. Experimental results show that the spindle rotation speed is the most influential factor. The thrust andthe torque decrease under the condition of high rotation rate. With the decrease of the feed speed, the thrust and the torque decrease. But the effect of the feed speed is less than that of the spindle rotation rate. Moreover, the effect of drill materials on the thrust and the torque is more notable than that of the drill geometries and the feed speed. The thrust is greatly affected by the feed speed while the torque is obviously affected by drill geometries.

Prediction of high-speed train induced ground vibration based on train-track-ground system model

The development of analysis on train-induced ground vibration is briefly summarized. A train-track- ground integrated dynamic model is introduced in the paper to predict the ground vibration induced by high-speed trains. Representative dynamic responses of the train-track-ground system predicted by the model are presented. Some major results measured from two field tests on the ground vibration induced by two high-speed trains are reported. Numerical prediction with the proposed train-track-ground model is validated by the high-speed train running experiments. Research results show that the wheel/rail dynamic interaction caused by track irregularities has a significant influence on the ground acceleration and little influence on the ground displacement. The main frequencies of the ground vibration induced by high-speed trains are usually below 80 Hz. Compared with the ballasted track, the ballastless track structure can produce much larger train-induced ground vibration at frequencies above 40 Hz. The vertical ground vibration is much larger than the lateral and longitudinal components.

Development of an ε-type actuator for enhancing high-speed electro-pneumatic ejector valve performance

A novel ε-type solenoid actuator is proposed to improve the dynamic response of electro-pneumatic ejector valves by reducing moving mass weight. A finite element analysis (FEA) model has been developed to describe the static and dynamic operations of the valves. Compared with a conventional E-type actuator, the proposed ε-type actuator reduced the moving mass weight by almost 65% without significant loss of solenoid force, and reduced the response time (RT) typically by 20%. Prototype valves were designed and fabricated based on the proposed ε-type actuator model. An experimental setup was also established to investigate the dynamic characteristics of valves. The experimental results of the dynamics of valves agreed well with simulations, indicating the validity of the FEA model.

Experimental Investigation on Cavitating Flow Shedding over an Axisymmetric Blunt Body

Nowadays,most researchers focus on the cavity shedding mechanisms of unsteady cavitating flows over different objects,such as 2D/3D hydrofoils,venturi-type section,axisymmetric bodies with different headforms,and so on.But few of them pay attention to the differences of cavity shedding modality under different cavitation numbers in unsteady cavitating flows over the same object.In the present study,two kinds of shedding patterns are investigated experimentally.A high speed camera system is used to observe the cavitating flows over an axisymmetric blunt body and the velocity fields are measured by a particle image velocimetry（PIV）technique in a water tunnel for different cavitation conditions.The U-type cavitating vortex shedding is observed in unsteady cavitating flows.When the cavitation number is 0.7,there is a large scale cavity rolling up and shedding,which cause the instability and dramatic fluctuation of the flows,while at cavitation number of 0.6,the detached cavities can be conjunct with the attached part to induce the break-off behavior again at the tail of the attached cavity,as a result,the final shedding is in the form of small scale cavity and keeps a relatively steady flow field.It is also found that the interaction between the re-entrant flow and the attached cavity plays an important role in the unsteady cavity shedding modality.When the attached cavity scale is insufficient to overcome the re-entrant flow,it deserves the large cavity rolling up and shedding just as that at cavitation number of 0.7.Otherwise,the re-entrant flow is defeated by large enough cavity to induce the cavity-combined process and small scale cavity vortexes shedding just as that of the cavitation number of0.6.This research shows the details of two different cavity shedding modalities which is worthful and meaningful for the further study of unsteady cavitation.

Visualization of High-Speed Impact of Projectile in Granular Sheet with Destructive Collision of Particles

The impact and penetration of a projectile in a particle-laden space, which are expected to have frequently occurred during the formation of the solar system and will occur in the case of an impact probe for future planetary exploration, were experimentally simulated by using the ballistic range. A two-dimensional sheet made from small glass beads or emery powder was formed by the free-falling device through a long slit in the test chamber evacuated down to about 35 Pa. A polycarbonate projectile of a hemi-sphere-cylinder or sphere shape with the mass and diameter about 4 g and 25 mm, respectively, was launched at the velocity up to 430 m/s, and the phenomena were observed by the high-speed camera at 20,000 fps. From a series of images, the bow-shock-wave-like laterally facing U-shaped pattern over the projectile and the absence of particles in the trail behind it were clearly seen. At the impact of the particles on the projectile surface, fine grains were formed due to the destructive collision and injected outward from the projectile. The images obtained by different lighting methods including the laser light sheet were compared. The effects of the particle diameter, its material and the impact velocity were also investigated.

Visualization of High-Speed Impact of Penetrator into Icy Target

For application to exploration under the surface of icy objects in the solar system, the penetration of an impact probe into an icy target was experimentally simulated by using the ballistic range. Slender projectiles with a cylindrical body and various nose shapes were tested at the impact velocity 130 - 420 m/s. The motion of the penetrator, fragmentation of ice and crater forming were observed by the high-speed camera. It revealed that the crown-shaped ejection was made for a short time after the impact and then the outward normal jet-like stream of ice pieces continued for much longer time. The concave shape of the crater was successfully visualized by pouring the plaster into it. The two-stage structure, the pit and the spall, was clearly confirmed. The rim was not formed around the crater. Observation of the crater surface and the ice around the trace of the penetrator shows that both crushing into smaller ice pieces and recompression into ice blocks are caused by the forward motion of the penetrator. In case of a body with a flow-through duct, ice pieces entering the inlet at the nose tip were ejected from the tail, resulting in relaxation of the impact force. The correlation of the penetration distance and the crater diameter with the impact velocity was investigated.

Experimental investigation on the plasma morphology of ablative pulsed plasma thruster with tongue-shaped and flared electrodes

Ablative pulsed plasma thrusters(APPTs)are considered as an attractive propulsion option for station-keeping and drag makeup purposes for mass-and power-limited satellites.In order to understand the physical mechanism of APPTs,high-speed camera and optical emission spectroscopy are utilized to investigate the plasma characteristics including the spatial distribution and composition between the electrodes.The plume images and spectra at different times and positions are experimentally recorded,and the spatial distribution,composition,and trajectory of plasmas can be concluded through analyzing them.With the increase of the distance from the ablation surface,two clusters of plasmas near the anode and cathode meet downstream,and the species and density of plasmas tend to be uniform.

基于高速摄像技术的气液两相流型分析实验设计

针对流体力学教学中难以观察流体动态运动过程的问题,通过调整课程结构,将高速摄像技术与传统的气液两相流实验平台相结合,使流体力学抽象概念得到具象化呈现。实验结果表明,借助该可视化实验教学平台,能够研究气泡的运移特征,研究旋流场内气泡的破碎和聚并行为,分析不同工况条件下的气泡形态,得出旋流场内气液两相流型。对培养学生分析和解决问题能力,提升实验教学效果有很好的促进作用。

基于单高速相机3D-DIC的涡轮叶片全场振动测量

采用成本较低、结构紧凑且使用便捷的单高速相机三维数字图像相关方法(single-camera high-speed three-dimensional digital image correlation,简称SCHS 3D-DIC)对涡轮叶片的振动特性进行试验研究。首先,介绍了测量装置和原理,以悬臂铝板为对象开展验证试验,结果证明了该测量系统的准确性与有效性;其次,开展了叶片的全场振动特性测量,得到了其三维形貌、模态特性、全场位移与应变分布,获得了叶片在振动载荷作用下的高应变区域位置及应变分布特点。研究表明,SCHS 3D-DIC方法相比常规双高速相机3D-DIC方法具有更高的视场利用率,适合于细长型的涡轮叶片的振动测量试验。

The influence of the leading-edge angle of subgrade on the aerodynamic loads of a high-speed train in a wind tunnel

The purpose of this study is to establish the correlation between the boundary layer over the subgrade and the aerodynamic loads act-ing on the train model in conventional wind tunnel tests.Firstly,flow characteristics around the subgrade with different leading-edge angles(15°,30°and 45°)are investigated through the particle image velocimetry(PIV)experimental test method.Then,wind tunnel tests of the aerodynamic performance of a high-speed train are carried out.The results are compared with previous experimental data obtained by moving model tests.Results show that,due to the presence of a boundary layer,the pressure acting on the lower part of the train head decreases,while other locations are not significantly affected.This is the reason for the reduction of the aerodynamic drag and lift on the train.In addition,the reduction effects become more obvious when the thickness of the boundary layer increases.The experimental results obtained could serve as a calibration of aerodynamic forces for wind tunnel tests on high-speed trains.

基于CMOS相机近眼显示的关键光学性能测试系统

设计一种基于双目CMOS相机的近眼显示测试设备,在此基础上提出了主要光学参数的测量方法。根据NED光学相关原理,通过推导建模、系统设计和标定实验,实现了对NED器件光学参数的快捷、低成本测量。最终通过实验可见,本测试系统比传统系统的测量时间节省约60%,并且关键参数测试误差小于5%。

基于眼动实验的运动相机造型设计研究

对市场上现有运动相机的不同风格的造型设计进行对比研究。把3种不同造型风格的运动相机典型样本作为研究对象,对运动相机消费者进行基于语义差分法的感性评价试验和眼动追踪实验。结合消费者的主观评价结果和眼动数据并进行综合分析。对消费者对运动相机造型的认知行为特征和偏好进行总结,为设计师在运动相机产品造型设计过程中满足消费者感性需求的目标提供建议与思路。