High-Speed Permanent Magnet Electrical Machines - Applications, Key Issues and Challenges

In this paper,application examples of high-speed electrical machines are presented,and the machine structures are categorized.Key issues of design and control for the high-speed permanent magnet machines are reviewed,including bearings selection,rotor dynamics analysis and design,rotor stress analysis and protection,thermal analysis and design,electromagnetic losses analysis and reduction,sensorless control strategies,as well as comparison and selection of sine-wave and square-wave drive modes.Some challenges are also discussed,so that future studies could be focused.

Calculation for Stator Loss of High-Speed Permanent Magnet Synchronous Machine in Torque-speed Envelope and Restraint Approach for Circulating Current in Windings

Iron loss and copper loss are the significant parts of electrical loss of machines,which are the major parts particularly under high frequency condition.High-speed permanent magnet synchronous machines(HS-PMSM)have the benefits of high power density,high efficiency and wide speed range.Which causes the calculation for iron loss and copper loss in whole operating range complex.By analyzing the components and influencing factors of iron loss and copper loss in stator,we have deduced the calculation formula of iron loss and copper loss in whole operating range based on the analytical solution and finite element approach(EFA)solution.According to the calculation solution,taking the influence of operating temperature on the iron loss and copper loss into account,we propose a temperature correction factor and establish the calculation method for the iron loss and copper loss with temperature influences.Finally,by the conductor transposition,we restrain the circulating current under high-frequency operating condition.

Development and Application of Complete Equipment for High-speed Tunnel Boring and Bolting Machines

With the improvement of coal mining speed and mechanization level in China,traditional tunnel boring methods can no longer meet the actual needs.In order to solve the problems of low efficiency,high labor intensity,slow tunnel boring speed,bad working environment and poor safety in traditional tunnel boring,on the basis of analyzing the development and application of coal roadway tunnel boring equipment at home and abroad,complete equipment for high-speed tunnel boring and bolting machines was developed by using the integrated technology of tunnel boring and bolting.The complete equipment for high-speed tunnel boring and bolting machines has the functions of tunnel boring and bolting synchronization,once-tunneling,negative pressure dust removal,digital guidance,independent cutting feed,digital cutting,safety monitoring and data interaction,which has the advantages of safety in use,reliability and efficiency.

Continuous prediction method of earthquake early warning magnitude for high-speed railway based on support vector machine

Purpose–Using the strong motion data ofK-net in Japan,the continuous magnitude prediction method based on support vector machine(SVM)was studied.Design/methodology/approach–In the range of 0.5–10.0 s after the P-wave arrival,the prediction time window was established at an interval of 0.5 s.12 P-wave characteristic parameters were selected as the model input parameters to construct the earthquake early warning(EEW)magnitude prediction model(SVM-HRM)for high-speed railway based on SVM.Findings–The magnitude prediction results of the SVM-HRM model were compared with the traditional magnitude prediction model and the high-speed railway EEW current norm.Results show that at the 3.0 s time window,themagnitude prediction error of the SVM-HRMmodel is obviously smaller than that of the traditionalτc method and Pd method.The overestimation of small earthquakes is obviously improved,and the construction of the model is not affected by epicenter distance,so it has generalization performance.For earthquake events with themagnitude range of 3–5,the single station realization rate of the SVM-HRMmodel reaches 95%at 0.5 s after the arrival of P-wave,which is better than the first alarm realization rate norm required by“The TestMethod of EEW andMonitoring Systemfor High-Speed Railway.”For earthquake eventswithmagnitudes ranging from3 to 5,5 to 7 and 7 to 8,the single station realization rate of the SVM-HRM model is at 0.5 s,1.5 s and 0.5 s after the P-wave arrival,respectively,which is better than the realization rate norm of multiple stations.Originality/value–At the latest,1.5 s after the P-wave arrival,the SVM-HRM model can issue the first earthquake alarm that meets the norm of magnitude prediction realization rate,which meets the accuracy and continuity requirements of high-speed railway EEW magnitude prediction.

An Optimal Feed Interpolator Based on G^2 Continuous Bézier Curves for High-Speed Machining of Linear Tool Path

A numerical control (NC) tool path of digital CAD model is widely generated as a set of short line segments in machining. However, there are three shortcomings in the linear tool path, such as discontinuities of tangency and curvature, huge number of line segments, and short lengths of line segments. These disadvantages hinder the development of high speed machining. To smooth the linear tool path and improve machining efficiency of short line segments, this paper presents an optimal feed interpolator based on G^2 continuous Bézier curves for the linear tool path. First, the areas suitable for fitting are screened out based on the geometric characteristics of continuous short segments (CSSs). CSSs in every area are compressed and fitted into a G^2 Continuous Bézier curve by using the least square method. Then a series of cubic Bézier curves are generated. However, the junction between adjacent Bézier curves is only G^0 continuous. By adjusting the control points and inserting Bézier transition curves between adjacent Bézier curves, the G^2 continuous tool path is constructed. The fitting error is estimated by the second-order Taylor formula. Without iteration, the fitting algorithm can be implemented in real-time environment. Second, the optimal feed interpolator considering the comprehensive constraints (such as the chord error constraint, the maximum normal acceleration, servo capacity of each axis, etc.) is proposed. Simulation and experiment are conducted. The results shows that the proposed method can generate smooth path, decrease the amount of segments and reduce machining time for machining of linear tool path. The proposed research provides an effective method for high-speed machining of complex 2-D/3-D profiles described by short line segments.

Adaptation of feed rate for 3-axis CNC high-speed machining

To improve the efficiency of CNC machining, assumptive transit circular arc is used to contour two adjacent moves together on the comer to make smooth paths. The radios of transit circular arc can be adjusted with contour accuracy, and the feed rate on the corner can be controlled through limiting the maximum feed rate of transit circular arc segment. A look-ahead algorithm for a series of moves is proposed for speed adjustment in advance, which avoids the occurrence of overload of cutting tool on the comer and reduces the servo track error of parts on the corner or of circular arc move. Equivalent trapezoidal velocity profile is used to analyze the speed of S-curve velocity profile and work out its accurate interpolation, which overcomes the disadvantage of looking up table to calculate feed rate approximately, hence high accuracy and fine surface quality can be obtained while the machining speed is high. The proposed methods can meet the requirements of real-time analysis of high-speed machining. The presented algorithm is effective and has been adopted by CNC system of newly developed high-speed milling machine.

Machine learning for fault diagnosis of high-speed train traction systems: A review

High-speed trains(HSTs)have the advantages of comfort,efficiency,and convenience and have gradually become the mainstream means of transportation.As the operating scale of HSTs continues to increase,ensuring their safety and reliability has become more imperative.As the core component of HST,the reliability of the traction system has a substantially influence on the train.During the long-term operation of HSTs,the core components of the traction system will inevitably experience different degrees of performance degradation and cause various failures,thus threatening the running safety of the train.Therefore,performing fault monitoring and diagnosis on the traction system of the HST is necessary.In recent years,machine learning has been widely used in various pattern recognition tasks and has demonstrated an excellent performance in traction system fault diagnosis.Machine learning has made considerably advancements in traction system fault diagnosis;however,a comprehensive systematic review is still lacking in this field.This paper primarily aims to review the research and application of machine learning in the field of traction system fault diagnosis and assumes the future development blueprint.First,the structure and function of the HST traction system are briefly introduced.Then,the research and application of machine learning in traction system fault diagnosis are comprehensively and systematically reviewed.Finally,the challenges for accurate fault diagnosis under actual operating conditions are revealed,and the future research trends of machine learning in traction systems are discussed.

Heterogeneity identification method for surrounding rock of large-section rock tunnel faces based on support vector machine

Purpose–The purpose of the study is to quickly identify significant heterogeneity of surrounding rock of tunnel face that generally occurs during the construction of large-section rock tunnels of high-speed railways.Design/methodology/approach–Relying on the support vector machine(SVM)-based classification model,the nominal classification of blastholes and nominal zoning and classification terms were used to demonstrate the heterogeneity identification method for the surrounding rock of tunnel face,and the identification calculation was carried out for the five test tunnels.Then,the suggestions for local optimization of the support structures of large-section rock tunnels were put forward.Findings–The results show that compared with the two classification models based on neural networks,the SVM-based classification model has a higher classification accuracy when the sample size is small,and the average accuracy can reach 87.9%.After the samples are replaced,the SVM-based classification model can still reach the same accuracy,whose generalization ability is stronger.Originality/value–By applying the identification method described in this paper,the significant heterogeneity characteristics of the surrounding rock in the process of two times of blasting were identified,and the identification results are basically consistent with the actual situation of the tunnel face at the end of blasting,and can provide a basis for local optimization of support parameters.

Development of High-speed Machining Database with Case-based Reasoning

Applying high-speed machining technology in shop floor has many benefits, such as manufacturing more accurate parts with better surface finishes. The selection of the appropriate machining parameters plays a very important role in the implementation of high-speed machining technology. The case-based reasoning is used in the developing of high-speed machining database to overcome the shortage of available high-speed cutting parameters in machining data handbooks and shop floors. The high-speed machining database developed in this paper includes two main components: the machining database and the case-base. The machining database stores the cutting parameters, cutting tool data, work pieces and their materials data, and other relative data, while the case-base stores mainly the successfully solved cases that are problems of work pieces and their machining. The case description and case retrieval methods are described to establish the case-based reasoning high-speed machining database. With the case retrieval method, some succeeded cases similar to the new machining problem can be retrieved from the case-base. The solution of the most matched case is evaluated and modified, and then it is regarded as the proposed solution to the new machining problem. After verification, the problem and its solution are packed up into a new case, and are stored in the case-base for future applications.

Tool-path planning for free-form surface high-speed high-resolution machining using torus cutter

In CNC machining, two essential components decide the accuracy and machining time for a sculptured surface: one is the step-size interval, the other is the tool-path interval. Due to the limitation of the conventional method for calculating the tool-path interval, it cannot satisfy the machining requirement for high-speed and high-resolution machining. Accordingly, for high-speed and high-resolution machining, the current study proposes a new tool-path interval algorithm, plus a variable step-size algorithm for NURBS. Furthermore, a new type cutter, which can improve the cutting efficiency, is investigated in the paper. The transversal equation of the torus cutter onto the flat plan is given in this paper. The tool-path interval is calculated with the transversal equation and the proposed algorithm. The illustrated example shows that the redundant tool paths can be reduced because an accurate tool-path interval could be calculated.

Microstructure and cutting performance of CrTiAlN coating for high-speed dry milling

Using a closed field unbalanced magnetron sputtering system,the cemented carbide end mills were coated with a CrTiAlN hard coating,which consisted of a Cr adhesive layer,a CrN interlayer and a CrTiAlN top layer.The microstructure and mechanical properties of the coating were investigated by X-ray diffraction（XRD）,scanning electron microscopy（SEM）,transmission electron microscopy（TEM）,micro indentation and scratch test.The cutting performance of the coated end mills were conducted by high-speed dry milling hardened steel（P20,HRC 45）.The results indicates that the coating is composed of（Cr,Ti,Al）N columnar grains with nanolayers.The coating exhibits good adhesion to cemented carbide substrate and high microhardness of around 30 GPa.The coated end mills show significant improvement on tool life and much lower cutting force as compared to the uncoated ones.And the related mechanisms were discussed.

Research Progress of Key Technology of High-Speed and High Precision Motorized Spindles

High speed machining and high precision machining are two tendencies of themanufacturing technology worldwide. The motorized spindle is the core component of the machine toolsfor achieving the high speed and high precise machining, which affects the general developmentlevel of the machine tools to a great extent. Progress of the key techniques is reviewed in thispaper, in which the high speed and high precision spindle bearings, the dynamical and thermalcharacteristics of spindles, the design technique of the high frequency motors and the drivers, theanti-electromagnetic damage technique of the motors, and the machining and assembling technique areinvolved. Finally, tha development tendencies of the motorized spindles are presented.

Failure mode change and material damage with varied machining speeds:a review

High-speed machining(HSM) has been studied for several decades and has potential application in various industries, including the automobile and aerospace industries. However,the underlying mechanisms of HSM have not been formally reviewed thus far. This article focuses on the solid mechanics framework of adiabatic shear band(ASB) onset and material metallurgical microstructural evolutions in HSM. The ASB onset is described using partial differential systems. Several factors in HSM were considered in the systems, and the ASB onset conditions were obtained by solving these systems or applying the perturbation method to the systems. With increasing machining speed, an ASB can be depressed and further eliminated by shock pressure. The damage observed in HSM exhibits common features. Equiaxed fine grains produced by dynamic recrystallization widely cause damage to ductile materials, and amorphization is the common microstructural evolution in brittle materials. Based on previous studies, potential mechanisms for the phenomena in HSM are proposed. These include the thickness variation of the white layer of ductile materials. These proposed mechanisms would be beneficial to deeply understanding the various phenomena in HSM.

Energy field-assisted high-speed dry milling green machining technology for difficult-to-machine metal materials

Energy field-assisted machining technology has the potential to overcome the limitations of machining difficult-to-machine metal materials,such as poor machinability,low cutting efficiency,and high energy consumption.High-speed dry milling has emerged as a typical green processing technology due to its high processing efficiency and avoidance of cutting fluids.However,the lack of necessary cooling and lubrication in high-speed dry milling makes it difficult to meet the continuous milling requirements for difficult-to-machine metal materials.The introduction of advanced energy-field-assisted green processing technology can improve the machinability of such metallic materials and achieve efficient precision manufacturing,making it a focus of academic and industrial research.In this review,the characteristics and limitations of high-speed dry milling of difficult-to-machine metal materials,including titanium alloys,nickel-based alloys,and high-strength steel,are systematically explored.The laser energy field,ultrasonic energy field,and cryogenic minimum quantity lubrication energy fields are introduced.By analyzing the effects of changing the energy field and cutting parameters on tool wear,chip morphology,cutting force,temperature,and surface quality of the workpiece during milling,the superiority of energy-field-assisted milling of difficult-to-machine metal materials is demonstrated.Finally,the shortcomings and technical challenges of energy-field-assisted milling are summarized in detail,providing feasible ideas for realizing multi-energy field collaborative green machining of difficult-to-machine metal materials in the future.

基于PSO-SVM的矿井输送带火灾危险程度预测模型研究

矿井带式输送机输送带火灾严重威胁煤矿安全生产。矿井输送带火灾风险监测预警方面存在指标内在关联性差、火灾不同发展阶段的标志性气体和特征温度不明确、火灾风险预警指标缺失等难题。因此,采用热重红外联用仪和锥型量热仪装置,研究了矿井输送带火灾热解燃烧的特性,热解初始温度段,首先生成较多的CO_(2)、H2O以及少量CO、HCl,温度升至252℃时,HCl生成量开始迅速增加,298℃时HCl的生成量达到峰值1.26%;CO在416℃时生成量开始迅速增加,485℃时CO的生成量达到峰值0.29%;CO_(2)在整个热解过程中产生量最大,总结出CO、CO_(2)、HCl作为输送带火灾监测预警指标。建立了基于粒子群算法优化支持向量机的模型,并对模型进行了最优参数与效果的研究分析。为了验证模型的准确性和可靠性,采用最小二乘误差指标将PSOSVM与SVM预测结果进行对比。

激光加工氧化铝生瓷微结构制备方法

Al_(2)O_(3)陶瓷具备机械强度高、耐热性好、耐腐蚀的优势。基于激光减材加工技术,介绍了Al_(2)O_(3)生瓷激光减材加工的基本原理。通过建立激光能量密度模型,计算改变激光加工参数时的激光能量密度,从而对加工深度进行预测。通过对比激光加工功率、填充间距、扫描速度和激光重复频率的实验结果,分析了不同加工参数对Al_(2)O_(3)生瓷加工深度和表面粗糙度的影响规律。实验结果表明,通过使用合适的加工参数,在Al_(2)O_(3)生瓷上可制备深度12~280μm和表面粗糙度0.5~1.0μm的腔体。单脉冲能量是影响Al_(2)O_(3)生瓷加工深度的主要因素。在激光能量密度不变的情况下,单脉冲能量(20~200μJ)越高,加工深度越深。该研究验证了激光减材加工技术在Al_(2)O_(3)生瓷腔体直接成型加工中的可行性,推动了激光加工腔体技术在陶瓷封装外壳中的应用。

基于S7-1200PLC的全自动胶带封箱机控制系统设计

针对人工封箱或使用手动胶带封箱机封箱的效率低、工作强度大的问题,设计了一套基于S7-1200 PLC的全自动控制系统,使手动胶带封箱机变为全自动胶带封箱机,能够根据纸箱的尺寸大小自动调节夹紧机构和压紧机构,实现对不同尺寸的纸箱快速封箱。通过实验验证,对尺寸多变的纸箱封箱工作,该全自动胶带封箱机的工作效率高于人工封箱和使用手动胶带封箱机封箱,大大降低了工人劳动强度。

高温超导电缆应用场景与产业发展

高温超导电缆具有容量大、损耗低、自限流、环境友好等突出优点,是解决城市电网升级难题、实现高效率电力传输、赋能大容量电力应用的新兴解决方案,探讨相关产业发展兼具基础研究与工程应用价值。本文剖析了高温超导电缆的技术特点与应用要素,凝练了超级开关站、大电流专线、数据中心供电、基于新能源的电解铝与电解水制氢、集中型充电站、城市轨道交通、大容量直流电网等高温超导电缆的应用场景;从国际、国内两方面总结了高温超导电缆的研制及应用进展,尤其是全面梳理了我国的关键产品研制、关键技术研究、工程项目实施情况。进一步探讨了加强运维技术、攻克大型制冷机技术、降低工程整体造价、与传统电网设施的耦合、形成收益共享机制等高温超导电缆产业未来发展挑战,并针对性地提出了发展建议。相关内容可为高温超导电缆产业高质量发展研究提供参考。

包装机物料站胶带自动供给装置结构设计

随着烟草机械技术不断进步,设备生产速度也越来越高,对设备自动化的要求也越来越高,烟草包装机生产物料无法自动化供给的短板逐渐显现出来.其中,胶带供给装置是影响包装机械全自动供给系统的主要因素.现有胶带供给装置多为人工操作,人工预先切割要求长度的胶带,需要拼接时,将胶带放置在拼接位置,效率较低,易失误.为解决这一问题,介绍一种新型包装机物料站胶带自动供给装置.

一种电缆自动绕包机的设计与实现

针对输配电重要部件高压电缆在发生线芯断裂、绝缘层破损等故障时,人工绕包维修存在效率较低、易损伤电气性能等问题,文中提出了一种利用微控制器自动化调节齿轮做卷绕运动的电缆自动绕包机设计。电缆自动绕包机的机械结构利用步进电机与C型齿轮结构实现卷绕机械运动,其控制系统的硬件部分利用传感器、微控制器、串口电路、数模转换处理电路等实现高压电缆绕包过程的恒张力反馈系统,软件部分通过运行模式和调试模式满足绕包过程的实时性和交互性需求。利用绕包过程中常用的3种带材完成自动绕包的实际效果测试,测试结果表明,所提出的电缆自动绕包机在对3种材料进行的绕包过程中,可以保证张力的恒定,其结果满足铺设电缆所需要的性能,提升了绕包效率和质量。