Analysis of the Pump-turbine S Characteristics Using the Detached Eddy Simulation Method

Current research on pump-turbine units is focused on the unstable operation at off-design conditions, with the characteristic curves in generating mode being S-shaped. Unlike in the traditional water turbines, pump-turbine operation along the S-shaped curve can lead to difficulties during load rejection with unusual increases in the water pressure, which leads to machine vibrations. This paper describes both model tests and numerical simulations. A reduced scale model of a low specific speed pump-turbine was used for the performance tests, with comparisons to computational fluid dynamics（CFD） results. Predictions using the detached eddy simulation（DES） turbulence model, which is a combined Reynolds averaged Naviers-Stokes（RANS） and large eddy simulation（LES） model, are compared with the two-equation turbulence mode results. The external characteristics as well as the internal flow are for various guide vane openings to understand the unsteady flow along the so called S characteristics of a pump-turbine. Comparison of the experimental data with the CFD results for various conditions and times shows that DES model gives better agreement with experimental data than the two-equation turbulence model. For low flow conditions, the centrifugal forces and the large incident angle create large vortices between the guide vanes and the runner inlet in the runner passage, which is the main factor leading to the S-shaped characteristics. The turbulence model used here gives more accurate simulations of the internal flow characteristics of the pump-turbine and a more detailed force analysis which shows the mechanisms controlling of the S characteristics.

3D Two-way Coupled TEHD Analysis on the Lubricating Characteristics of Thrust Bearings in Pump-turbine Units by Combining CFD and FEA

The thermal elastic hydro dynamic （TEHD） lubrication analysis for the thrust bearing is usually conducted by combining Reynolds equation with finite element analysis （FEA）. But it is still a problem to conduct the computation by combining computational fluid dynamics （CFD） and FEA which can simulate the TEHD more accurately. In this paper, by using both direct and separate coupled solutions together, steady TEHD lubrication considering the viscosity-temperature effect for a bidirectional thrust bearing in a pump-turbine unit is simulated combining a 3D CFD model for the oil film with a 3D FEA model for the pad and mirror plate. Cyclic symmetry condition is used in the oil film flow as more reasonable boundary conditions which avoids the oil temperature assumption at the leading and trailing edge. Deformations of the pad and mirror plate are predicted and discussed as well as the distributions of oil film thickness, pressure, temperature. The predicted temperature shows good agreement with measurements, while the pressure shows a reasonable distribution comparing with previous studies. Further analysis of the three-coupled-field reveals the reason of the high pressure and high temperature generated in the film. Finally, the influence of rotational speed of the mirror plate on the lubrication characteristics is illustrated which shows the thrust load should be balanced against the oil film temperature and pressure in optimized designs. This research proposes a thrust bearing computation method by combining CFD and FEA which can do the TEHD analysis more accurately.

Flow-Induced Instabilities in Pump-Turbines in China

The stability of pump-turbines is of great importance to the operation of pumped storage power （PSP） stations. Both hydraulic instabilities and operational instabilities have been reported in PSP stations in China. In order to provide a reference to the engineers and scientists working on pump-turbines, this paper summarizes the hydraulic instabilities and performance characteristics that promote the operational instabilities encountered in pump-turbine operations in China. Definitions, analytical methods, numerical and experimental studies, and main results are clarified. Precautions and countermeasures are also provided based on a literature review. The gaps between present studies and the need for engineering practice are pointed out.

Impact loading in female runners with single and multiple bone stress injuries during fresh and exerted conditions

Background:Bone stress injuries(BSIs)are common in female runners,and recurrent BSI rates are high.Previous work suggests an association between higher impact loading during running and tibial BSI.However,it is unknown whether impact loading and fatigue-related loading changes discriminate women with a history of multiple BSIs.This study compared impact variables at the beginning of a treadmill run to exertion andthe changes in those variables with exertion among female runners with no history of BSI as well as among those with a history of single or multiple BSIs.Methods:We enrolled 45 female runners(aged 18-40 years)for this cross-sectional study:having no history of diagnosed lower extremity BSI(N-BSI,n=14);a history of 1 lower extremity BSI(1-BSI,n=16);and diagnosed by imaging,or a history of multiple(>3)lower extremity BSIs(M-BSI,n=15).Participants completed a 5-km race speed run on an instrumented treadmill while wearing an Inertial Measurement Unit.The vertical average loading rate(VALR),vertical instantaneous loading rate(VILR),vertical stiffness during impact via instrumented treadmill,and tibial shock determined as the peak po sitive tibial acceleration via Inertial Measurement Unit were measured at the beginning and the end of the run.Results:There were no differences between groups in VALR,VILR,vertical stiffness,or tibial shock in a fresh or exerted condition.However,compared to N-BSI,women with M-BSI had greater increase with exertion in VALR(-1.8%vs.6.1%,p=0.01)and VILR(1.5%vs.4.8%,p=0.03).Similarly,compared to N-BSI,vertical stiffness increased more with exertion among women with M-BSI(-0.9%vs.7.3%,p=0.006)and 1-BSI(-0.9%vs.1.8%,p=0.05).Finally,compared to N-BSI,the increase in tibial shock from fresh to exerted condition was greater among women with M-BSI(0.9%vs.5.5%,p=0.03)and 1-BSI(0.9%vs.11.2%,p=0.02).Conclusion:Women with 1-BSI or M-BSIs experience greater exertion-related increases in impact loading than women with N-BSI.These observations imply that exertion-related changes in gait biomechanics may contribute to risk of BSI.

A master-slave generalized predictive synchronization control for preheating process of multi-cavity hot runner system

As a key component of injection molding,multi-cavity hot runner(MCHR)system faces the crucial problem of polymer melt filling imbalance among the cavities.The thermal imbalance in the system has been considered as the leading cause.Hence,the solution may rest with the synchronization of those heating processes in MCHR system.This paper proposes a’Master-Slave’generalized predictive synchronization control(MS-GPSC)method with’Mr.Slowest’strategy for preheating stage of MCHR system.The core of the proposed method is choosing the heating process with slowest dynamics as the’Master’to track the setpoint,while the other heating processes are treated as‘Slaves’tracking the output of’Master’.This proposed method is shown to have the good ability of temperature synchronization.The corresponding analysis is conducted on parameters tuning and stability,simulations and experiments show the strategy is effective.

Power Stabilization System with Counter-Rotating Type Pump-Turbine Unit for Renewable Energy

Traditional type pumped storage system contributes to adjust the electric power unbalance between day and night, in general. The pump-turbine unit is prepared for the power stabilization system, in this serial research, to provide the constant power with good quality for the grid system, even at the suddenly fluctuating/turbulent output from renewable energies. In the unit, the angular momentum changes through the front impeller/runner must be the same as that through the rear impeller/runner, that is, the axial flow at the outlet should be the same to the axial flow at the inlet. Such flow conditions are advantageous to work at not only the pumping mode but also the turbine mode. This work discusses experimentally the performance of the unit, and verifies that this type unit is very effective to both operating modes.

Counter-Rotating Type Pump-Turbine Unit Stabilizing Momentarily Fluctuating Power from Renewable Energy Resources

It is difficult for renewable energy resources to provide constant power with excellent quality for the grid system. This serial research proposes a power stabilization system with a pumped storage to guarantee power quality and capacity, while the outputs from the energy resources are at unstable and/or fluctuating conditions. The power stabilization system with a counter-rotating type pump-turbine unit was prepared and operated at the pumping and the turbine modes. The unit composed of the tandem impellers/runners connected to the inner and the outer armatures of the unique motor/generator. The experiments have verified that this type pump-turbine unit is reasonably effective to stabilize momentarily/instantaneously the fluctuating power from the renewable energy resources.

轴流式水轮发电机组不对中-碰摩耦合故障振动特性分析

针对轴流式水轮发电机组因联轴器偏角不对中引起的碰摩转子-转轮系统振动问题,基于修正的LuGre摩擦模型,该研究推导了联轴器不对中故障下转轮叶片碰摩力表达式。在此基础上,搭建了综合考虑不平衡磁拉力等外激励作用下系统动力学模型。采用数值方法研究了不对中角度对系统振动特性的影响,并结合Floquet理论分析了以转速为控制变量的系统周期解稳定性。结果表明,不对中的存在增大了系统发生失稳可能性,显著改变了系统动态特性。此外,不对中角度对转子与转轮振动响应的影响具有较大差异,随着不对中角度的增加,转轮振动变化明显且碰摩程度较为恶劣。该研究结果可为轴流式水轮发电机组安全运行及稳定性分析提供有益借鉴。

热流道板真空钎焊有限元模拟与分析

采用BNi-2镍基钎料对热流道板进行真空钎焊,须根据钎焊件设定加热工艺曲线。加热工艺曲线的设定是钎焊过程最重要的环节之一,决定着钎焊的质量和效率。该文结合真空加热的特点及钎焊要求,运用Ansys有限元软件数值模拟的方法,对壁厚、体积较大的多层热流道板真空钎焊进行仿真分析,通过对比不同工艺方案及不同钎焊件的模拟结果,探究真空钎焊过程升温规律,从而调整各阶段的相关参数及制定合理的加热工艺曲线,避免了现场反复调试参数造成的资源浪费,节约了时间和成本,提高了效率。此外,通过在实际钎焊试验过程中布置热电偶对钎焊件测量温度,并与数值模拟结果对比,两者基本吻合,验证了有限元分析的准确性,能为之后其他零部件的真空钎焊提供参考。

中长跑运动员穿不同鞋垫跑步时的足底压力探究

目的:选取参与训练与教学课程的27名中长跑运动员,通过在相同速度下穿着不同类型鞋垫跑步时的实验测试,揭示跑步时足底压力、压强生物力学参数指标特征,为中长跑运动员提供生物力学的理论依据。方法:采用实验法、文献资料法、专家访谈法、数理统计法,利用足底压力测试系统与处理软件进行数据整理分析。结果:中长跑运动员穿着不同类型测试鞋垫跑步时左脚和右脚足底平均压力、最大压强在8个分布区域情况不一,两两对比重复测量方差分析存在不同差异,表现为足跟区是跑步时落地缓冲阶段足部主要的受力区域。结论:①无鞋垫时,左、右脚的M2、M4、M5、M6区足底压力均大于其他3种鞋垫;而无鞋垫时足底除M3区外,其他区域内的足底压强均大于其他3种鞋垫。②M5(第2~4跖骨区)、M6(第1跖骨区)是跑步蹬地发力阶段主要受力区域。M1(足跟区)是跑步时落地缓冲阶段足部主要的受力区域。③无鞋垫时,左、右脚的M2、M5、M6区的足底压力值以及左、右脚的M2、M4、M5、M6区的最大压强值均与其他3种鞋垫存在显著性差异。④足底压力值和足底压强值显示A型鞋垫在减压、抗震方面的功能较好。

痛并快乐:资深马拉松业余跑者良性自虐的现象学研究

为了深入探讨资深马拉松业余跑者良性自虐的表现形式、动机来源和认知特点,运用现象学研究方法以13名资深马拉松业余跑者为访谈对象,并对访谈文本进行分析。研究结果表明:(1)良性自虐现象普遍存在于资深马拉松业余跑者群体中;(2)资深马拉松业余跑者良性自虐的表现形式主要体现在环境、生理和心理等3个方面;(3)资深马拉松业余跑者良性自虐的动机来源主要包括挑战自我、过往经历、同伴激励、追求刺激和探索未知等5个方面;(4)资深马拉松业余跑者良性自虐在认知上反映出追求认同接纳、能力体现和利弊权衡的结果。研究认为良性自虐行为对于资深马拉松业余跑者利弊共存,需要积极引导宣传、正确教育和制度合理管控,保障马拉松跑者安全科学运动,促进身心健康。

PEMFC船形堵块阴极流场的性能

建立流体体积(VOF)两相流模型,研究船形堵块流道的排水性能。建立不同开孔率的船形堵块流道三维模型,研究船形堵块及开孔率对质子交换膜燃料电池(PEMFC)性能的影响。船形堵块流道峰值净功率密度相较于传统直流道可提升9.4%,相较于同堵塞率下的梯形堵块流道可提高2.9%,具有较好的强化传质作用。通过提高船形堵块流道的开孔率,PEMFC可以获得更好的性能。在相同开孔率下,船形堵块流道的氧气摩尔浓度较直流道和梯形堵块流道分别提高28.6%和14.0%。结果表明,相较于传统直流道,船形堵块流道可降低排水周期和流道内平均水含量,具有更好的排水性能。

左右后雾灯边框的顺序阀热流道注塑模设计

结合新能源汽车的左右后雾灯边框注塑时易产生熔接痕和脱模时易变形的问题,设计了1模2腔的侧浇口二板式热流道注塑模具。基于Moldflow模拟分析结果,确定了左右后雾灯边框的最佳浇口位置、浇口数量,通过综合分析塑件尺寸、生产技术和效率等设计了模具的浇注系统、冷却系统、抽芯机构、脱模机构等结构。为合理控制塑件的熔接痕,采用冷流道与热流道相结合的复合流道,利用顺序阀控制进浇点的进浇时间;为了实现高效脱模,将模具引入了斜顶机构、倒装的斜导柱侧抽芯的组合式脱模结构,替代了传统注塑推杆式脱模,采用两侧油缸驱动推板运动的脱模方式。最后,利用UG软件对模具的导向机构、复位机构和其他辅助机构进行分析,完成了模具设计。

基于MRD优化布置的水轮发电机组碰摩系统振动抑制

针对水轮发电机组转子-转轮系统碰摩故障问题,采用磁流变液阻尼器(magneto-rheological damper,MRD)对轴系振动进行抑制,旨在探究MRD对机组轴系振动的影响规律及其对系统碰摩故障的抑制效果。首先,将机组轴向位置函数引入MRD非线性动力学模型,推导了碰摩故障下含轴向分布参数的MRD-转子-转轮系统动力学方程。其次,基于数值模拟方法,以机组转速为控制参数对比分析了是否考虑MRD的转子-转轮系统非线性动力学行为。最后,研究了不同MRD轴向布置参数对碰摩转子-转轮系统动力学行为的影响。研究结果表明:MRD的加入对转子、转轮非稳态运动具有良好约束作用,能够显著减小转子、转轮振动幅值,有效避免了机组轴系碰摩故障的发生;当阻尼器位置参数s_(1)、s_(2)分别取0.25与0.95时,MRD对系统的减振效果最佳。通过在机组轴系合理布置MRD,可有效改善系统振动情况,从而为水轮发电机组振动控制提供有益指导。

异形分流管热流道家族注塑模具设计

介绍了某款异形分流管零件热流道注塑模具的设计过程。模具设计中,首先,分析了注塑件的零件特征和生产要求,确定了模具的基本结构方案;再利用Moldflow软件分析模具注塑成型过程,预测零件的成型时间、翘曲变形量、熔接痕位置等,最终完成整套模具的设计。模具采用两板式热流道冷浇口注塑成型,浇口选择潜伏式点浇口形式,开模时自动拉断与注塑件分离;模具定模型腔设计了1个弹性脱模镶件,保证了开模时塑件紧贴型芯侧;模具分型面上共分布了5个侧抽芯滑块结构,由弯销导向并延时开模。对常用型弯销滑块机构进行了改进,将两段式弯销改进为三段式弯销,有效地避免了常用弯销滑块机构容易出现卡死和锁闭不紧的问题。模具经过实际生产验证可知,结构合理可靠,制备得到的零件尺寸精度满足设计要求。

基于NX与VERICUT转轮体五轴高效加工方案研究与实践

介绍了一种基于NX和VERICUT的转轮体五轴高效加工方案。首先,通过NX软件建立转轮体的三维模型,并进行CAD/CAM预处理,得到数控加工程序。其次,通过VERICUT虚拟加工系统进行仿真验证,优化加工策略。最后,在GS200五轴高速机床上对零件进行高效加工验证。文中的研究结果对于提高零件加工精度和效率具有一定的借鉴价值。

壁挂空调底盘模具结构设计

根据空调底盘的结构和外观要求,设计了一种含有多种脱模结构的热流道塑料模具。模具中,产品两端的扣位采用“斜导柱+滑块”机构脱模;出水管采用“油缸+滑块+斜抽芯”机构脱模;排风口、排风口旁边的V形槽、排风口内部的筋位采用组合滑块机构脱模;排风口中间的筋位采用由排风口滑块驱动的,先横向脱模、再纵向移动的滑块机构脱模;产品右上角的圆柱孔采用“斜导柱+斜抽芯”机构脱模;产品内表面的扣位采用定模斜顶结构脱模;在滑块上设置避空孔,防止滑块与顶杆发生干涉;根据产品结构设计的冷却系统,有利于模温均匀。

基于NX的转轮体五轴加工应用研究

结合NX软件在零件加工方面的强大功能,利用GS200五轴高速机床,提出一套对转轮体进行五轴数控加工的工艺整体方案,构建了加工刀路,生成了转轮体的后置处理程序,并在GS200五轴高速机床对零件进行了试切加工验证。加工结果表明:通过刀路的检查与实际加工可及时发现刀具跟零件之间有无过切、干涉、碰撞等问题,对五轴加工零件加工工艺方案制定具有实际指导意义。

碎纸机塑件外壳大型注塑模具设计

以碎纸机塑件外壳为研究对象,设计了一副结构复杂的大型热流道塑胶模具。根据塑件的结构特点和使用要求,模具设计两点热咀进胶方式保证进胶的均衡性;采用1个油缸驱动的定模隧道滑块抽芯机构,1个天侧油缸驱动的滑块抽芯机构,1个地侧斜销驱动的滑块抽芯机构,滑块还包括延时弹针设计,5个斜顶抽芯机构,解决塑件所有倒扣的脱模难题。定模采用U形水路设计,动模采用水井均布的方式,滑块上单独水路冷却设计,使模具在实际生产过程中塑件的成型周期和品质均表现优异。模具顶出主要采用直顶块顶出机构的方式配合斜顶完成。

水轮机转轮根切现象研究及预防

混流式水轮发电机组生产制造过程中,需手工打磨转轮叶片与上冠、下环之间的焊缝。在打磨焊缝过程中,易产生根切现象影响工件质量。本文对混流式转轮根切现象进行了全面的分析及研究,特别针对根切的预防措施做了详细介绍,极大程度减少了根切现象的产生,具有积极的指导意义及推广价值。