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The purpose of the paper is to predict the aerodynamic performance of a complete scale model H-Darrieus vertical axis wind turbine (VAWT) with end plates at different operating conditions. This paper aims at understanding the flow physics around a model VAWT for three different tip speed ratios corresponding to three different flow regimes.

This study achieves a first three-dimensional hybrid lattice Boltzmann method/very large eddy simulation (LBM-VLES) model for a complete scaled model VAWT with end plates and mast using the solver PowerFLOW. The power curve predicted from the numerical simulations is compared with the experimental data collected at Erlangen University. This study highlights the complexity of the turbulent flow features that are seen at three different operational regimes of the turbine using instantaneous flow structures, mean velocity, pressure iso-contours, blade loading and skin friction plots.

The power curve predicted using the LBM-VLES approach and setup provides a good overall match with the experimental power curve, with the peak and drop after the operational point being captured. Variable turbulent flow structures are seen over the azimuthal revolution that depends on the tip speed ratio (TSR). Significant dynamic stall structures are seen in the upwind phase and at the end of the downwind phase of rotation in the deep stall regime. Strong blade wake interactions and turbulent flow structures are seen inside the rotor at higher TSRs.

The computational cost and time for such high-fidelity simulations using the LBM-VLES remains expensive. Each simulation requires around a week using supercomputing facilities. Further studies need to be performed to improve analytical VAWT models using inputs/calibration from high fidelity simulation databases. As a future work, the impact of turbulent and nonuniform inflow conditions that are more representative of a typical urban environment also needs to be investigated.

The LBM methodology is shown to be a reliable approach for VAWT power prediction. Dynamic stall and blade wake interactions reduce the aerodynamic performance of a VAWT. An ideal operation close to the peak of the power curve should be favored based on the local wind resource, as this point exhibits a smoother variation of forces improving operational performance. The 3D flow features also exhibit a significant wake asymmetry that could impact the optimal layout of VAWT clusters to increase their power density. The present work also highlights the importance of 3D simulations of the complete model including the support structures such as end plates and mast.

Accurate predictions of power performance for Darrieus VAWTs could help in better siting of wind turbines thus improving return of investment and reducing levelized cost of energy. It could promote the development of onsite electricity generation, especially for industrial sites/urban areas and renew interest for VAWT wind farms.

A first high-fidelity simulation of a complete VAWT with end plates and supporting structures has been performed using the LBM approach and compared with experimental data. The 3D flow physics has been analyzed at different operating regimes of the turbine. These physical insights and prediction capabilities of this approach could be useful for commercial VAWT manufacturers.

This paper presents a comparative study of different stator-segmentation topologies of a permanent magnet synchronous machine (PMSM) used in traction drives and their effect on iron losses. Using stator segmentation allows one to achieve more significant copper fill factors, resulting in increased power densities and efficiencies. The segmentation of the stators creates additional air gaps and changes the soft magnetic material’s material properties due to the cut edge effect. The aim of this paper is to present an in-depth analysis of the influence of stator segmentation on iron losses. The main goal was to compare various segmentation methods under equal excitation conditions in terms of their influence on iron loss.

A transient finite element method analysis combined with an extended iron-loss model was used to evaluate discussed effects on the stator’s iron losses. The workflow to obtain a homogenized airgap length accounting for cut edge effects was established.

The paper concludes that the segmentation in most cases slightly decreases the iron losses in the stator because of the overall reduced magnetic flux density B due to the additional air gaps in the magnetic circuit. An increase of the individual components, as well as total power loss, was observed in the Pole Chain segmentation design. In general, segmentation did not change the total iron losses significantly. However, different segmentation methods resulted in the different distortion of the magnetic field and, consequently, in different iron loss compositions. The analysed segmentation methods exhibited different iron loss behaviour with respect to the operation points of the machine. The final finding is that analysed stator segmentations had a negligible influence on the total iron loss. Therefore, applying segmentation is an adequate measure to improve PMSMs as it enables, e.g. increase of the winding fill factor or simplifying the assembly processes, etc.

The influence of stator segmentation on iron losses was analysed. An in-depth evaluation was performed to determine how the discussed changes influence the individual iron loss components. A workflow was developed to achieve a computationally cheap homogenized model.

This study aims to investigate the suitability of a multi-step prototyping strategy for producing pneumatic rotary vane actuators (RVAs) for the development of lightweight robots and actuation systems.

RVAs typically have cast aluminum housings and injection-molded seals that consist of hard thermoplastic cores and soft elastomeric overmolds. Using a combination of additive manufacturing (AM), computer numerical control (CNC) machining and elastomer molding, a conventionally manufactured standard RVA was replicated. The standard housing design was modified, and polymeric replicas were obtained by selective laser sintering (SLS) or PolyJet (PJ) printing and subsequent CNC milling. Using laser-sintered molds, actuator seals were replicated by overmolding laser-sintered polyamide cores with silicone (SIL) and polyurethane (PU) elastomers. The replica RVAs were subjected to a series of leakage, friction and durability experiments.

The AM-based prototyping strategy described is suitable for producing functional and reliable RVAs for research and product development. In a representative durability experiment, the RVAs in this study endured between 40,000 and 1,000,000 load cycles. Frictional torques were around 0.5 Nm, which is 10% of the theoretical torque at 6 bar and comparable to that of the standard RVA. Models and parameters are provided for describing the velocity-dependent frictional torque. Leakage experiments at 10,000 load cycles and 6 bar differential pressure showed that PJ housings exhibit lower leakage values (6.8 L/min) than laser-sintered housings (15.2 L/min), and PU seals exhibit lower values (8.0 l/min) than SIL seals (14.0 L/min). Combining PU seals with PJ housings led to an initial leakage of 0.4 L/min, which increased to only 1.2 L/min after 10,000 load cycles. Overall, the PU material used was more difficult to process but also more abrasion- and tear-resistant than the SIL elastomer.

More work is needed to understand individual cause–effect relationships between specific design features and system behavior.

To date, pneumatic RVAs have been manufactured by large-scale production technologies. The absence of suitable prototyping strategies has limited the available range to fixed sizes and has thus complicated the use of RVAs in research and product development. This paper proves that functional pneumatic RVAs can be produced by using more accessible manufacturing technologies and provides the tools for prototyping of application-specific RVAs.

Numerous metals can be processed using the additive manufacturing process laser-based powder bed fusion of metals (PBF-LB/M, ISO/ASTM 52900). The main advantages of additive manufacturing technologies are the high degree of design freedom and the cost-effective implementation of lightweight structures. This could be profitable for gears with increased power density, combining reduced mass with considerable material strength. Current research on additively manufactured gears is focused on developing lightweight structures but is seldom accompanied by simulations and even less by mechanical testing. There has been very little research into the mechanical and material properties of additively manufactured gears. The purpose of this study is to investigate the behavior of lightweight structures in additively manufactured gears under static loads.

This research identifies the static load-carrying capacity of helical gears with different lightweight structures produced by PBF-LB/M with the case hardening steel 16MnCr5. A static gear loading test rig with a maximum torque at the pinion of T₁ = 1200 Nm is used. Further focus is set on analyzing material properties such as the relative density, microstructure, hardness depth profile and chemical composition.

All additively manufactured gear variants show no failure or plastic deformation at the maximum test load. The shaft hub connection, the lightweight hub designs and the gearing itself are stable and intact regarding their form and function. The identified material characteristics are comparable to conventionally manufactured gears (wrought and machined), but also some particularities were observed.

This research demonstrates the mechanical strength of lightweight structures in gears. Future research needs to consider the dynamic load-carrying capacity of additively manufactured gears.

Small highly saturated interior permanent magnet- synchronous machines (IPMSMs) show a very nonlinear behaviour. Such machines are mostly controlled with a closed-loop cascade control, which is based on a d-q two-axis dynamic model with constant concentrated parameters to calculate the control parameters. This paper aims to present the identification of a complete current- and rotor position-dependent d-q dynamic model, which is derived by using a finite element method (FEM) simulation. The machine’s constant parameters are determined for an operation on the maximum torque per ampere (MTPA) curve. The obtained MTPA control performance was evaluated on the complete FEM-based nonlinear d-q model.

A FEM model was used to determine the nonlinear properties of the complete d-q dynamic model of the IPMSM. Furthermore, a fitting procedure based on the nonlinear MTPA curve is proposed to determine adequate constant parameters for MTPA operation of the IPMSM.

The current-dependent d-q dynamic model of the machine models the relevant dynamic behaviour of the complete current- and rotor position-dependent FEM-based d-q dynamic model. The most adequate control response was achieved while using the constant parameters fitted to the nonlinear MTPA curve by using the proposed method.

The effect on the motor’s steady-state and dynamic behaviour of differently complex d-q dynamic models was evaluated. A workflow to obtain constant set of parameters for the decoupled operation in the MTPA region was developed and their effect on the control response was analysed.

Two-handed automobile steering at low vehicle speeds may lead to reduced steering ability at large steering wheel angles and shoulder injury at high steering wheel rates (SWRs). As a first step toward solving these problems, this study aims, firstly, to design a surface electromyography (sEMG) controlled steering assistance interface that enables hands-free steering wheel rotation and, secondly, to validate the effect of this rotation on path-following accuracy.

A total of 24 drivers used biceps brachii sEMG signals to control the steering assistance interface at a maximized SWR in three driving simulator scenarios: U-turn, 90º turn and 45º turn. For comparison, the scenarios were repeated with a slower SWR and a game steering wheel in place of the steering assistance interface. The path-following accuracy of the steering assistance interface would be validated if it was at least comparable to that of the game steering wheel.

Overall, the steering assistance interface with a maximized SWR was comparable to a game steering wheel. For the U-turn, 90º turn and 45º turn, the sEMG-based human–machine interface (HMI) had median lateral errors of 0.55, 0.3 and 0.2 m, respectively, whereas the game steering wheel, respectively, had median lateral errors of 0.7, 0.4 and 0.3 m. The higher accuracy of the sEMG-based HMI was statistically significant in the case of the U-turn.

Although production automobiles do not use sEMG-based HMIs, and few studies have proposed sEMG controlled steering, the results of the current study warrant further development of a sEMG-based HMI for an actual automobile.

This study aims to introduce the achievements and benefits of applying wheel/rail-force–based maintenance interval extension of the C80 series wagon in China.

Chinese wagons' existing maintenance strategy had left a certain safety margin for the characteristics of widely running range, unstable service environment and submission to transportation organization requirements. To reduce maintenance costs, China railway (CR) has attempted to extend the maintenance interval since 2020. The maintenance cycle of C80 series heavy haul wagons is extended by three months (no stable routing) or 50,000 km (regular routing). However, in the meantime, the alarming rate of the running state, a key index to reflect the severe degree of hunting stability, by the train performance detection system (TPDS) for the C80 series heavy haul wagons has increased significantly.

The present paper addresses a big data statistical way to evaluate the risk of allowing the C80 series heavy haul wagons to remain in operation longer than stipulated by the maintenance interval initial set. Through the maintenance and wayside-detector data, which is divided into three stages, the extension period (three months), the current maintenance period and the previous maintenance period, this method reveals the alarming rate of hunting was correlated with maintenance interval. The maintainability of wagons will be achieved by utilizing wagon performance degradation modeling with the state of the wheelset and the often-contact side bearing. This paper also proposes a statistical model to return to the average safety level of the previous maintenance period's baseline through correct alarming thresholds for unplanned corrective maintenance.

The paper proposes an approach to reduce safety risk due to maintenance interval extension by effective maintenance program. The results are expected to help the railway company make the optimal solution to balance safety and the economy.

This study aims to focus on verifying the possibility of monitoring the condition of a turboprop engine using data recorded by on-board avionics Garmin G1000. This approach has potential benefits for operators without the need to invest in specialised equipment. The main focus was on the inter-turbine temperature (ITT). An unexpected increase in temperature above the usual value may indicate an issue with the engine. The problem lies in the detection of small deviations when the absolute value of the ITT is affected by several external variables.

The ITT is monitored by engine sensors and stored by avionics 1× per second onto an SD card. This process generates large amount of data that needs to be processed. Therefore, an algorithm was created to detect the steady states of the engine parameters. The ITT value also depends on the flight parameters and surrounding environment. As a solution to these effects, the division of data into clusters that represent the usual flight profiles was tested. This ensures a comparison at comparable ambient pressures. The dominant environmental influence then remain at the ambient air temperature (OAT). Three OAT compensation methods were tested in this study. Compensation for the standard atmosphere, compensation for the standard temperature of the given flight level and compensation for the speed of the generator, where the regression analysis proved the dependence between the ambient temperature and the speed of the generator.

The influence of ambient temperature on the corrected ITT values is noticeable. The best method for correcting the OAT appears to be the use of compensation through the revolutions of the compressor turbine NG. The speed of the generator depends on several parameters, and can refine the corrected ITT value. During the long-term follow-up, the ITT differences (delta values) were within the expected range. The tested data did not include the behaviour of the engine with a malfunction or other damage that would clearly verify this approach. Therefore, the engine monitoring will continue.

This study presents a possible approach to turbine engine condition monitoring using limited on board avionic data. These findings can support the development of an engine condition monitoring system with automatic abnormality detection and low operating costs.

This article represent a practical description of problems in monitoring the condition of a turboprop engine in an aircraft with variable flight profiles. The authors are not aware of a similar method that uses monitoring of engine parameters at defined flight levels. Described findings should limit the influence of ambient air pressure on engine parameters.

This paper aims to deal with the design optimization of a synchronous reluctance machine to be used in an X-ray tube, where the goal is to maximize the torque while keeping low the amount of material used, by means of gradient-based free-form shape optimization.

The presented approach is based on the mathematical concept of shape derivatives and allows to obtain new motor designs without the need to introduce a geometric parametrization. This paper presents an extension of a standard gradient-based free-form shape optimization algorithm to the case of multiple objective functions by determining updates, which represent a descent of all involved criteria. Moreover, this paper illustrates a way to obtain an approximate Pareto front.

The presented method allows to obtain optimal designs of arbitrary, non-parametric shape with very low computational cost. This paper validates the results by comparing them to a parametric geometry optimization in JMAG by means of a stochastic optimization algorithm. While the obtained designs are of similar shape, the computational time used by the gradient-based algorithm is in the order of minutes, compared to several hours taken by the stochastic optimization algorithm.

This paper applies the presented gradient-based multi-objective optimization algorithm in the context of free-form shape optimization using the mathematical concept of shape derivatives. The authors obtain a set of Pareto-optimal designs, each of which is a shape that is not represented by a fixed set of parameters. To the best of the authors’ knowledge, this approach to multi-objective free-form shape optimization is novel in the context of electric machines.

In recent years, owing to the rapidly increasing labor costs, the demand for robots in daily services and industrial operations has been increased significantly. For further applications and human–robot interaction in an unstructured open environment, fast and accurate tracking and strong disturbance rejection ability are required. However, utilizing a conventional controller can make it difficult for the robot to meet these demands, and when a robot is required to perform at a high-speed and large range of motion, conventional controllers may not perform effectively or even lead to the instability.

The main idea is to develop the control law by combining the SMC feedback with the ADRC control architecture to improve the robustness and control quality of a conventional SMC controller. The problem is formulated and solved in the framework of ADRC. For better estimation and control performance, a generalized proportional integral observer (GPIO) technique is employed to estimate and compensate for unmodeled dynamics and other unknown time-varying disturbances. And benefiting from the usage of GPIO, a new SMC law can be designed by synthesizing the estimation and its history.

The employed methodology introduced a significant improvement in handling the uncertainties of the system parameters without compromising the nominal system control quality and intuitiveness of the conventional ADRC design. First, the proposed method combines the advantages of the ADRC and SMC method, which achieved the best tracking performance among these controllers. Second, the proposed controller is sufficiently robust to various disturbances and results in smaller tracking errors. Third, the proposed control method is insensitive to control parameters which indicates a good application potential.

High-performance robot tracking control is the basis for further robot applications in open environments and human–robot interfaces, which require high tracking accuracy and strong disturbance rejection. However, both the varied dynamics of the system and rapidly changing nonlinear coupling characteristic significantly increase the control difficulty. The proposed method gives a new replacement of PID controller in robot systems, which does not require an accurate dynamic system model, is insensitive to control parameters and can perform promisingly for response rapidity and steady-state accuracy, as well as in the presence of strong unknown disturbances.