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Static inverters are very important for the emergency energy distribution system of aircraft and similar machines. At the same time, the electrical energy produced at high frequency for electrical devices is used to reduce the weight of the cables in the aircraft and spacecraft because of the skin effect. In the high-frequency system, a thinner cable cross-section is used, and a great weight reduction occurs in the aircraft. So, fuel economy, less and late wear of the materials (landing gear, etc.) can be obtained with decreasing weight. This paper aims to present the development of a functional multilevel inverter (FMLI) with fractional sinus pulse width modulation (FSPWM) and a reduced number of switches to provide high-frequency and quality electrical energy conversion.

After the production of FSPWM for FMLI with a reduced component, which, to the best of the authors’ knowledge, is presented for the first time in this study, is explained step by step, and eight operating states are given according to different FSPWMs operating the circuit. The designed inverter and modulation technique are compared by testing the conventional modular multilevel inverter on different loads.

According to application results, it is seen that there is a 50% reduction in cross-section from 100 Hz to 400 Hz with the skin effect. At 1000 Hz, there is a 90% cross-section reduction. The decrease can be in cable weights that may occur in aircraft from 10 kg to 100 kg according to different frequencies. It causes less harmonic distortion than conventional converters. This supports the safer operation of the system. Compared to the traditional system, the proposed system provides more amplitude in converting the source to alternating voltage and increases the efficiency.

FSPWM is developed for multilevel inverters with reduced components at the high frequency and cascaded switching studies in the power electronics of aircraft.

Although the proposed system has less current and power loss as mentioned in the previous sections, it contains fewer power elements than conventional inverters that are equivalent for different hardware levels. This not only reduces the cost of the system but also provides ease of maintenance. To reduce the cable load in aircraft and create more efficient working conditions, 400 Hz alternative voltage is used. The proposed system causes less losses and lower harmonic distortions than traditional systems. This will reduce possible malfunctions and contribute to aircraft reliability for passengers and cargo. As technology develops, it is revealed that the proposed inverter system will be more efficient than traditional inverters when devices operating at frequencies higher than 400 Hz are used. With the proposed inverter, safer operation will be ensured, while there will be less energy loss, less fuel consumption and less carbon emissions to the environment.

The proposed inverter structure shows that it can provide energy transmission for electrical devices in space and aircraft by using the skin effect. It also contains less power elements than the traditional inverters, which are equivalent for different levels of hardware.

Induction heating processes need to adapt to complex geometries or variable processes that require a high degree of flexibility in the induction heating setup. This is usually done using complex inductors or adaptable resonant tanks, which leads to costly and constrained implementations. This paper aims to propose a multi-level, versatile power supply able to adapt the output to the required induction heating process.

This paper proposes a versatile multilevel topology able to generate versatile output waveforms. The methodology followed includes simulation of the proposed architecture, design of the power electronics, control and magnetic elements and laboratory tests after building a 10-level prototype.

The proposed converter has been designed and tested using an experimental prototype. The designed generator is able to operate at 1 kVpp and 100 A at 250 kHz, proving the feasibility of the proposed approach.

The proposed converter enables versatile waveform generation, enabling advanced tests and processes on induction heating system. The proposed system allows for multifrequency generation using a single inductor and converter, or advanced tests for inductive and capacitive components used on induction heating systems. Unlike previous multifrequency proposals, the proposed generator enables a significantly improved versatility in terms of operational frequency and amplitude in a single converter.

Photovoltaic (PV) systems are experiencing exponential growth due to environmental concerns, unlimited and ubiquitous solar energy, and starting-to-make-sense panel costs. Alongside designing more efficient solar panels, installing solar trackers and special circuitry for optimizing power delivery to the load according to a maximum power point tracking (MPPT) algorithm are other ways of increasing efficiency. However, it is critical for any efficiency increase to account for the power consumption of any amendments. Therefore, this paper aims to propose a novel tracker while using MPPT to boost the PV system's actual efficiency accounting for the involved costs.

The proposition is an experimental pneumatic dual-axis solar tracker using light-dependent resistor (LDR) sensors. Due to its embedded energy storage, the pneumatic tracker offers a low duty-cycle operation leading to tracking energy conservation, fewer maintenance needs and scalability potential. While MPPT assures maximum load power delivery, the solar PV's actual delivered power is calculated for the first time, accounting for the solar tracking and MPPT power costs.

The experiments' results show an increase of 37.6% in total and 35.3% in actual power production for the proposed solar tracking system compared to the fixed panel system, with an MPPT efficiency of 90%. Thus, the pneumatic tracking system offers low tracking-energy consumption and good actual power efficiency. Also, the newly proposed pneumatic stimulant can significantly simplify the tracking mechanism and benefit from several advantages that come along with it.

To the best of the authors’ knowledge, this work proposes, for the first time, a single-motor pneumatic dual-axis tracker with less implementation cost, less frequent operation switching and scalability potential, to be developed in future works. Also, the pneumatic proposal delivers high actual power efficiency for the first time to be addressed.

This experimental study aims to deal with the improvement of process performance of electric discharge drilling (EDD) for fabricating true blind holes in titanium alloy Ti6Al4V. Micro EDD was performed on Ti6Al4V and blind holes were drilled into the workpiece.

The effects of input parameters (i.e. voltage, capacitance and spindle speed) on responses (i.e. material removal rate, tool wear rate and surface roughness [SR]) were evaluated through response surface methodology. The data was analyzed using analysis of variance and multi-optimization was performed for the optimized set of parameters. The optimized process parameters were then used to drill deeper blind holes.

Blind holes have few characteristics such as SR, taper angle and corner radius. The value of corner radius reflects the quality of the hole produced as well as the amount of tool roundness. The optimized process parameters suggested by the current experimental study lower down the response values (i.e. SR, taper angle and corner radius). The process is found very effective in producing finished blind holes.

This experimental study establishes EDD as a feasible process for the fabrication of truly blind holes in Ti6Al4V.

The purpose of this paper is to present the influence of inter-turn short circuit faults (ITSF) on electromagnetic vibration in high-voltage line-starting permanent magnet synchronous motor (HVLSPMSMS).

In this paper, the ampere–conductor wave model of HVLSPMSM after ITSF is established. Second, a mathematical model of the magnetic field after ITSF is established, and the influence law of the ITSF on the air-gap magnetic field is analyzed. Further, the mathematical expression of the electromagnetic force density is established based on the Maxwell tensor method. The impact of HVLSPMSM torque ripple frequency, radial electromagnetic force spatial–temporal distribution and rotor unbalanced magnetic tension force by ITSF is revealed. Finally, the electromagnetic–mechanical coupling model of HVLSPMSM is established, and the vibration spectra of the motor with different degrees of ITSF are solved by numerical calculation.

In this study, it is found that the 2np order flux density harmonics and (2 N + 1) p order electromagnetic forces are not generated when ITSF occurs in HVLSPMSM.

By analyzing the multi-harmonics of HVLSPMSM after ITSF, this paper provides a reliable method for troubleshooting from the perspective of vibration and torque fluctuation and rotor unbalanced electromagnetic force.

The purpose of this paper is to present current state of understanding on jet electrodeposition manufacturing; to compare various experimental parameters and their implication on as deposited features; and to understand the characteristics of jet electrodeposition deposition defects and its preventive procedures through available research articles.

A systematic review has been done based on available research articles focused on jet electrodeposition and its characteristics. The review begins with a brief introduction to micro-electrodeposition and high-speed selective jet electrodeposition (HSSJED). The research and developments on how jet electrochemical manufacturing are clustered with conventional micro-electrodeposition and their developments. Furthermore, this study converges on comparative analysis on HSSJED and recent research trends in high-speed jet electrodeposition of metals, their alloys and composites and presents potential perspectives for the future research direction in the final section.

Edge defect, optimum nozzle height and controlled deposition remain major challenges in electrochemical manufacturing. On-situ deposition can be used as initial structural material for micro and nanoelectronic devices. Integration of ultrasonic, laser and acoustic source to jet electrochemical manufacturing are current trends that are promising enhanced homogeneity, controlled density and porosity with high precision manufacturing.

This paper discusses the key issue associated to high-speed jet electrodeposition process. Emphasis has been given to various electrochemical parameters and their effect on deposition. Pros and cons of variations in electrochemical parameters have been studied by comparing the available reports on experimental investigations. Defects and their preventive measures have also been discussed. This review presented a summary of past achievements and recent advancements in the field of jet electrochemical manufacturing.

This paper aims to present a novel lightweight distribution grid operating robot system with focus on lightweight and multi-functionality, aiming for autonomous and live-line maintenance operations.

A ground-up redesign of the dual-arm robotic system with 12-DoF is applied for substantial weight reduction; a dual-mode operating control framework is proposed, with vision-guided autonomous operation embedded with real-time manual teleoperation controlling both manipulators simultaneously; a quick-swap tooling system is developed to conduct multi-functional operation tasks. A prototype robotic system is constructed and validated in a series of operational experiments in an emulated environment both indoors and outdoors.

The overall weight of the system is successfully brought down to under 150 kg, making it suitable for the majority of vehicle-mounted aerial work platforms, and it can be flexibly and quickly deployed in population dense areas with narrow streets. The system equips with two dexterous robotic manipulators and up to six interchangeable tools, and a vision system for AI-based autonomous operations. A quick-change tooling system ensures the robot to change tools on-the-go without human intervention.

The resulting dual-arm robotic live-line operation system robotic system could be compact and lightweight enough to be deployed on a wide range of available aerial working platforms with high mobility and efficiency. The robot could both conduct routine operation tasks fully autonomously without human direct operation and be manually operated when required. The quick-swap tooling system enables lightweight and durable interchangeability of multiple end-effector tools, enabling future expansion of operating capabilities across different tasks and operating scenarios.

Aluminum alloy is considered an ideal material in aerospace, automobile and other fields because of its lightweight, high specific strength and easy processing. However, low hardness and strength of the surface of aluminum alloys are the main factors that limit their applications. The purpose of this study is to obtain a composite coating with high hardness and lubricating properties by applying GO–PVA over MAO coating.

A pulsed bipolar power supply was used as power supply to prepare the micro-arc oxidation (MAO) coating on 6061 aluminum sample. Then a graphene oxide-polyvinyl alcohol (GO–PVA) composite coating was prepared on MAO coating for subsequent experiments. Samples were characterized by Fourier infrared spectroscopy, X-ray diffraction, Raman spectroscopy and thermogravimetric analysis. The friction test is carried out by the relative movement of the copper ball and the aluminum disk on the friction tester.

Results showed that the friction coefficient of MAO samples was reduced by 80% after treated with GO–PVA composite film.

This research has made a certain contribution to the surface hardness and tribological issues involved in the lightweight design of aluminum alloys.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-12-2023-0427/

The purpose of this paper is to compile a comprehensive status report on pipes/piping networks across different industrial sectors, along with specifications of materials and sizes, and showcase welding avenues. It further extends to highlight the promising friction stir welding as a single solid-state pipe welding procedure. This paper will enable all piping, welding and friction stir welding stakeholders to identify scope for their engagement in a single window.

The paper is a review paper, and it is mainly structured around sections on materials, sizes and standards for pipes in different sectors and the current welding practice for joining pipe and pipe connections; on the process and principle of friction stir welding (FSW) for pipes; identification of main welding process parameters for the FSW of pipes; effects of process parameters; and a well-carved-out concluding summary.

A well-carved-out concluding summary of extracts from thoroughly studied research is presented in a structured way in which the avenues for the engagement of FSW are identified.

The implications of the research are far-reaching. The FSW is currently expanding very fast in the welding of flat surfaces and has evolved into a vast number of variants because of its advantages and versatility. The application of FSW is coming up late but catching up fast, and as a late starter, the outcomes of such a review paper may support stake holders to expand the application of this process from pipe welding to pipe manufacturing, cladding and other high-end applications. Because the process is inherently inclined towards automation, its throughput rate is high and it does not need any consumables, the ultimate benefit can be passed on to the industry in terms of financial gains.

To the best of the authors’ knowledge, this is the only review exclusively for the friction stir welding of pipes with a well-organized piping specification detailed about industrial sectors. The current pipe welding practice in each sector has been presented, and the avenues for engaging FSW have been highlighted. The FSW pipe process parameters are characteristically distinguished from the conventional FSW, and the effects of the process parameters have been presented. The summary is concise yet comprehensive and organized in a structured manner.

This study aims to investigate the daily performance of the proposed microgrid (MG) that comprises photovoltaic, wind turbines and is connected to the main grid. The load demand is a residential area that includes 20 houses.

The daily operational strategy of the proposed MG allows to vend and procure utterly between the main grid and MG. The smart metre of every consumer provides the supplier with the daily consumption pattern which is amended by demand side management (DSM). The daily operational cost (DOC) CO2 emission and other measures are utilized to evaluate the system performance. A grey wolf optimizer was employed to minimize DOC including the cost of procuring energy from the main grid, the emission cost and the revenue of sold energy to the main grid.

The obtained results of winter and summer days revealed that DSM significantly improved the system performance from the economic and environmental perspectives. With DSM, DOC on winter day was −26.93 ($/kWh) and on summer day, DOC was 10.59 ($/kWh). While without considering DSM, DOC on winter day was −25.42 ($/kWh) and on summer day DOC was 14.95 ($/kWh).

As opposed to previous research that predominantly addressed the long-term operation, the value of the proposed research is to investigate the short-term operation (24-hour) of MG that copes with vital contingencies associated with selling and procuring energy with the main grid considering the environmental cost. Outstandingly, the proposed research engaged the consumers by smart meters to apply demand-sideDSM, while the previous studies largely focused on supply side management.