Browse Topic: Tools and equipment
The gearbox is a key component of the mechanical transmission system, and its fault diagnosis is essential to the reliability of the equipment. However, obtaining fault samples under actual working conditions for gearbox fault diagnosis is challenging. In this paper, the rigid-flexible coupling dynamic simulation model of the gearbox is established, and the co-simulation of gear normal, crack, and breakage is carried out in the ADAMS and MATLAB environments. The comparison between the simulated and measured signals shows that the simulation method can accurately reflect the key characteristics, such as rotation frequency and meshing frequency, and verify its reliability and accuracy. The research results can provide effective data support for gearbox fault diagnosis and improve the operational safety of mechanical systems.
Current lithium-ion batteries should generally only be charged above 0 °C, as charging below this temperature can promote lithium plating and irreversible degradation. However, conventional pack-level heating elements increase system mass and design complexity. In addition, heat is transferred from outside into the cell, causing the temperature inside the cell to rise slowly. This study evaluates internal Joule heating of cylindrical Li-ion cells using a zero-mean square-wave current excitation and quantifies the associated aging impact. LG INR21700-M50L cells were tested at 0 °C, −10 °C, and −20 °C with three excitation frequencies (50 Hz, 1 Hz, 10 mHz) at 5 A amplitude. Each cycle consisted of 30 min heating followed by 60 min cooling; reference capacity-based state of health (SOH) was assessed every 50 cycles up to 400 cycles. A maximum surface temperature rise of 14.3 K was achieved, with larger temperature rise at lower ambient temperature and lower excitation frequency. Capacity
Researchers discover texts, phone calls, military communication, internal corporate networks all easily eavesdropped on using off-the-shelf equipment. University of California San Diego, La Jolla, CA With $800 of off-the-shelf equipment and months' worth of patience, a team of U.S. computer scientists set out to find out how well geostationary satellite communications are encrypted. And what they found was shocking. Close to half of the communications beamed from satellites to the ground that the researchers were able to listen in on were not encrypted. This included sensitive data including cellular text messages, voice calls, as well as sensitive military information, data from internal corporate and bank networks, and the in-flight online activity of airline passengers.
The impact of ship airwake on helicopter operations to rear flight decks has been a topic of much research over the past three decades. While generic ships have been developed over the years to enable analysis tool and knowledge development, actual ships can vary significantly, resulting in different airwake features. The study of variations in ship geometry is important both to understand how differences may impact operations, but also to understand the level of geometrical fidelity that is required on ship models undergoing analysis. In Canada, the newly launched (2018) Harry DeWolf-class Arctic Offshore Patrol Ships (AOPS) have unique features that have been studied for their impact on airwake characteristics. This paper explores different geometrical characteristics from the perspective of their operational impacts and also considering their importance for inclusion in simulation. The paper shows that turbulence level is the parameter most affected by the minor variations that were
Metal-elastomer bonded components can suffer from manufacturing defects such as porosity and bond-line voids. Nondestructive evaluation (NDE) methods can replace or supplement existing destructive tests; however, implementation can be challenging for manufacturers due to the initial equipment cost, time required per test, and imaging quality. These criteria were used to evaluate shearography, high-resolution ultrasound testing (UT), 2D projection X-ray, computed tomography (CT), and acoustic emission (AE) testing, culminating in trade studies for different sample part types. Experimental work was performed on three samples of varying geometries and sizes with seeded defects, applying feasible NDE methods to each. Shearography succeeded in detecting void defects and flow fronts. X-ray and CT failed to detect flaws in 2 out of 3 part types due to energy and time constraints. UT could not reliably detect defects in parts with complex geometries because of scatter. Acoustic emission
Understanding the fluid flow behavior over and into narrow gaps is crucial for many industrial applications, particularly in the automotive sector. Evaluating the potential of water ingress into narrow pathways and towards components is of great importance to design the water management of such components. The employment of CFD simulations supports the evaluation of potential water ingress into such gaps. Lagrangian based tools are used in a variety of simulation scenarios of fluid flow, especially due to their ability to easily simulate free surfaces with strong curvatures. In our previous work, a validated simulation setup was developed using the meshless simulation tool MESHFREE from Fraunhofer ITWM [8] for simulating water entering small gaps. Especially for industrial use cases, the computation time of several days is too expensive. Thus, we enhanced this approach to a fast and robust CFD simulation that realizes industrial use cases within appropriate time. The development was
In the stringent market of BEV, the development of integrated Drive Modules (iDM) fitting environmental and customer needs is mandatory. It is important to extract the best from the less. To achieve those goals, a deep insight into complex multiphysics phenomena occurring in an iDM has been achieved by accurate and validated models. This engineering methodology is applied through the development of BorgWarner products, comprising non-exhaustively iDM 180-HF, Externally Excited Synchronous Machine and Multi-Level Inverter. The paper will review the methodology development for deeper understanding involving in-house technical excellence and complemented by strategic partnerships with academic institutions and start-ups. It will present the approach of integrating advanced multiphysics models with high-quality experimental validations, specifically on loss evaluation on electrical machines and inverters. Complex models involving multiphysics such as thermal/fluid coupling or electric
The useability of development processes in the automotive sector has decreased in the past years to a level at which their application and true benefit to is being questioned. Such degradation can be attributed to new additions to the processes and introduction of FuSa and Cybersecurity standards. The processes try to keep up with the shift from the traditional ‘plan–implement–test–roll-out' methodology to more agile methods. In addition, process departments typically in charge of these processes, focus on compliance to the letter of the standard to achieve certification, often with little thought to the actual implementation and the process they will be used by their engineering teams. Process growth to meet the needs of new and more complex technologies often mandates the use of new tools, which if implemented incorrectly can lead to unnecessary bureaucracy and additional overheads. Furthermore, the language of these new processes is in a form from assessor, making it difficult for
With the rise of software-defined vehicles and the emergence of cyber threats to vehicular systems, developing teams are compelled to conduct extensive testing on both virtual and physical prototypes at an accelerated pace. This new development landscape necessitates diagnostic tools that are both precise and adaptable. However, proprietary systems dominate this field, often hindering accessibility for students and researchers due to high costs and restrictive licensing. This paper presents the design and implementation of an open-source, low-cost remote testing system tailored for automotive development and diagnostics. The proposed system utilizes Arduino and Raspberry Pi processing units, along with relay-based switching modules, to provide secure remote control of vehicle components through a web-based dashboard equipped with authentication, scheduling, and real-time synchronization capabilities. The tested prototype showcased robust scalability, secure session handling, and
This document is a guideline for format, structure and content for ground support equipment (GSE) technical manuals. This document focuses on requirements specific to the GSE industry and does not cover general technical publication practices. Additional standards for GSE and for manufacturer’s publications exist and may add requirements beyond what is covered in this standard. This may include EU Directive 2006/42/EC. This document is written in specific terms by intention, and conforms to recognized practices in the industry. When the word SHALL is used in this standard, it indicates a requirement that must be adhered to in total and does not allow for variance. When the word SHOULD is used, it indicates a recommended practice which allows the manual writer to use discretionary judgment. This document does not apply to electronic test equipment.
Off-highway equipment operates in an environment defined by extremes - extreme loads, extreme duty cycles, extreme temperatures and extreme expectations. OEMs and fleet operators face mounting pressure to deliver more power, more uptime and more precision from platforms that are becoming increasingly compact, intelligent and complex. Whether the task is hauling, lifting, dumping, clearing or moving materials, the equipment must deliver consistent, reliable performance without compromise. This pressure is reshaping the mobile-hydraulic ecosystem. The industry is steadily shifting away from piecemeal systems and toward integrated, intelligent power architectures that maximize efficiency across the entire vehicle. Leaders in this space, Eaton among them, demonstrate how a system-level approach to PTOs, hydraulic pumps and control valves is enabling a new generation of off-highway innovation.
A 4-rotor uninhabited air vehicle is described, with a primary mission of supporting personnel fighting wildfires. The paper demonstrates the use of technical design tools for a small Uninhabited Aircraft System (sUAS). A description of the design process is provided, including developing requirements, identifying constraints, the software tools employed, and examination of results. The vehicle is capable of delivering more than 20 kg of supplies to a delivery point 10 nm away while penetrating 30 kt winds. The sized vehicle is transportable in a medium-duty pickup truck and can be picked up and moved for ground handling by one or two individuals. The vehicle information will be publicly released for NDARC software users. Future work will examine other requirements, such as maneuvering and gust rejection.
The Rotor Optimization for the Advancement of Mars eXploration (ROAMX) project has demonstrated that rotor designs optimized for the Mars aerodynamic regime can provide substantial improvements in aerodynamic efficiency relative to heritage designs. This paper evaluates the vehicle-level performance implications of these improvements using the NASA Design and Analysis of Rotorcraft (NDARC) tool. Performance predictions for Ingenuity-class and Mars Science Helicopter (MSH)-class rotorcraft are generated using ROAMX rotor aerodynamic inputs and are compared against a configurations using the Ingenuity rotor. Parametric studies are conducted to investigate the trade between increasing payload mass and resulting changes in vehicle range and hover time, including the effects of rotor solidity and rotor type. The results show that ROAMX rotor designs enable significant increases in payload capability and operational range across both vehicle classes. These findings demonstrate how ROAMX
Tire noise reduction is important for improving ride comfort, especially in electric vehicle due to lack of engine noise and majority of the noise generated in-cabin is from tire-road interaction. Therefore, the tire tread pattern contribution is one of the important criteria for NVH performance apart from other structurally generated noise and vibration. In this work a GUI-based pitch sequence optimization tool is developed to support tire design engineers in generating acoustically optimized tread sequences. The tool operates in two modes: without constraints, where the pitch sequence is optimized freely to reduce tonal noise levels; and with constraints, where specific design rules are applied to preserve pattern consistency and manufacturability. The key point to be considered in this pitch sequence is that it should be reducing the tonal sound and equally spread i.e., the same pitch cannot be concentrated on one side which may lead to non-uniformity. So, the restriction is that
This study presents a simulation-based approach to estimate the dog clutch engagement probability maps under different vehicle operating conditions. The developed probability function incorporates multiple critical parameters including initial speed differential between engaging components, application of countershaft brake, number of tooth in dog clutch, friction coefficients at tooth interfaces, applied actuation force, dog tooth geometry, and component inertia. Using MATLAB and Simulink, comprehensive simulation models were developed to analyze engagement dynamics and produce detailed probability maps at different vehicle speeds. The present work effectively outlines optimal operational zones for successful engagement while identifying critical regions prone to tooth clash and engagement failure. The effect of tooth geometry on engagement probability has been investigated to study its effect on the optimal mismatch speeds. The resulting engagement maps serve as valuable diagnostic
The U.S. Food and Drug Administration (FDA) has taken a substantial step in its digital modernization strategy with the deployment of agentic artificial intelligence capabilities across all agency employee groups. The move represents an expansion of the agency’s internal AI tools, intended to streamline complex, multi-step processes that support regulatory science, product review, and compliance activities. The deployment strengthens the FDA’s ongoing effort to embed structured, secure, and transparent AI systems into daily workflows, building on the rapid adoption of the LLM-based tool Elsa earlier this year.
High-power fiber lasers have become increasingly indispensable tools in automotive manufacturing over the past two decades. They are now widely deployed in welding and brazing applications for body-in-white, powertrains, engine components, and more.
Current world conflicts have proven that drones are now indispensable tools in modern warfare. Whether for reconnaissance, loitering munitions, or asymmetric tactics that exploit vulnerabilities in conventional defenses, unmanned aerial systems (UAS) are redefining the rules of engagement.
Lithium-ion batteries (LIBs) have consolidated their place in the technology market for the energetic transition, with global manufacturing capacity exceeding 1 TWh in recent years and costs falling in this competitive environment. At the same time, the number of end-of-life LIBs is increasing, stimulating the recycling industry to process battery streams, thus promoting the circular economy to meet the increased demand for strategic raw materials and decarbonization. Vehicle electrification is the main driver of battery production, but their end-of-life will take some time to be significant in volume in the next years. Consumer electronics such as smartphones, laptops and power tools are now available at an appropriate volume enabling the preparation of recycling industry for the moment. In this scenario, recyclers are looking for sustainable routes to absorb all these streams and the different LIBs chemistries (LFP, NCA, NMC, LCO, LMO) to recover the critical metals (Ni, Co, Cu, Mn
Finland-based Metos Oy, a manufacturer of professional stainless steel kitchen equipment, needed a welding solution that could deliver flawless, pressure-rated welds for small batches of high-spec products, which feature tubular structures and circular shafts that required continuous, precision welding.
Like octopi squeezing through a tiny sea cave, metatruss robots can adapt to demanding environments by changing their shape. These mighty morphing robots are made of trusses composed of hundreds of beams and joints that rotate and twist, enabling astonishing volumetric transformations.
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