Towards a better energy efficiency through a systems approach in an industrial forklift

The purpose of this study is to improve the potential energy recovery to electric energy in an electrohydraulic forklift system. The initial achieved result for energy saving ratio after structural optimization is 40 %. Component optimization is applied to the tested drive which consists of a DTC controlled electric servo motor directly running a reversible hydraulic pump. According to the study the energy efficiency and the energy recovery from the electro-hydraulic forklift system can be increased by 11 % units. New ideas and directions of further research were obtained during the study.

Studies on grain refinement and alloying additions on the microstructure and mechanical properties of Mg-8Zn-4Al alloy

MAGNESIUM ALLOYS have strong potential for weight reduction in a wide range of technical applications because of their low density compared to other structural metallic materials. Therefore, an extensive growth of magnesium alloys usage in the automobile sector is expected in the coming years to enhance the fuel efficiency through mass reduction. The drawback associated with the use of commercially cheaper Mg-Al based alloys, such as AZ91, AM60 and AM50 are their inferior creep properties above 100ºC due to the presence of discontinuous Mg17A112 phases at the grain boundaries. Although rare earth-based magnesium alloys show better mechanical properties, it is not economically viable to use these alloys in auto industries. Recently, many new Mg-Al based alloy systems have been developed for high temperature applications, which do not contain the Mg17Al12 phase. It has been proved that the addition of a high percentage of zinc (which depends upon the percentage of Al) to binary Mg-Al alloys also ensures the complete removal of the Mg17Al12 phase and hence exhibits superior high temperature properties.ZA84 alloy is one such system, which has 8%Zn in it (Mg-8Zn-4Al-0.2Mn, all are in wt %) and shows superior creep resistance compared to AZ and AM series alloys. These alloys are mostly used in die casting industries. However, there are certain large and heavy components, made up of this alloy by sand castings that show lower mechanical properties because of their coarse microstructure. Moreover, further improvement in their high temperature behaviour through microstructural modification is also an essential task to make this alloy suitable for the replacement of high strength aluminium alloys used in automobile industry. Grain refinement is an effective way to improve the tensile behaviour of engineering alloys. In fact, grain refinement of Mg-Al based alloys is well documented in literature. However, there is no grain refiner commercially available in the market for Mg-Al alloys. It is also reported in the literature that the microstructure of AZ91 alloy is modified through the minor elemental additions such as Sb, Si, Sr, Ca, etc., which enhance its high temperature properties because of the formation of new stable intermetallics. The same strategy can be used with the ZA84 alloy system to improve its high temperature properties further without sacrificing the other properties. The primary objective of the present research work, “Studies on grain refinement and alloying additions on the microstructure and mechanical properties of Mg-8Zn-4Al alloy” is twofold: 1. To investigate the role of individual and combined additions of Sb and Ca on the microstructure and mechanical properties of ZA84 alloy. 2. To synthesis a novel Mg-1wt%Al4C3 master alloy for grain refinement of ZA84 alloy and investigate its effects on mechanical properties.

Effect of Improving Energy Efficiency on System Reliability

In the present scenario of energy demand overtaking energy supply top priority is given for energy conservation programs and policies. Most of the process plants are operated on continuous basis and consumes large quantities of energy. Efficient management of process system can lead to energy savings, improved process efficiency, lesser operating and maintenance cost, and greater environmental safety. Reliability and maintainability of the system are usually considered at the design stage and is dependent on the system configuration. However, with the growing need for energy conservation, most of the existing process systems are either modified or are in a state of modification with a view for improving energy efficiency. Often these modifications result in a change in system configuration there by affecting the system reliability. It is important that system modifications for improving energy efficiency should not be at the cost of reliability. Any new proposal for improving the energy efficiency of the process or equipments should prove itself to be economically feasible for gaining acceptance for implementation. In order to arrive at the economic feasibility of the new proposal, the general trend is to compare the benefits that can be derived over the lifetime as well as the operating and maintenance costs with the investment to be made. Quite often it happens that the reliability aspects (or loss due to unavailability) are not taken into consideration. Plant availability is a critical factor for the economic performance evaluation of any process plant.The focus of the present work is to study the effect of system modification for improving energy efficiency on system reliability. A generalized model for the valuation of process system incorporating reliability is developed, which is used as a tool for the analysis. It can provide an awareness of the potential performance improvements of the process system and can be used to arrive at the change in process system value resulting from system modification. The model also arrives at the pay back of the modified system by taking reliability aspects also into consideration. It is also used to study the effect of various operating parameters on system value. The concept of breakeven availability is introduced and an algorithm for allocation of component reliabilities of the modified process system based on the breakeven system availability is also developed. The model was applied to various industrial situations.

Development of mechanical methods for cell-tray propagation and field transplanting of dwarf napiergrass (Pennisetum purpureum Schumach.)

Since dwarf napiergrass (Pennisetum purpureum Schumach.) must be propagated vegetatively due to lack of viable seeds, root splitting and stem cuttings are generally used to obtain true-to-type plant populations. These ordinary methods are laborious and costly, and are the greatest barriers for expanding the cultivation area of this crop. The objectives of this research were to develop nursery production of dwarf napiergrass in cell trays and to compare the efficiency of mechanical versus manual methods for cell-tray propagation and field transplanting. After defoliation of herbage either by a sickle (manually) or hand-mowing machine, every potential aerial tiller bud was cut to a single one for transplanting into cell trays as stem cuttings and placed in a glasshouse over winter. The following June, nursery plants were trimmed to a 25–cm length and transplanted in an experimental field (sandy soil) with 20,000 plants ha^(−1) either by shovel (manually) or Welsh onion planter. Labour time was recorded for each process. The manual defoliation of plants required 44% more labour time for preparing the stem cuttings (0.73 person-min. stemcutting^(−1)) compared to using hand-mowing machinery (0.51 person-min. stem-cutting^(−1)). In contrast, labour time for transplanting required an extra 0.30 person-min. m^(−2) (14%) using the machinery compared to manual transplanting, possibly due to the limited plot size for machinery operation. The transplanting method had no significant effect on plant establishment or plant growth, except for herbage yield 110 days after planting. Defoliation of herbage by machinery, production using a cell-tray nursery and mechanical transplanting reduced the labour intensity of dwarf napiergrass propagation.

Facilitating Mechanical Design with Augmented Reality

By enhancing a real scene with computer generated objects, Augmented Reality (AR), has proven itself as a valuable Human-Computer Interface (HCI) in numerous application areas such as medical, military, entertainment and manufacturing. It enables higher performance of on-site tasks with seamless presentation of up-to-date, task-related information to the users during the operation. AR has potentials in design because the current interface provided by Computer-aided Design (CAD) packages is less intuitive and reports show that the presence of physical objects help design thinking and communication. This research explores the use of AR to improve the efficiency of a design process, specifically in mechanical design.

Ventilation for air quality and energy efficiency

This article addresses the need for providing good standards of indoor air quality (IAQ) in buildings from the view point of health, well-being and productivity of building occupants. It briefly outlines the role of ventilation in achieving the required IAQ targets and discusses the performance of different types of ventilation systems in use. As a result of new energy efficiency directives and legislations in Europe and elsewhere, the ventilation energy component of HVAC systems has increased in relative terms and this article introduces a method for evaluating the performance air distribution systems that is based on ventilation and energy effectiveness. A range of ventilation systems are discussed, including mechanical and natural ventilation, and results for more recently developed mechanical air distribution systems are compared with conventional systems. The article provides an assessment and comparison of some of these systems with reference to ventilation performance and energy efficiency

Thermodynamic efficiency and entropy production in the climate system

We present an outlook on the climate system thermodynamics. First, we construct an equivalent Carnot engine with efficiency and frame the Lorenz energy cycle in a macroscale thermodynamic context. Then, by exploiting the second law, we prove that the lower bound to the entropy production is times the integrated absolute value of the internal entropy fluctuations. An exergetic interpretation is also proposed. Finally, the controversial maximum entropy production principle is reinterpreted as requiring the joint optimization of heat transport and mechanical work production. These results provide tools for climate change analysis and for climate models’ validation.

Evaluation of the light polymerization efficiency of copolymers used in dental formulations by differential scanning calorimetry

Different compositions of visible-light-curable triethylene glycol dimethacrylate/bisglycidyl methacrylate copolymers used in dental resin formulations were prepared through copolymerization photoinitiated by a camphorquinone/ethyl 4-dimethylaminobenzoate system irradiated with an Ultrablue IS light-emitting diode. The obtained copolymers were evaluated with differential scanning calorimetry. From the data for the heat of polymerization, before and after light exposure, obtained from exothermic differential scanning calorimetry curves, the light polymerization efficiency or degree of conversion of double bonds was calculated. The glass-transition temperature also was determined before and after photopolymerization. After the photopolymerization, the glass-transi-tion temperature was not well defined because of the breadth of the transition region associated with the properties of the photocured dimethacrylate. The glass-transition temperature after photopolymerization was determined experimentally and compared with the values determined with the Fox equation. In all mixtures, the experimental value was lower than the calculated value. Scanning electron microscopy was used to analyze the morphological differences in the prepared copolymer structures. (C) 2007 Wiley Periodicals, Inc.

Dynamic characteristics and efficiency of a fluidized bed heat treatment process

The dynamic characteristics of gas bubbles in fluidized beds are important to determine the heat and mass transfer rates at component surfaces and the treated profiles of components. They also have great impact on the components’ structural, mechanical and physical properties. However, it has been very difficult to monitor those characteristics dynamically. In this paper, a specifically designed fluidized bed was introduced to facilitate the capturing of its dynamic characteristics and a new video image processing and analysis algorithm was developed. The algorithm is robust and adaptive in terms of locating both bubbles and components in beds with a single or multiple components. It has many advantages in dynamic characterization of gas bubbles and monitoring component treatment. By using this algorithm, the properties of gas bubbles over any period of time can be accurately obtained. This technology will provide a potential on-line dynamic monitoring and quality control system for the chemical heat treatment processes with fluidized beds.

Large-scale mechanical peeling of boron nitride nanosheets by low-energy ball milling

Mechanical cleavage by Scotch tape was the first method to produce graphene and is still widely used in laboratories. However, a critical problem of this method is the extremely low yield. We have tailored ball milling conditions to produce gentle shear forces that produce high quality boron nitride (BN) nanosheets in high yield and efficiency. The in-plane structure of the BN nanosheets has not been damaged as shown by near edge X-ray absorption fine structure measurements. The benzyl benzoate acts as the milling agent to reduce the ball impacts and milling contamination. This method is applicable to any layered materials for producing nanosheets.

Microstructure modeling and prediction of the mechanical properties of advanced high strength steels

Dual phase (DP) steels were modeled using 2D and 3D representative volume elements (RVE). Both the 2D and 3D models were generated using the Monte-Carlo-Potts method to represent the realistic microstructural details. In the 2D model, a balance between computational efficiency and required accuracy in truly representing heterogeneous microstructure was achieved. In the 3D model, a stochastic template was used to generate a model with high spatial fidelity. The 2D model proved to be efficient for characterization of the mechanical properties of a DP steel where the effect of phase distribution, morphology and strain partitioning was studied. In contrast, the current 3D modeling technique was inefficient and impractical due to significant time cost. It is shown that the newly proposed 2D model generation technique is versatile and sufficiently accurate to capture mechanical properties of steels with heterogeneous microstructure.

Organizational design as an enabler for innovation: evidence from a German Mechanical Engineering Company

Over the past two decades there has been a profusion of empirical studies of organizational design and its relationship to efficiency, productivity and flexibility of an organization. In parallel, there has been a wide range of studies about innovation management in different kind of industries and firms. However, with some exceptions, the organizational and innovation management bodies of literature tend to examine the issues of organizational design and innovation management individually, mainly in the context of large firms operating at the technological frontier. There seems to be a scarcity of empirical studies that bring together organizational design and innovation and examine them empirically and over time in the context of small and medium sized enterprises. This dissertation seeks to provide a small contribution in that direction. This dissertation examines the dynamic relationship between organizational design and innovation. This relationship is examined on the basis of a single-case design in a medium sized mechanical engineering company in Germany. The covered time period ranges from 1958 until 2009, although the actual focus falls on the recent past. This dissertation draws on first-hand qualitative empirical evidence gathered through extensive field work. The main findings are: 1. There is always a bundle of organizational dimensions which impacts innovation. These main organizational design dimensions are: (1) Strategy & Leadership, (2) Resources & Capabilities, (3) Structure, (4) Culture, (5) Networks & Partnerships, (6) Processes and (7) Knowledge Management. However, the importance of the different organizational design dimensions changes over time. While for example for the production of simple, standardized parts, a simple organizational design was appropriate, the company needed to have a more advanced organizational design in order to be able to produce customized, complex parts with high quality. Hence the technological maturity of a company is related to its organizational maturity. 2. The introduction of innovations of the analyzed company were highly dependent on organizational conditions which enabled their introduction. The results of the long term case study show, that some innovations would not have been introduced successfully if the organizational elements like for example training and qualification, the build of network and partnerships or the acquisition of appropriate resources and capabilities, were not in place. Hence it can be concluded, that organizational design is an enabling factor for innovation. These findings contribute to advance our understanding of the complex relationship between organizational design and innovation. This highlights the growing importance of a comprehensive, innovation stimulating organizational design of companies. The results suggest to managers that innovation is not only dependent on a single organizational factor but on the appropriate, comprehensive design of the organization. Hence manager should consider to review regularly the design of their organizations in order to maintain a innovation stimulating environment.

Performance of a reciprocal shaker in mechanical dispersion of soil samples for particle-size analysis

A dispersão da amostra de solo é uma etapa fundamental da análise granulométrica, sendo realizada mediante o uso de dispersantes químicos e agitação mecânica. O objetivo deste trabalho foi avaliar a eficiência de mesa agitadora reciprocante de baixa rotação na dispersão mecânica de amostras de solos de diferentes classes texturais. Foram realizadas análises granulométricas em 61 amostras com quatro repetições, empregando o método da pipeta para determinação da fração argila e tamisagem para determinação das frações areia grossa, areia fina e areia total, sendo o silte determinado por diferença. Na avaliação de desempenho, os resultados obtidos com uso da mesa agitadora reciprocante (MAR) foram comparados com dados disponíveis para as mesmas amostras oriundos de relatórios do Ensaio de Proficiência IAC para Laboratórios de Análises de Solos - Prolab/IAC. Análises de acurácia foram realizadas com base nos valores dos intervalos de confiança definidos para cada fração granulométrica componente de cada amostra ensaiada. Indicadores gráficos também foram utilizados na comparação de dados, por meio de dispersão e ajuste linear. A estatística descritiva indicou preponderância de baixa variabilidade em mais de 90 % dos resultados obtidos para as amostras de texturas arenosa, média e argilosa e em 68 % dos obtidos para as amostras de textura muito argilosa, indicando boa repetibilidade dos resultados obtidos com a MAR. Média variabilidade foi mais frequentemente associada à fração silte, seguida da fração areia fina. Os resultados das análises de sensibilidade indicam acurácia de 100 % nas três frações granulométricas - areia total, silte e argila - para todas as amostras analisadas pertencentes às classes texturais muito argilosa, argilosa e média. Para as nove amostras de textura arenosa, a acurácia média foi de 85,2 %, e os maiores desvios ocorreram em relação à fração silte. Nas aproximações lineares, coeficientes de correlação igual (silte) ou superiores (areia total e argila) a 0,93, bem como diferenças menores do que 0,16 entre os coeficientes angulares das retas e o valor unitário, indicam alta correlação entre os resultados de referência (Prolab/IAC) e os obtidos nos ensaios com a MAR. Conclui-se pelo desempenho satisfatório da mesa agitadora reciprocante de baixa rotação para dispersão mecânica de amostras de solo de diferentes classes texturais para fins de análise granulométrica, permitindo recomendar o uso alternativo do equipamento quando se emprega agitação lenta. As vantagens do uso do equipamento nacional incluem o baixo custo, a possibilidade de análise simultânea de grande número de amostras e o uso de frascos comuns, de vidro ou de plástico, baratos e de fácil reposição.

Effects of simulated herbivory on photosynthesis and N resorption efficiency in Quercus pyrenaica Willd. saplings

We examined the effects of simulated folivory by caterpillars on photosynthetic parameters and nitrogen (N) resorption efficiency in Quercus pyrenaica saplings. We analyzed the differences between intact leaves in control plants, punched leaves in damaged plants, and intact leaves in damaged plants. We then established two levels of simulated folivory: low (approximate to 13% of the leaf area of one main branch removed per plant) and high (approximate to 26% of the leaf area of one main branch removed per plant) treatments. No differences were found in net assimilation rate and conductance between either leaf type or treatment during the most favourable period for photosynthesis. However, the N content was lower in punched than in intact leaves, and as a result PNUE was higher in damaged leaves from treated trees. In leaf-litter samples, N mass was significantly higher in punched than in intact leaves in treated plants, and LMA was significantly higher in damaged than in intact leaves of both the treated and control plants. Consequently, N resorption efficiency was around 15% lower in damaged leaves as compared with intact leaves from treated and control plants. Mechanical injury to leaves not only triggered no compensatory photosynthetic response to compensate a lower carbon uptake due to leaf area loss, but also affected the resorption process that characterizes leaf senescence.

Global analysis of aerodynamics deflectors efficiency in the grinding process

The conventional, grinding methods in some cases are not very efficient because the arising of thermal damages in the pieces is very common. Optimization methods of cutting fluid application in the grinding zone are essential to prevent thermal problems from interaction of the wheel grains with the workpiece. surface. The optimization can happen through the correct selection of the cut parameters and development of devices that eliminate air layer effects generated around the grinding wheel. This article will collaborate with the development of an experimentation methodology which allows evaluating, comparatively, the performance of the deflectors in the cutting region to minimize the air layer effect of the high speed of the grinding wheel. The air layers make the cutting fluid jet to dissipate in the machine. An optimized nozzle was used in order to compare the results with the conventional method (without baffles or deflectors) of cutting fluid application. The results showed the high eficciency of the deflectors or baffles in the finish results. Copyright © 2006 by ABCM.