Weldability study of round aluminium magnet wires for lightweight low-cost traction electric motor applications

This paper explores the weldability of 1xxx and 6xxx series aluminium (Al) round wire welded to a range of Al and copper (Cu) plates to represent busbar and terminals for remote laser welding (RLW) and ultrasonic welding (USW), respectively. The motivations for materials are discussed and evaluated from a performance and high-volume manufacturing perspective for low-cost traction motors. The welding processes are assessed for their suited winding schemes. This paper proposes a novel approach of using USW to weld multiple thicker conductors with the aim of producing stranded wire terminations, similar to that commonly used for wire harnesses. The paper also proposes an alternative weld configuration as the main contribution for RLW. This utilises an axially focused laser beam direct to the interface between the wire and busbar. The aim is that this will improve the weldability of the Al-to-Cu specimens without the use of filler wire, commonly adopted in these scenarios, in addition to simplifying manufacturability. Lastly, the paper reviews the results of the proposed methods and discusses the manufacturing implications

Smart Textiles as the Digital Interface of the Future

The growing field of smart textiles could change everyday life, adding an element of interactivity to commonly used items such as clothing and furniture. Smart textiles measure then respond to external stimuli. For scalability in the future, smart textiles must be produced using conventional textile manufacturing craftsmanship. The resulting textile must be durable and comfortable while retaining electrical capabilities. Smart textiles can be fabricating through embroidery, weaving, and knitting using conductive threads. Electronics can also be printed onto textiles. Researchers are also creating higher-order electronics, such as the transistor, on the fiber-level to make the technology in smart textiles as discreet as possible. A variety of sensors can be produced with smart textile technology, and these sensors can be utilized in medical and protective applications. Smart textiles can then communicate a response through output devices such as lighting displays. As smart textiles develop, the ethics of manufacturing must be considered. Lightweight sources of power generation besides batteries are needed to make textiles systems more robust. As the smart textile market continues to grow, there are several obstacles in the way of smart textiles entering everyday life. Two traditionally different sectors—textiles and electronics—must converge. Consumers must also be motivated to trade up to smart textile products through increased electronic functions. As smart textiles continue to mature, more applications will be accepted by society and begin impacting day to day life

A swath inverter for accelerated drying of hay before packaging

Drying both top and bottom surfaces of wide, thin hay swaths with solar energy is a promising approach to decreasing the time of drying while keeping leaf losses due to machine manipulation at a minimum. The main objective of this research was to design and construct a machine for inverting a swath of hay without bunching it and for redepositing it in a wide, thin swath for solar drying of the newly exposed surface. The machine designed and constructed was towed by a tractor. The main components were a pickup-conveyor and an inverting mechanism which functioned together to pick up a swath of hay, invert it, then redeposit the inverted swath on the ground. A rotating hexagonal cross-section drum with multiple belts moving axially was used to carry the hay in a helical path towards the back of the machine and thus accomplish the swath inversion. A side shield placed around the drum kept the hay from falling to the ground before complete inversion. The drive assembly for the machine consisted of a friction driven lugged wheel engaging each of two support wheel tires to turn a cross shaft which in turn drove the center shaft of the inverting mechanism and the pickup-conveyor mechanism cross shaft. The lugged wheels could be disengaged from the tires by means of hydraulic cylinders. Field test of the machine operation showed an incomplete swath inverting action. The swath was bunched by the machine and not redeposited on the ground in a wide, thin layer. Problems causing this action were identified, however, and changes in the machine for correction were recommended. Swath inversion by hand gave improved drying rate of 2.47 percentage points of moisture content per hour compared to 1.91 percentage points per hour for the uninverted swath and 1.5 percentage points per hour for the machine inverted swath

HEAT: Hydraulic and Electric Animation Team

Each New Years’ Day, the Cal Poly Rose Float presents a flower-covered float to the world at the Tournament of Roses parade. This floral display, paired with moving mechanical animations, shows off Cal Poly to the world. This project strove to keep Cal Poly on the cutting edge of technology both in parade floats, and in engineering, by creating a completely electric-powered animation system. To accomplish this, a group of students set out to make the fully electric animation system that can power both the hydraulic and electric mechanisms on the Float. This was accomplished through months of planning and development leading up to manufacturing, assembling, and testing the system. The students used deep cycle lead acid batteries to power an electric motor. This motor turns a hydraulic pump that pumps fluid throughout the animated mechanism actuators. Aside from being cutting edge, this new animation system is both quieter and a lower-profile on the float. This allows for the design of the float to be lower, more unique, and beautiful. It also creates less noise pollution during animation testing and makes communication easier during this time

A LabView Based Condition Monitoring Program for a Wind Tunnel Based on Motor Temperature and Fan Vibration

The objective of this research is to create a condition monitoring software program that is able to monitor the operating conditions of the components of an open-loop pusher-style wind tunnel. The implementation of the condition monitoring program will play an important role to prevent the most unexpected failures as well as performance degradation in wind tunnel components that result from unusual operating conditions such as high temperature and high vibration. To identify the parameters that need to be monitored using the condition monitoring program, fault tree analysis is used. The study finds that wind tunnel failure happens as a result of motor and fan failure. The most likely failure indicators of motor and fan failure are high temperature and high vibration, respectively. To estimate the probability of wind tunnel failure based on motor temperature and fan vibration, a statistical model is developed using the union rule of probability. Furthermore, using the cumulative distribution function of the Beta distribution, the study defines failure probability functions for the motor and fan in terms of operating temperature and vibration, respectively. The condition monitoring program is implemented in LabView software and this research uses simulated data to demonstrate the functionality of the program. The program can perform real-time motor and fan condition monitoring if data acquisition devices are used that are compatible with the LabView software. The user interface of the LabView program displays motor and fan conditions and provides feedback to the wind tunnel user to make appropriate decisions for operation with high motor temperature and/or fan vibration

NASA patent abstracts bibliography: A continuing bibliography. Section 1: Abstracts (supplement 19)

Abstracts are cited for 130 patents and patent applications introduced into the NASA scientific and technical information system during the period of January 1981 through July 1981. Each entry consists of a citation, an abstract, and in most cases, a key illustration selected from the patent or application for patent

NASA patent abstracts bibliography: A continuing bibliography. Section 1: Abstracts (supplement 14)

Abstracts are cited for 213 patents and applications for patent introduced into the NASA scientific and technical information system during the period of July 1978 through December 1978. Each entry consists of a citation, an abstract, and in most cases, a key illustration selected from the patent or application for patent

A comprehensive review and performance evaluation in solar (PV) systems fault classification and fault detection techniques

The renewable energy industry is growing faster than ever before and in particular solar systems have significantly expanded. Abnormal conditions lead to a reduction in the maximum available power from solar (photovoltaic) systems. Thus, it is necessary to identification, detection, and monitoring of various faults in the PV system that they are the key factors to increase the efficiency, reliability, and lifetime of these systems. Up to now, faults on PV components and systems have been identified; some of them have physical damage on PV systems and some of them are electrical faults that occur on the DC side or AC side of the PV system. Here, the faults will be divided into groups based on their location of occurrence. This paper provides a comprehensive review of almost all PV system faults and fault detection techniques of PV system proposed in recent literature