This paper uses heat transfer experiments and computational fluid dynamics (CFD) simulations to investigate the conjugate heat transfer (CHT) in a high-pressure pneumatic control valve assembly. A heat transfer test rig was constructed, and time–temperature histories of five test points placed on the valve assembly’s outer surface were recorded for study validation. The Unsteady Reynolds-Averaged Navier–Stokes (URANS) CFD methods with the standard k-ε turbulence closure equations were adopted in the numerical computations. Polyhedral grids were used; time step and mesh convergence studies were conducted. Simulated and measured temperatures profile comparisons revealed a good agreement. The CHT results obtained from CFD showed huge velocity fields downstream of the valve throat and the vent hole. The airflow through the valve was icy, mainly in the supersonic flow areas. Low temperatures below 273.15 K were recorded on the internal and external walls of the valve assembly. The consistency of the measured data with the numerical results demonstrates the effectiveness of polyhedral grids in exploring the CHT using CFD methods. The local entropy production rate analysis revealed that irreversibility is mainly due to viscous dissipation. The current CHT investigation provides a potential basis for thermostress analysis and optimization.

Underwater manipulation is one of the most significant functions of the deep-sea crawling and swimming robot (DCSR), which relies on the high-accuracy control of the body posture. As the actuator of body posture control, the position control performance of the underwater mechanical leg (UWML) thus determines the performance of the underwater manipulation. An adaptive super-twisting sliding mode control method based on the extended state observer (ASTSMC-ESO) is proposed to enhance the position control performance of the UWML by taking into account the system’s inherent nonlinear dynamics, uncertainties, and the external disturbances from hydrodynamics, dynamic seal resistance, and compensation oil viscous resistance. This newly designed controller incorporates sliding mode (SMC) feedback control with feedforward compensation of the system uncertainties estimated by the ESO, and the external disturbances of the hydrodynamics by fitting the parameters, the dynamic seal resistance, and the compensation oil viscous resistance to the tested results. Additionally, an adaptive super-twisting algorithm (AST) with integral action is introduced to eliminate the SMC’s chattering phenomenon and reduce the system’s steady-state error. The stability of the proposed controller is proved via the Lyapunov method, and the effectiveness is verified via simulation and comparative experimental studies with SMC and the adaptive fuzzy sliding mode control method (AFSMC).

The air compressor piston is one of the most important components of the positive displacement compressor, which takes air at low pressure, and delivers it at high pressure. Its performance is influenced by the thermal and mechanical loads acting on its surface, which affect the stress distribution in its structure and its life cycle. This paper presents the structural optimization of the air compressor piston for design-life performance improvement. The objectives are to reduce the weight of the piston and increase its lifecycle simultaneously. The parametric geometry of the piston was modeled in Ansys Workbench DesignModeler 17.0. The combination of the Design of Experiments (DOE) and the Finite Element Analysis (FEA) is used to investigate the stress distribution, the factor of safety, and the lifecycle of the parametric geometry of the piston. Optimization coupled with the FEA and the DOE is performed using Multi-objective Genetic Algorithm (MOGA) method based on pre-established objectives. Results showed that the mass of the piston decreased by 26.4% while the minimum lifecycle increased by 4044%. The present study helps to understand how the structure optimization made on the air compressor piston can improve its lifecycle with the potential to obtain a robust design.

The performance of underwater crawling and adjustment of the body posture for underwater manipulating of the deep-sea crawling and swimming robot (DCSR) is directly influenced by the dynamic performance of the underwater mechanical legs (UWML), as it serves as the executive mechanism of the DCSR. Compared with the mechanical legs of legged robots working on land, the UWML of the DCSR not only possesses the characteristics of the land used mechanical legs, but is also affected by the influence of the deep-sea underwater working environment (i.e., the hydrodynamic force, viscous resistance and dynamic seal resistance). To reduce these influence, firstly, the hydrodynamic force of the UWML were researched based on theory and experiment, and the hydrodynamic model was established with the fitted hydrodynamic parameters. Secondly, the oil viscous resistance and the dynamic seal resistance were studied experimentally, and the change laws of both with respect to the joint speed and the ambient pressure (depth of operation) were obtained. The results provide a basis for the subsequent research on the structure optimization and high performance control of the UWML and DCSR.