High-speed fuel solenoid valves (HFSVs) are the key control elements of aero-engine vane regulators. A strong electromagnetic force generated from the HFSVs is essential to achieve precise control over timing and quantification for fuel supply. In this paper, the Taguchi method is adopted to improve the HFSV’s static electromagnetic characteristics. First, an electromagnetic model of the HFSV was established and experiments were conducted to modify and validate the model. Effects of key structural factors on the static electromagnetic characteristics of the HFSV are then investigated via the finite element method (FEM). Based on the optimization, an HFSV prototype is finally manufactured and tested. The experiment results are in good agreement with those of the simulations. It provides a significant guideline for the manufacturing process of such HFSVs.

This paper aims to study the natural heat dissipation capacity of a hydraulic tank during its miniaturization revolution. A theoretical model of heat dissipation was built up on the basis of experimental analysis. Then, the natural heat dissipation power was deduced and shown to be relevant. Influencing factors were analyzed, which were the oil height proportion, design proportion, volume, material type, and wall thickness. The results showed that the heat dissipation power is proportional to the height of the oil in the tank. The power increases with the height proportional coefficient k2, while it first decreases and then increases with the length proportional coefficient k1. The lengthwise coefficient obviously has a more significant effect. The influence degree of reduction methods on natural heat dissipation is in the following order: length reduction > equal proportion reduction > height reduction > width reduction. Additionally, when the thermal conductivity λ is greater than 10 W/(m·K), the material and wall thickness of the tank slightly influence the heat dissipation capacity; otherwise, the influence is evident.

Given the challenging operational environment of forging machines, characterized by harsh conditions, dynamic load fluctuations, and multi-axis force coupling, traditional force measurement and sensing methods often fail to meet the high demands for precision and reliable load sensing. To address this challenge, this study introduces a novel force sensing methodology based on a Backpropagation (BP) neural network for the clamping mechanism of forging machines. First, a force sensing model is developed to describe the behavior of the clamping mechanism under forging conditions, elucidating the force transmission laws and identifying key hinge points for force sensing. Next, a BP neural network model is constructed to analyze and decouple the forging state, exploring the impact of hidden layer neuron nodes on decoupling effectiveness and determining the optimal configuration of these nodes. The effectiveness of the proposed methodology is demonstrated through the network’s ability to decouple both the direction and magnitude of internal forging forces. The results confirm that this approach enables accurate and reliable force sensing for the clamping mechanism, providing a robust foundation for force control in forging machines.

To address the difficulty of directly detecting internal stresses in high-temperature forgings during dual-manipulator control experiments and the significant safety risks associated with high-temperature environments, this study developed an experimental device to simulate the deformation behavior of such forgings. First, numerical simulations of the elongation process were conducted using DEFORM V11 software to examine the deformation mechanisms of high-temperature forgings. Quantitative results for axial deformation, maximum deformation velocity, and deformation force ranges were obtained, which defined the operational specifications and functional requirements of the device. Second, the mechanical structure and hydraulic system were designed based on engineering principles. The dynamic response characteristics of the simulation device under conventional PID and fuzzy PID control were compared through simulations, and the feasibility of the fuzzy PID control strategy was experimentally verified. Finally, a joint simulation model of the high-temperature forging deformation simulation device and the dual forging manipulator clamping system was established. This model was used to analyze the dynamic response of the simulated workpiece under typical cooperative conditions of dual manipulators and to assess the accuracy of the simulation process during clamping. The results confirmed the practical applicability of the device. Overall, the developed simulation device can effectively reproduce the deformation behavior of high-temperature forgings under ambient conditions, providing a safe and reliable platform for studying coordinated control strategies of dual forging manipulators.