To improve the accuracy of calculating the aluminum electrolysis pre-close wind volume, this study focused on optimizing the two main factors that influence its magnitude: the aluminum output speed and the pre-close wind volume coefficient. First, the Unscented Kalman Filter (UKF) algorithm was used to estimate the aluminum output speed, and its application in real production was verified through simulation experiments. The results demonstrate that UKF provides more accurate speed estimates when handling the non-linear dynamic system of aluminum electrolysis. When there was a sudden change in speed, the UKF achieved a relative error of only 0.0373%, significantly lower than the 2.52% error of the traditional Kalman Filter (KF). At the same time, the UKF exhibited a shorter runtime in the simulation. Additionally, this research introduces a self-correction mechanism for the pre-close wind volume coefficient for the first time. By dynamically adjusting the parameter based on aluminum output deviations and applying the Average Filter (AF) to improve the compensation accuracy, the pre-close wind volume coefficient can be precisely calculated. The combination of these methods significantly enhances the accuracy and robustness of pre-close wind volume calculations, providing solid theoretical foundations and the technical support needed to achieve high-precision aluminum output control.

Addressing the issue of leakage in practical scenarios involving hose pumps, this paper conducts an analysis on hose pumps with existing compression gaps. The model is simplified to represent the two-dimensional Newtonian fluid pulsating flow of a single-sided sine wave passing through the tube. The study derives the axial flow velocity distribution within the tube while establishing correlations between the leakage volume, tube clearance, pressure differential, deformed cross-sectional length of the tube, rotor speed (which exhibits a negative correlation), the deformation length of the tube in the x-direction, and the fluid's dynamic viscosity (demonstrating a positive correlation). Utilizing a bidirectional fluid-structure coupling method, this analysis investigates hose pumps with compression gaps. Specifically, it examines the flow field pressure, velocity, and vortex intensity of two Newtonian fluids with Reynolds numbers of 10–30 and 6000–15 000, respectively, within a 180° bend tube with a curvature-to-inner-diameter ratio of 4.6. This analysis is conducted under inlet velocities of 0.32 and 0.6 m/s, and outlet pressures of 0 and 0.1 MPa. The study identifies the positions of extreme leakage rates, elucidating the flow field characteristics and their impact on leakage. Furthermore, it investigates the causes of secondary flows within the tube, concluding that the fluid inside the tube exhibits symmetric helical motion. This research establishes the periodic variations in flow field vortex intensity and secondary flow intensity, along with the conclusion that leakage rates are positively correlated with axial vortex intensity and negatively correlated with secondary flow intensity.

Xinjiang, as a major agricultural region, offers extensive application potential for hose pumps, given their excellent performance as fertilization devices. Analyzing the pulsation characteristics of hose pumps during operation is valuable for reducing noise and extending pump service life. To investigate the pulsation characteristics and unsteady flow of hose pumps with different roller numbers, this study adopts a bidirectional fluid-structure interaction (FSI) method and utilizes ANSYS 19.0 commercial finite element software to analyze the outlet and inlet pressure pulsations, outlet flow velocity pulsations, and the distribution of the flow field at the intermediate plane for both two-roller and three-roller pumps transporting high and low Reynolds number fluids under the same working conditions. It was observed that the three-roller pump exhibited higher outlet pressure compared with the inlet and that the pulsation intensity was lower in the three-roller pump than in the two-roller pump under the same conditions, with an analysis provided on the reasons for this phenomenon. This study offers theoretical support for the selection and further optimization of hose pump designs. To further reduce the negative effects of pulsations, it is recommended to increase the number of rollers in the design while also considering shape optimization of the pump casing or using feedback control systems to adjust and reduce pulsation intensity.

Hose pumps, renowned for their ability to efficiently transport highly viscous and corrosive fluids, hold an irreplaceable position in numerous engineering domains. With a wide range of fluid types being transported by hose pumps, the study of pressure variations during the conveyance of different fluid states is of paramount importance, as it positively contributes to optimizing hose pump structures, reducing noise, and enhancing hose pump longevity. To investigate pressure variations in hose pumps during the conveyance of varying fluid states, this paper employs a bidirectional fluid–structure coupling method and utilizes commercial finite element software, ANSYS. The research validates the causes of variations in hose pumps during fluid conveyance and examines the overall pressure distribution within the fluid domain of hose pumps conveying different fluid states at varying rotor speeds. The results indicate that when the fluid within the hose pump is in a turbulent state, pressure variations exhibit multiple minor amplitude oscillations, whereas in a laminar state, pressure variations display fewer oscillations but with more significant amplitudes. Moreover, higher rotor speeds exacerbate pressure variations. Recommendations include optimizing the shape of the squeezing roller and enhancing pressure variation control through shell angle optimization.