Reliable and energy-efficient capacity control in high-pressure single-rotor screw compressors requires precise regulation of adjustable ring mechanisms operating under combined gas and thermal loading. Thermo-mechanical deformation, friction-induced torque demand, and stress concentration near discharge windows significantly influence structural integrity, clearance stability, and actuation performance. This study presents an integrated thermo-structural and analytical investigation of a regulating ring system with a hydraulic wedge-groove drive concept. Three groups of geometric variants (nine configurations total) were analyzed using coupled Steady-State Thermal and Static Structural finite element modeling in ANSYS 19.2. Thermal asymmetry between suction (22 °C) and discharge (120 °C) regions produced peak thermally induced deformation of 0.17–0.18 mm, consuming up to 60–70% of nominal operating clearance. Neglecting thermal effects underestimated peak thermally induced structural deformation of the regulating ring by 12–15%. Among the configurations, variant 2b provided the most balanced response, reducing peak equivalent stress by 12–15% and required actuation torque by 8–11%. An analytical model for friction torque and driving force was derived based on distributed contact pressure. The results reveal quadratic sensitivity of torque to contact radius and strong dependence on groove geometry. The proposed framework supports reliable clearance design and efficient actuation in heavy-duty rotating machinery.

Screw compressors are critical equipment in oil and gas production and transportation, where efficiency losses caused by rotor geometry, inlet pressure pulsations, and harsh climatic conditions can accumulate into substantial annual energy penalties and reliability degradation. This study provides a quantitative assessment of these coupled effects within a unified multiphysics framework that combines time-accurate transient CFD simulations based on a fixed Cartesian immersed-boundary formulation with a climate-calibrated offline physics-based digital twin—functioning as a digital shadow with one-way data flow from archival SCADA records—a reduced-order seasonal model with no real-time updating, calibrated against a full calendar year of SCADA records and validated against a held-out cold-season dataset (October–December 2022, T_amb = −15 to +8 °C); summer-period predictions rely on calibrated extrapolation beyond the validation window—an integration not previously demonstrated for oil-flooded screw compressors. Two rotor profile configurations (Type A and Type B) were analyzed to quantify geometry-driven differences in static pressure distribution, leakage tendency, and pulsation sensitivity. Transient suction conditions were modeled using harmonic and quasi-random inlet pressure disturbances to evaluate pressure amplification, phase lag, leakage intensification, and efficiency degradation. Seasonal performance was assessed by integrating temperature-dependent gas properties, oil viscosity behavior, and external heat transfer into an annual climatic load framework. The results show that inlet oscillations are amplified inside the chambers (pressure amplification factor П_p ≈ 1.95; П_p up to 2.3 under quasi-random excitation), reducing mass flow and volumetric efficiency by 8–10% and decreasing polytropic efficiency from 0.78 to 0.69–0.71, while increasing leakage by up to 27% and raising peak contact pressures to 167–171 MPa. Seasonal variability (+30 to −30 °C) increased suction density by 38% but raised drive power by ~9% due to viscosity-driven mechanical losses, producing an energy penalty up to 10.8% and an estimated annual additional consumption of approximately 186 MWh per compressor, decomposed as: cold-season contribution ~113 MWh (±10 MWh, directly field-validated against October–December 2022 SCADA data) and summer-season contribution ~51 MWh (calibrated extrapolation; additional uncertainty unquantified and not included in the ±10 MWh bound). The full annual figure of 186 MWh should be interpreted as a model-based estimate rather than a fully validated result. These findings demonstrate that rotor design optimization and mitigation of nonstationary suction effects, coupled with climate-aware offline physics-based digital shadow operation, represent high-priority levers for improving efficiency and reducing energy penalties in field conditions; reliability implications require further validation against summer-season field measurements.

This study focuses on the design and optimization of the geometric parameters of gears in electric vehicle (EV) transmissions to enhance performance, efficiency, and noise reduction. The optimization process was conducted using KISSsoft, considering constraints such as input speed and torque, transmission system volume, and gear ratios for each driving mode. A novel aspect of this research is the integration of transmission efficiency analysis with a variable efficiency coefficient into the optimization workflow, which has been demonstrated to significantly influence the optimal design of multi-speed EV transmissions. Throughout the optimization, key factors such as tooth bending stress, contact stress, contact ratio, and specific sliding were analyzed. Additionally, the impact of module variations on gear profile geometry, overlap ratio, tooth count, and gear pair mass was investigated. Strength calculations for the optimized gear pairs, determined for all geometric parameters using KISSsoft, were performed in accordance with the mathematical model outlined in ISO 6336, and the results were subsequently compared. The findings emphasize the critical role of profile modifications and precise gear design in optimizing gear performance, ultimately contributing to improved efficiency, reliability, and service life. Keywords: gear design optimization, electric vehicle transmission, KISSsoft, gear profile modification, ISO 6336.

Бұл мақалада үш түрлі материалдан: сұр шойыннан (SF), полимерлі бетоннан (PB) және FDM басып шығару әдісімен өндірілген ABS пластиктен жасалған жақ ұсатқыш корпусының кешенді ақырлы элементтік талдауы (MCE) берілген. Ортада статикалық кернеуді талдау, модальді (жиіліктік) талдау және жылулық талдау жүргізілді SolidWorks Simulation екі жүктеме деңгейінде: 50 кН (жұмсақ жыныс) және 150 кН (гранит). Нәтижелер шойынның қауіпсіздік коэффициентін FOS = 9,7 @ 50КН қамтамасыз ететінін көрсетеді, ал полимерлі бетон мен ABS пластмассасы сәйкесінше FOS = 3,76 және 2,8 береді. 150 кН жүктеме кезінде (гранит) ABS пластикасы бұзылады (FOS = 0,93 < 1,0), ал шойын FOS = 3,2 сақтайды, ал полимерлі бетон FOS = 1,2 жетеді. Модальды талдау полимербетонның меншікті қаттылық қатынасы √(E/ρ) жоғары болғандықтан ең жоғары табиғи жиілікке (1143,5 Гц) ие екенін көрсетті. Термиялық талдау ABS пластмассасының 111,8 °C-қа дейін қызып, әйнектің ауысу температурасынан (80–100 °C) асып, оны термиялық тұрғыдан жарамсыз ететінін анықтады. Шойын өнеркәсіптік ұсатқыштар үшін оңтайлы материал болып табылады; полимерлі бетон зертханалық қондырғылар үшін перспективалы болып табылады; ABS пластмассасы тек демонстрациялық материал ретінде жарамды. Кілтті сөздер: жақ ұсатқыш; ақырғы элементтерді талдау; полимерлі бетон; сұр шойын; ABS-пластик; SolidWorks Simulation; модальды талдау; жылулық талдау.