If the shaft diameter can be measured in-situ during the finishing process, the closed-loop control of the shaft diameter processing process can be realized and the machining accuracy can be improved. Present work studies the measurement of shaft diameter with the structured light system composed of a laser linear light source and a camera. The shaft is a kind of part with rotationally symmetric structure. When the linear structured light irradiates the surface of the shaft, a light stripe will be formed, and the light stripe is a part of the ellipse. Therefore, the in-situ measurement of the shaft diameter can be realized by the light stripe and the rotational symmetry of the shaft. The measurement model of shaft diameter is established by the ellipse formed by the intersection of the light plane and the measured shaft surface. Firstly, in the camera coordinate system, normal vector of the light plane and the coordinates of the ellipse center are obtained by the calibration; then, the equation of oblique elliptic cone is established by taking the ellipse as the bottom and the optical center of the camera as the top. Next, the measurement model of shaft diameter is obtained by the established oblique elliptic cone equation and theoretical image plane equation. Finally, the accuracy of the measurement model of shaft diameter is tested by the checkerboard calibration plate and a lathe. The test results show that the measurement model of shaft diameter is correct, and when the shaft diameter is 36.162mm, the speed is 1250r/min, the maximum average measurement error is 0.019mm. The measurement accuracy meets the engineering requirement.

The gear shaft needs to measure its radial runout for straightening before finishing, while it is difficult to measure the gear shaft radial runout without rotating the gear shaft by the existing measurement technology, which results the measurement inefficient. Present work puts forward a method of measuring a gear shaft radial runout with line structured light vision. This method can measure the radial runout value and direction online for straightening the bending of the gear shaft. The center position of the gear shaft cross section is obtained by the ellipse geometric fitting on the laser plane to eliminate the influence of projection distortion. The measurement method is tested by a specialized experiment, and the experimental results show that measurements of the method meet the requirements of straightening the gear shaft. The method can realize online measurement of the gear shaft radial runout just by a single image without rotating the gear shaft, so it features fast measurement compared with the existing measurement technology.

As a part of vehicle thermal management, water-cooled intercoolers play an important role in engine efficiency. The incompressible simulation model was usually applied to estimate the performance of water-cooled intercoolers. In this paper, the computational fluid dynamics (CFD) compressible model is taken to analyze more accurate prediction models. The rate of section change, heat exchange, and the surface friction coefficient are used as the comparison basis of the compressible flow model and incompressible model on the pressurized air side of the water-cooled intercooler. By comparing the simulation results of the air side, it was found that the compressible simulation is closer to the experimental value than the incompressible simulation. Compared with the experiment, the compressible model heat transfer maximum value of deviation is 6.5%, and the pressure loss maximum deviation is 7.5%. This provides guidance to optimize the design of heat exchangers, in order to save on costs and shorten development times.

Advanced cascade design theories and methods are crucial to the rapid development of torque converters. Therefore, the study proposed a new parametric design method for a hydrodynamic torque converter cascade. The method is embodied by using a cubic non-uniform rational B-splines (NURBS) open curve and closed curve, respectively, to carry out the parametric design of the unit blade camberline and unit blade thickness distribution, and the curvature of the designed blade curve is continuous. Then, the author developed batch and script files in the Isight platform for a fully automated integrated design of the hydrodynamic torque converter, including cascade parametric modeling, meshing, computational fluid dynamics (CFD) simulation, post-processing, and optimization design. A three-dimensional cascade integrated optimization design system of the hydrodynamic torque converter is established with CFD technology as the bottom layer design, a control file as the middle layer, and an optimization algorithm as the top layer drive. Finally, multi-objective optimization was carried out for the key cascade parameters (camberline peak height). Compared with the original blade, the optimized NURBS blade increased by 7.207% in high-efficiency region width (G_η), and the optimized blade increased by 2.673% in peak efficiency (η_max) to meet the actual engineering requirements. The new parametric design method of the blade shape and the integrated optimization design system of a three-dimensional cascade of torque converter proposed in this paper significantly reduces the design costs and shortens the design cycle of the torque converter, which will provide a valuable reference for engineers of turbomachinery.

To improve the efficiency of heat transfer from the cooling system of non-road mobile machinery, a modification has been made to the classic cooling system. Specifically, we divide the classic cooling system into two independent cooling loops, namely, the high-temperature cooling loop and the low-temperature cooling loop. Through simulation and experimentation, the dual-loop cooling system was systematically studied, and it was found that the heat dissipation of the dual-loop cooling system was better than that of the single-loop cooling system. In comparison with the classic cooling system, the volume factor of our system increased by 49.3%, the power factor increased by 24.5%, the effective drag coefficient increased by 5.8%, and the compressed air loop length was shortened by 54.5%. In addition, the dual-loop cooling system can greatly reduce the temperature of pressurized air. The proposed new system can better meet the cooling needs of non-road mobile machinery.