Hydraulic support is an important supporting equipment to ensure the safe production of coal mines. Affected by the harsh working conditions and complex geological conditions under the coal mine wells, even at the initial stage of using the hydraulic support under the well, there might be frequent problems such as leakage of hydraulic components, extrusion and wear of pipes between supports, falling of fasteners, column rotation, difficulty in disassembly and maintenance of some parts, etc. In order to improve the performance of hydraulic support products, the design and implementation scheme of preproduction test covering reliability, adaptability and transportation scheme test was proposed. In the prototype stage of hydraulic support (the first support), after the sealing, strength and life test of the prototype, the preproduction test was immediately carried out on the prototype, the correlation among hydraulic components, pipeline system and support was fully considered, and the corrective measures were put forward in time. Since the implementation of such a measure, preproduction tests of more than 70 sets of hydraulic support prototypes have been carried out, and more than 500 problems have been found and positively rectified, which has put an end to the possibility of quality problems in the mass production stage, greatly shortening the production cycle and improving the quality management level.

In order to objectively evaluate the die-cutting, indentation and packaging quality of boxed cigarette package, a measuring device for the die-cutting size and angle of cigarette packages was designed based on linear array CCD (Charge-Coupled Device) and three-dimensional reconstruction. Through CCD scanning, images were captured; through image processing such as threshold segmentation, corrosion, expansion, Sobel and Hough transform, the edge line of cigarette label can be accurately extracted and detected. The results showed : 1) The size indication error of the measuring device is less than 5 μm, the uncertainty is 0.9 μm, the relative error of the angle is less than 0.2%, and the coefficient of variation is less than 0.02%. 2) The time required for 38 detection indexes (including die-cutting size, angle and indentation width) is less than 240 s, which greatly improves the detection efficiency of boxed cigarette labels compared with traditional manual measurement. 3) Through the three-dimensional reconstruction model of the boxed cigarette package, not only the molding effect of the boxed cigarette package is visually displayed, but also the appearance quality of the boxed cigarette package can be evaluated by using the lap value predicted by the model.

Traditional pavement crack detection adopted manual analysis and identification, which was easily affected by subjectivity and has low accuracy. A pavement crack detection device based on cross platform computer vision library OpenCV was designed. Taking the ESP32-CAM development board with Internet of Things function and camera as the core hardware system, the pavement crack images were identified, collected, analyzed and transmitted; on the computer side, the images from ESP32-CAM were processed by using the functions such as graying, filtering and edge detection in OpenCV to ensure and display the crack detection results. 50 crack sample images were selected for testing, and the recognition accuracy was as high as 88%, with a better recognition effect for cracks with large size and deep depth. In the follow-up, the detection effect under different crack lengths and widths and the characterization of pavement damage severity need to be studied to realize the intelligent robot detection system.

A set of automatic vibration test equipment for the AC contactor is developed to realize the real-time detection of the vibration performance of the AC contactor products. The equipment is composed of conveying module, detecting station, data acquisition and analysis system, control system, etc. In the detecting station, devices including the acceleration sensor and the pressure sensor are integrated, and designs on the electric probe, test state, anti-vibration leakage and environmental interference isolation are performed; in particular, an elastic spring is designed for the acceleration sensor, which can effectively retain the vibration of the product itself, so that the acceleration data can be effectively collected. In the data acquisition and analysis system, the time-domain waveform is transformed into the frequency spectrum by the Fast Fourier Transform (FFT), the spectrum data is converted into the vibration energy value of the product according to the Parseval theorem, and the product quality is judged by comparing with the preset threshold value. The comparison between manual detection and machine detection shows that the machine detection prevents excess wrong judgments in the manual detection, with no wrong judgment and the detection result is more accurate. The automatic vibration detection equipment foe the AC contactor meets the requirements of use, and the AC contactor products tested meet the factory standard, and thus, the equipment is suitable for use in the intelligent manufacturing workshop.

The performance of hydraulic braking system is related to the safety of maglev train, and is one of the important indexes to evaluate the running quality of maglev train. The hydraulic braking system of small maglev train is studied. Based on the overall technological parameters, combined with the industrial standards such as Q/CRRC J 1060-2020, the function and configuration of the braking system are determined, the schematic diagram of the hydraulic braking system is designed, and the function planning of the hydraulic braking system and the theoretical calculation of the key braking parameters are completed. The simulation analysis of the designed hydraulic braking system by AMEsim shows that: 1) the error between the accumulator charging time and the theoretical calculation is less than 1%; 2) the emergency braking accumulator can implement emergency braking for 3 times, which is higher than the industry standard requirements for 2 times; 3) when the orifice diameter of the emergency braking solenoid valve is greater than 4 mm, the emergency braking response time is 0.5 s, which is less than 1 s generally required in the industry; 4) when the orifice diameter of the service braking solenoid valve is greater than 1.6 mm, under the intervention of the electronic control system, it can not only meet the requirements of service braking deceleration, but also control the service braking impact rate in a reasonable range.

In order to realize high performance energy spectrum acquisition of neutron activation analysis instrument, a design scheme of digital multichannel analyzer is proposed. The FIR (finite length unit impulse response) filter is used to differential the pulse signal, as to solve the baseline drift problem of the pulse signal, and the accurate time information of the pulse signal is obtained; the pulse trapezoidal shaping technology is proposed, as to improve the differential nonlinearity of the ADC, reduce the influence of noise in the signal, and accurately judge the signal amplitude information through the trapezoidal pulse; by comparing the waveform parameters, judge whether the pulse is stacked or not, and the stacked pulse is removed from the energy spectrum to further improve the energy resolution of the energy spectrum. The test results show that the developed digital multichannel analyzer has high integration, strong anti-interference and good operating reliability. The pass rate of random pulse counting is more than 250 kcps, and the energy resolution is less than 7.5%, meeting the performance requirements and index requirements, as well as the application requirements of industrial online detection instruments on the neutron activation analysis.

In order to overcome the disadvantages such as, the poor position synchronization of six cylinders, non-conducive to the synthesis of super-hard materials, of the traditional hydraulic control system of hexahedral press, a new hydraulic control system of hexahedral press based on direct drive volume control is proposed. According to the working characteristics of each process of the hexahedral press, focusing on the important indexes of empty forward and liquid filling processes with high position synchronization requirements, the mathematical model is built to realize the segmented control and PID parameter tuning. Compared with the traditional hydraulic control system of hexahedral press, the position synchronization control optimized hydraulic control system solves the inaccuracy of using hydraulic valve to adjust the synchronization of the system, and reduces the throttling loss of the system. The position synchronism of the hexahedral press is tested, and the results show that the relative position deviation of each hydraulic cylinder is less than 0.1 mm, which can better meet the demand of super-hard material synthesis.

The iterative upgrading of smart grid has put forward higher requirements on the detection accuracy and efficiency of external circuit breaker for electricity meters, and the development of its detection pipeline has become an urgent need. From two aspects, i.e. structural design and control system design, a set of design scheme of external circuit breaker detection pipeline for electricity meters is put forward. In terms of structural design, the pipeline is composed of conveying system, full inspection unit and sampling inspection unit, which is laid out with the concept of lean production to realize the simplification and high efficiency of conveying and inspection; the full inspection unit and sampling inspection unit are arranged separately to facilitate sectional design and reduce the complexity and coupling of the system; innovative design of some test modules is carried out to realize the concurrent use of various specifications of circuit breaker products. In terms of control system design, the detection pipeline is composed of the main control system and each unit control system. The architecture of main control system is divided into management layer, execution layer and equipment layer to meet the indicators including system reliability and maintainability; each unit control system realizes high-speed real-time control and data processing mechanism management through Programmable Logic Controller (PLC), built-in network port, etc. After the application implementation, the detection capacity of detection pipeline is increased to 350 000 per year, and the false detection rate is as low as 0.5%, which provides technological support for Guangdong power grid to promote more accurate remote cost acquistion and monitoring.

In order to realize the long-term preservation of cultural relics, set the low oxygen and constant humidity environment before the excavation of cultural relics in the cultural relic protection cabinet. The technology of nitrogen production by membrane separation is combined with the technology of constant humidity, and the cultural relic protection device is designed. The unit architecture of nitrogen generation unit, humidity control unit and nitrogen filling unit is proposed: the nitrogen generation unit adopts the membrane separation process with small occupation space and stable purity; the humidity control unit adjusts the proportion of dry nitrogen and wet nitrogen through saturator and mass flow controller, so as to realize the relative humidity adjustment; the nitrogen filling unit detects the pressure in the cultural relic protection cabinet in real time, so that the cabinet is always in a micro-positive pressure state. The performance evaluation test shows that: 1) the device can reduce the oxygen content in the cultural relic protection cabinet to less than 1%, so that the nitrogen purity can reach more than 99%; 2) the relative humidity in the cabinet can be flexibly adjusted within 30%RH~70%RH, and the humidity fluctuation is less than 2%RH; 3) the cabinet is always in a micro-positive pressure state of 0.000 2 ~ 0.000 4 MPa. The cultural relic protection device can effectively improve the storage environment and prolong the storage life of cultural relics.

The safe transportation of raw materials (coiling of copper foil/aluminum foil) of lithium battery and its docking with coating machine is a major difficulty in the manufacture of lithium battery. A technological scheme of applying Automatic Guided Vehicle (AGV) into the high precision docking between coiling of copper foil/aluminum foil and coating machine was put forward. The scheme adopted the idea of first docking and then adjusting: firstly, the docking process of the upper coil and the lower coil was put forward; then, the seven-axis adjusting mechanism of AGV corresponding to the docking process was designed, to form the best stress scheme of Y axis on overall translation, X axis (symmetrical 2 places), Z axis (symmetrical 2 places) and Y axis on both sides (symmetrical 2 places); finally, the AGV omni-directional gear train structural layout was optimized, and the optical communication module was installed to communicate with the optical communication module on the machine equipment, so as to further ensure that the docking position was accurate and in place. This technology solves the problem that the AGV's navigation accuracy is not enough. Without introducing third-party positioning equipment, the docking success rate can reach 100% and the docking accuracy can be controlled within 2 mm.

Installing a protective device on the mechanical arm to avoid personal injury when the operator touches the mechanical arm has become the focus of attention in industrial safety production. A pressure detection experimental system under mechanical arm protection was designed, which consists of BMP180 air pressure sensor, STC89C52 single chip microcomputer control system, NRF24L01 wireless transceiver module and LCD1602 displayer. BMP180 air pressure sensor measures the change of air pressure inside the airtight module; the data is transmitted to the upper computer through the NRF24L01 wireless transceiver module; the upper computer receives the data, which is processed by STC89C52 single chip microcomputer and then sent back to NRF24L01 wireless transceiver module. After entering the protected state, an alarm is sent out and displayed on LCD1602 displayer, realizing human-machine interaction and creating a safe working environment. 5 experiments of simulated sealed environment were repeated, and the alarm was realized outside the set pressure limit, which verified the feasibility of the system design, providing experimental scheme and data support for transplanting the experimental system to a real robot arm.

Aerostatic floating bearing is the key component of high precision equipment such as photoetching machine, and its static characteristics directly determine the precision of the equipment. Taking the vacuum preloaded orifice throttling aerostatic floating bearing as the research object, the influence of air supply pressure, vacuum degree, area ratio of vacuum chamber and orifice diameter on the static characteristics of the bearing was explored. Findings: there are 4 correlations between the film thickness and the static characteristics of the bearing. 1) When the film thickness is constant, the bearing capacity and the bearing stiffness increase with the increase of air supply pressure, and the film thickness corresponding to the maximum stiffness is 7~9 μm; 2) the greater the vacuum degree, the smaller the bearing capacity, but the vacuum degree has little influence on the bearing stiffness; 3) the introduction of vacuum chamber reduces the bearing capacity, but provides bidirectional stiffness for the bearing, the film thickness and the area ratio of the vacuum chamber are negatively correlated with the bearing stiffness; 4) the larger the orifice diameter, the greater the bearing capacity and the smaller the film thickness, the orifice diameter is negatively correlated with the bearing stiffness, and the film thickness corresponding to the maximum stiffness is 6~12 μm. When the film thickness exceeds 20 μm, the bearing stiffness in all analyzed cases tends to zero.

An automatic assembly line is designed for the whole manufacturing process of miniature circuit breakers. Based on the physical structure and working principle of miniature circuit breakers, the overall structure of the automatic assembly line is proposed. According to the characteristics of each process, the assembly line is divided into 11 units using the linear layout, and each unit is designed in depth. 3D scanning detection on product position, CCD visual detection on open distance, automatic detection on overrun and automatic detection on tripping force are adopted to improve the detection efficiency and accuracy; Manufacturing Execution System (MES) is introduced to the real-time monitoring and dynamic adjustment of assembly line to realize production collaboration, management visualization and quality tracking. The operation cost and recovery period of the automatic assembly line are calculated, showing that the labor cost is about 79.4% lower than that of the manual assembly line, and the recovery period of the investment cost is about 2.86 years.

The intelligent technology in the robot is the focus of current research. It becomes a reality that the robot replaces the artificial labor. The intelligent and precise control of the robot hand (i.e. mechanical claw) needs to be based on the needs of the industry. Taking the vex robot as the research object, the hardware structure of the two finger angular mechanical claw is designed, the software program to drive the robot to achieve the grasping task is developed, and the accuracy, adaptability and rotation angle of the robot's grasping control are tested and improved. In the implementation of the robot grasping method, software compilation and hardware debugging are carried out for many times, and experimental data are summarized to investigate the grasping accuracy. The results show that the accuracy of the robot's action can be improved by using the two finger angular mechanical claw and optimizing the robot encoder to control the rotation angle of the motor. The success rate of grasping can be over 88%.

Planetary gear bracket is one of the core parts of vehicles. In order to realize the automatic machining target of planetary gear bracket parts with high efficiency, low cost and high quality, an intelligent production line for core parts is designed. The production layout, feeding/unfeeding mode and product quality control of the production line are overall planned, and the technological processes including production preparation, feeding, processing and unfeeding are formulated. The control system of the production line is designed in detail, and an automatic control system integrating machining tool system, robot system, manual detection system, laser marking system, PLC system and SCADA system is formed. Especially, in the SCADA system, the managements of system authority, production task, process monitoring, quality data and report statistics are realized. Through a technological transformation on the production line, the informatization level of the workshop production planning management and quality management has been improved, reaching the expected goal.

Cylinder block is one of the most important parts of marine engine. The key of cylinder block machining is the fine boring of spindle hole and camshaft hole. A kind of fine boring machine tool is developed for a common cylinder block, i.e. V-shaped cylinder block in marine engines. An overall scheme is proposed, the overall layout is carried out for the mechanism architecture of the machine tool; according to the main action cycle of the machine tool, the structure, principle and operation process for the key components including the servo boring head, boring bar, CNC sliding table, hydraulic automatic fixture, automatic feeding device, boring template and cutter are designed in detail. The acceptance inspection of the test pieces is carried out, and the application practice of the machine shows that the diameter, cylindricity, coaxiality and parallelism of each hole system are qualified, the machining performance and accuracy of the machine tool meet the design requirements.

Valve-controlled liquid-filled hydraulic coupling is a soft starting device of the scraper conveyor, which can effectively prevent the impact and scraping events of the scraper conveyor. The CPC1600 valve-controlled liquid-filled hydraulic coupling is researched and developed. The main engine, key components and hydraulic water supply control system are designed. In the design of the main engine, the structure and material selection are both considered, the connection size of the scraper conveyor is matched, and the strength and corrosion resistance are ensured. In the component design, the reverse deduction of cavity, material selection and external characteristics simulation of the impeller are carried out to ensure that the pump wheel and turbine have sufficient safety margin, and the speed of centrifugal valve is designed. In the hydraulic water supply control system, the automatic liquid level maintaining open system (ALM) is developed for the coupling, which can reduce the action times of the solenoid valve. The results of laboratory test and field industrial test show that the operation of CPC1600 valve-controlled liquid-filled hydraulic coupling is reliable, its rated power can reach 1 600 kW, its rated slip (speed ratio) is 95.39%, its external characteristics meet the standard requirements, and the service life of its solenoid valve can be extended, showing that it can be widely applied into the scraper conveyor in the coal mine.

When the special tooling is used to process thread and sealing cone surface of spherical pipe joint parts, one part corresponds to one special tooling. The tooling is not only complex in structure, but also has no interchangeability with each other, resulting in waste of resources. A quick-change tooling for spherical pipe joint parts is designed, which is composed of fixture body, mandrel and installation template. The fixture body is a universal tooling. Different mandrels are used for different structural dimensions and positioning dimensions during processing, and alignment is carried out by the installation template. By grouping the structural dimensions and positioning dimensions of more than 300 parts, only 8 fixture bodies are enough to replace the original 300 special tooling. The quick-change tooling is easy to disassemble and accurate to locate, which greatly improves the processing efficiency while ensuring the product quality.

The palletizing robot is an industrial robot that can automatically palletize the products in the specified storage area according to the predetermined setting functions, and realize the accurate stacking and on-demand stacking of products. ABB—IRB120 robot was selected as the palletizing robot, and the palletizing intelligent operation workstation was designed in integration and simulated for validation by combining SolidWorks modeling and RobotStudio simulation software. SolidWorks was used to create the 3D model of palletizing workstation components, which was imported into the RobotStudio model library. RAPID offline programming and simulation was carried out on the robot jobs in RobotStudio. Technologies such as I/O interface communication and Smart component design were used to realize general functions such as cooperation on components and mechanical device, as well as cooperation on conveyor belt and palletizing. The simulation of palletizing operation verifies the feasibility of applying industrial robot computer workstation to the palletizing works. Such a design and simulation method has wide applicability, and provides the basic design basis for improving the efficiency of robot palletizing and even to create intelligent logistics system.

Manual detection and calibration method for gas pressure reducer required disassembling the pressure gauge and the pressure regulator to operate separately. Even if the whole detection could be realized, there were still some problems such as inconsistent rate of manual pressure adjustment and subjectivity of manual reading, which affect the consistency and efficiency of detection results. An automatic calibration device for gas pressure reducer was developed. The structure of the device was introduced. The device consists of air pressure generator, gas pressure booster/reducer, intelligent pressure controller, reducer connection platform, upper computer with calibration software and CDP pressure module, etc. Its methods were expounded. The reducer connection platform is the core component intelligent pressure controller. Gases such as oxygen, acetylene, propane connect the gas pressure reducer to the automatic calibration device, which can fully automatically control and adjust the pressure. Clear calibration rules were proposed. The calibration software can automatically collect data, automatically calculate indication error, and automatically generate calibration records and certificates. The results show: the gas pressure reducer can provide the standard pressure of 0~25 MPa. By cooperating with CDP pressure module, etc., it can adjust the output air pressure to the set value input by the calibration software interface, and realize the leak detection and safety valve detection. The developed automatic calibration device for gas pressure reducer is digital, intelligent and visual, which effectively improves the calibration safety, reliability and detection effect.

In order to make the users use the experimental equipment scientifically and normatively, and to make the teachers improve the efficiency of laboratory teaching, an experimental equipment recognition system based on deep learning is proposed. The system is equipped with Android platform environment. Users can select images of experimental equipment by taking photos or local albums. The Android client collects and cuts the image, and sends the image to the server using the TCP/IP network transmission protocol; the server uses the residual network and the improved YOLO network model to detect the image, and finds the experimental equipment corresponding to the image characteristic value in the database; the database feeds back the recognition result, the equipment use method and precautions to the Android client. The test shows that the recognition accuracy of the system to the experimental equipment can reach more than 99%. The experimental equipment recognition system can provide references for peers and improve the teaching efficiency and quality.

To achieve the goal of “high efficiency, high quality, long life, low consumption and cleanness”, the 1 380 m³ blast furnace body and public/auxiliary facilities are designed and optimized. The blast furnace body adopts the comprehensive long-life technology. The furnace type structure reduces the furnace body angle and the furnace belly angle, appropriately increases the height and diameter of the hearth, and properly deepens the depth of the dead iron layer, as to meet the requirements of reliable operation. The lining adopts the domestic high-quality refractory materials, its hearth and bottom adopt the structure of “carbon + ceramic cup composite hearth and bottom”, its bosh, waist and body adopt the brick & wall integrated structure to extend the life in the key parts. According to the different cooling positions of the blast furnace and the working characteristics of each area of the blast furnace, the closed circulation cooling water system of industrial water and soft water is optimized to maintain the stable operation of blast furnace production. The automatic detection and control system is installed for the blast furnace and cooling water system to provide accurate and reliable indexes and operating information for the blast furnace smelting operators. After the design and optimization, the service life of the blast furnace can reach 12 years, which is higher than the average level all over the world.

With the rapid development of vehicle technologies on light truck, micro truck, etc., higher requirements are put forward for the parking & brake performance of drum type central brake for light vehicles. The analysis of the structure form and installation characteristics of the existing brakes show that there are three main problems in them: the internal structure is too compact, the production and assembly process is tedious; the structure connection is not firm, the brake power transmission is limited; the brake block processing technology is backward, and the characteristics need to be further explored. Accordingly, targeted structural optimization schemes are proposed: simplify the internal structure of the brake, improve the installation convenience of operators; integrate sheet & metal forming, improve the overall stability of the system; process the outer circle of brake block according to the actual parking & brake state, improve the contact area between the brake block and the brake hub. After the structural optimization, the brake performance is improved by about 20%, which helps to promote the intelligent and batch assembly of transmission brake as well as performance improvement of brake products.

A multi-functional intelligent robot based on Turing robot is designed by integrating technologies including Internet of Things, wireless communication, Android system and voice text playback. In the hardware design of such a multi-functional intelligent system, STM32103C8T6 is used as the main control chip to drive the Bluetooth module to communicate with the mobile APP, and further to receive commands and actions; by communicating with the robot action control chip STC15W4K16S4, the joint steering gear of the robot is driven to rotate and realize various actions; the voice text playback module is driven to carry out the voice broadcast and realize the chat function. Meanwhile, in the software design, the software design of the main control chip, the program design of the action control chip, the design of the Android application interface and the program component are carried out, and with the help of Turing robot system, any dialogue with the user can be realized. Compared with traditional chat robots, the advanced Turing robot increases functions including gesture interaction and voice interaction, with a reasonable cost performance. Such a multi-functional intelligent robot cannot only accompany learning and entertainment, but also provide a new idea for the robot design and control in the industrial field.

In order to ensure the long-term and safe storage of paper files in the archives under the high temperature, humidity and dusty climate, the dust control, automatic temperature control and humidity control in the archive room are improved. A scheme is proposed: in terms of dust control, equipment such as cross flow air curtain machine, PVC dustproof screen, acrylic rubber strip and fresh air dust filter box are used to effectively prevent dust from entering the archive room. In terms of temperature control and humidity control, firstly, in the archive room (large environment), refrigeration and dehumidification control circuit and heating control circuit are designed, and high-tech carbon crystal heater is used to realize automatic control of temperature and humidity in different seasons; secondly, in the archive cabinet (small environment), the self-developed utility model patent “a filing cabinet with automatic temperature control function” is used to realize automatic auxiliary control in combination with the temperature control and humidity control circuit in the filing cabinet. In terms of safety assurance, wireless cameras with Wi-Fi and a loudspeaker are installed to deter illegal intruders, and smoke alarms and fire extinguishers are equipped, as to ensure fire safety. Statistics of monitoring data from January 2016 to December 2019 show that the dust resistance rate is more than 85%, the energy saving rate is more than 40%, the environmental temperature and humidity are controlled within 14~24±2℃, 45%~60%±5%RH, which conforms to the standard conditions of paper file storage, saves human costs and realizes energy conservation and consumption reduction.

With the emerge of concepts including full use of space and reasonable storage, more and more attention has been paid to the wall bed which can make full use of the housing space. Air spring is a very important opening and closing hardware of the wall bed, its design quality greatly affects the comfort and service life of the wall bed. From two aspects of the design of the gas spring, namely, the installation point optimal design and the bidirectional damping function design, the gas spring is selected and designed. In the optimization of the installation point optimal design, the straight wall bed is taken as an example, the coordinate system is established, and the mechanical model of the wall bed is built, to discuss the hand operation force under different opening and closing angles of the wall bed, which reduces the hand operation force when the wall bed is opened; in the enhancement of the bidirectional damping function design, the structural transformation of the air spring is carried out, and the mechanical spring and damping sheets are installed to avoid the phenomenon of board beating when the wall bed is closed. After optimization, the convenience, comfort and safety of users of the wall bed are improved, providing a design idea for the selection and design of air spring when it is applied to the wall bed.

To realize an intelligent assembly technology of dropper for the catenary of electrified railways, the automatic dropper production equipment is researched and developed. An intelligent assembly system composed of information processing, assembly and control is designed. Aiming at 3 key problems i.e. wire-end fusing, length precision control and pressure precision control, corresponding technological schemes are put forward. The layout of the assembly line is reasonably planned, and the functions including feeding, fusing, threading, crimping, length fixing, laser marking and grouping packaging are implemented. The test results show that the catenary dropper produced by the automatic dropper production equipment can maintain 3 min without damage under the force of 3.9 kN, and the maximum bearing capacity is 5.7 kN, whose index is better than the basic technological requirements. Compared with the production efficiency of traditional manual mode (180 s/PSC), the production efficiency of the equipment is 150 s/PSC. The efficiency is increased by 20%, the key data can be traced, and the product has good stability and uniformity.

The existing adsorption-type self-heating regeneration compressed air dryer has many problems, such as poor anti-interference, difficult to modify the production process parameters, and the energy-saving demand is not considered. According to the working principle and process requirements of the compressed air dryer, the adsorption and regeneration cycle diagram and sequence diagram of the dryer are designed. The PLC and switching power supply are organically combined to realize the integrated intelligent control. Per the standard program in the PLC, the functions including energy-saving and self-healing are added; the air drying effect under different pressure, temperature and humidity are optimized by setting different working cycles; new materials such as polypropylene (PP-R) and PAP are used to replace the original steel. The verification shows that, the compressed air dryer runs stably and reliably, technological indicators such as the dew point of finished gas meet the requirements, the energy saving and emission reduction reaches 30%, and the maintenance cost can be saved up to 5 000 RMB/(set·year); in addition, the material improvement is realized, the cost is reduced, and the reliability is enhanced.

In order to solve the problems such as huge energy consumption, uneven temperature field and poor exhaust effect in the traditional vacuum tube exhaust process of solar photothermal power generation, a new type of exhaust platform for vacuum tube of solar photothermal power generation is developed. Such equipment is composed of systems with functions including vacuum, thermos and automatic control system, which changes the traditional baking heating mode. The inner tube of the vacuum tube of solar photothermal power generation is used as the resistive load, the KT thyristor voltage regulator is used as the thermal power supply, and the high-precision temperature control is carried out by the temperature controller to directly heat the inner tube. The temperature control accuracy of the vacuum tube in the length direction of solar photothermal power generation is kept within ±5℃, and the thermal energy consumption conservation is more than 40%. It not only achieves the design purpose of high-precision temperature control and energy conservation, but also realizes the automatic control of the whole production process.

In the traditional electronic lock, the solenoid valve is used as a force component, which consumes too much power, and the instantaneous current of unlocking exceeds the allowable current of Narrow Band Internet-of-Things (NB-IoT) module, which is easy to cause component damage. Combined with the bearing capacity of NB-IoT module, an intelligent lock with low-power consumption and double-slider linkage mechanism is designed for the optical cabinets. In the linkage mechanism, the solenoid valve is no longer used as a force-bearing element, but as a trigger element. When unlocking, the solenoid valve is powered on instantaneously, and the power is cut off immediately after unlocking, as to realize the micro-current unlocking. The double-slider design is adopted to strictly control the travel error and reset process to realize short-time trigger. In the evaluation, in the range of 3.3~5 V supply voltage of the NB-IoT module, the power-on time of solenoid valve is reduced from 2 s to 0.40 s, and the peak current of unlocking is reduced from 300 mA to less than 120 mA, which improves the service life and reliability of the intelligent lock.

During the operation and service of high speed railway, the abnormal wear between the positioning hook and the positioning support of the catenary often occurs, which easily leads to the failure of parts, causing pantograph-catenary fault and affecting the normal transportation order of the railway. Taking Wuhan-Guangzhou high speed railway as an example, by combining with the statistical results of the abnormal wear defects in recent years, the reasons for the abnormal wear between the positioning hook and the positioning support were investigated and made clear from the factors including the device structure, stress situation, stress distribution and service environment, so as to point out the key points of daily maintenance of the positioning device and the assumption of improving the service performance. Findings: 1) the stress concentration caused by the hook-and-loop structure is the root cause of the abnormal wear on the hook-and-loop joint, and the insufficient horizontal tension of the positioner and the service environment of the positioning device are the important factors that cause the mutual wear of the positioning device; 2) the place with continuous and same positioning and the corrosive environment in the tunnel are more likely to cause the wear defects, which should be paid attention to in the daily maintenance; 3) adjusting the layout of catenary, improving the process of parts, and optimizing the hook-and-loop connection structure are expected to improve the service performance of the positioning device.

The time interval measurement equipment has a wide range of application scenarios in many fields, such as time-frequency fields and non-time-frequency fields. However, traditional measurement instruments have the characteristics of huge volume, high power consumption, high cost and difficult to integrate. A high resolution short time interval measurement system was proposed to break through the above technological bottlenecks: firstly, the FPGA with high integration and high speed data processing characteristics were used as the hardware design platform of the time interval measurement system; secondly, software research and development was carried out based on the multiphase sampling method and equivalent signal theory; thirdly, the digital phase-locked loop (PLL) integrated in the FPGA was used to generate the required signals with phase difference and same frequency, and XLINX ISERDESE Gbit serial-parallel high speed data processing module was used to sample the measured data, so as to realize data integration. The simulation data analysis shows that such a design achieves the design goal of 8-bit high resolution short time interval measurement at 300 MHz frequency, with the time interval measurement resolution of 0.416 ns and the sampling error as low as 0.015%~0.016%. This design has the characteristics of simple structure, which is conducive to system integration and easy to software upgrade. It can realize nanosecond resolution time interval measurement, and has good technological popularization value.

Inverter has a wide range of application scenarios, and there is a difficult point in its design to avoid its high-frequency electromagnetic interference and electromagnetic pollution to the electrical equipment. According to the application requirements of vehicle inverter, a sine wave vehicle inverter was designed and implemented. The hardware frame structure with Boost voltage-up circuit and full-bridge inverter circuit as the core was designed. The LC filter was optimized, the series impedance and parallel impedance were calculated, and the system function of low-pass filter was obtained, which made the output waveform closer to the sine wave. The control technology such as voltage differential feedback was adopted, the digital controller SMT32 adopted bipolar SPWM digital control mode to generate the driving control signal, and the PID double closed-loop control adjustment was used to realize the rapid stability of the output voltage. The test on the designed sine wave vehicle inverter is carried out, showing that the output power can reach more than 200 W, the efficiency exceeds 85%, and the total harmonic distortion (THD) value is less than 1% under resistive load and less than 3% under inductive load, which can fully meet the application requirements of various load types of electrical equipment.

Muon detection has the advantages such as wide detection range and wide application field, but its miniaturization, low power consumption and expansibility are challenged by the requirements of field detection. With silicon photomultiplier (SiPM) and scintillator as main components, a set of position sensitive readout electronics system, the core system of Muon detector, was developed. The overall structure design of the system was carried out, and the system was divided into front-end acquisition board, data processing board, main control board and power board. The data processing board played a key role in the logic processing of the system function, and achieved the functions such as digital signal discrimination, voltage stabilization compensation, data reporting, etc., by introducing modular and process designs such as noise reduction, time calibration, temperature reading, temperature-voltage conversion, data framing and data transmission. The actual measurement shows that such a system can stably read out the signal data of 400 channels in two layers, and the temperature coefficient of the temperature-voltage curve is 0.021, which is not much different from the specified value of SiPM bias voltage (0.021 5 V/℃) which varies with temperature, thus realizing the environmental temperature compensation. The system meets the requirements of miniaturization, easy expansibility and strong practicability, and provides a flexible solution for Muon detection.

The conventional calibration method of gas pressure reducer has some problems, such as inaccurate manual adjustment of gad pressure, disassembly and assembly of parts can cause damage to the tightness of pressure reducer, complicated operation steps, low calibration efficiency, etc. A new calibration device was designed for the gas pressure reducer. The master calibrator of the calibration device is the intelligent pressure controller, and the main supporting equipment includes the gas pressure generator, the gas supercharger, the connecting platform of pressure reducer and the upper computer with calibration software. The connecting platform has complete functions, complete supporting interfaces and convenient operation, which can realize the overall calibration of the pressure reducer. The calibration software of the upper computer has the function of automatic gas pressure control, which can help the calibrator to quickly complete the calibration of the pressure gauge and the detection of the safety valve without manual pressure adjustment, thus improving the work efficiency. The evaluation of uncertainty shows that the calibration method of the new pressure reducer is reasonable, and the expanded uncertainty of the indication error of each calibration point of the pressure gauge is better than 1/3 of the Maximum Permissible Error Absolute Value (MPEV).

The tower is an important supporting component of large-scale wind turbines, and its door opening area and door frame are weaknesses and difficulties in its structural design, which have a wide impact on the safety and reliability of wind turbines. Focusing on the optimization design of the door frame, the key points of the design were analyzed. Firstly, the stress state of the door opening of the wind turbine tower was studied. Then, four variables, i.e., the upper and lower elliptical semi-long axes of the door frame, the left and right elliptical semi-short axes of the door frame, the width of the door frame and the width of the door frame exposed to the outer cylinder wall of the tower, were considered to form four sets of design schemes. The feasibility of manufacturing technology and structural safety were taken into account, and the optimization law of the door frame structure was revealed. It is found out that the optimal design of the door frame can be achieved to a great extent by appropriately increasing the elliptical outer long axis of the door frame, reducing the elliptical outer short axis of the door frame, ensuring the appropriate width of the door frame, and ensuring the lengths of the door frame extending out of the cylinder inside and outside are consistent.

Axial flow blade demister is the core component of the air intake system in the marine engine room, which is used to remove high concentration salt mist aerosol from air on the sea surface and prevent the downstream equipment from being corroded. In view of the inherent limitations of the general separation mechanism of mist droplets and air by conventional demisters, an improvement idea of reasonably increasing the stage of axial flow blade was put forward. By using the Computational Fluid Dynamics (CFD) theory and method, the gas-liquid two-phase flow fields in the single-stage, two-stage and three-stage blade demisters were numerically simulated, and the effects of blade stages on the characteristics such as pressure resistance and separation efficiency were mainly investigated when the inlet flow rate was in the range of 1~7 m/s and the droplet size was 10~100 μm. Findings: 1) The unseparated droplets at the downstream of the blades are mainly concentrated in the thin layer near the wall, and the high concentration area can be further squeezed by connecting the blades, thus promoting the secondary separation. 2) Increasing the stage of blade has a pressure relief effect, which reduces the downstream flow energy consumption and makes the additional pressure resistance increase weakly. 3) Compared with the traditional single-stage blade, using two-stage blade is enough to effectively and economically improve the demist efficiency to nearly 100%.

The analysis on the electromagnetic noise characteristics of permanent magnet synchronous motor for vehicles were carried out to improve the ride comfort of electric vehicles and provide theoretical basis for motor structure design optimization. Taking a 72-slot 12-pole permanent magnet synchronous motor for vehicles with peak power of 230 kW as the research object, the electromagnetic noise simulation and optimization research were carried out: considering that the main causes of electromagnetic noise were radial electromagnetic force and multi-physical field coupling, a modal analysis method based on electromagnetic and structural weak coupling finite element method was proposed; taking electromagnetic force, cogging torque and peak torque as optimization objectives, a multi-objective optimization scheme based on the genetic algorithm was proposed. Modal analysis and test were carried out at the speed of 2 800 r/min, and the relative error of modal frequency of stator assembly was less than 5%, which verified the accuracy of the simulation method. After multi-objective optimization, the overall maximum sound pressure level of noise test is 70.5 dB(A), which is 17.64% lower than that of 85.6 dB(A) before optimization.

Aiming at the limitations of high-speed rescue by factors including high-speed rail lines, bridge carrying capacity and working space, innovative design schemes such as retractable outrigger, curved leveling structure and multi-outrigger underframe were proposed in the high-speed rescue railway crane, and overall optimization measures were ascertained. Aiming at the difficulty of the whole plug-in assembly, the plug-in quadrant assembly method was put forward by analyzing the plug-in structure. Aiming at the problem that the bearing surface clearance affected the conduction of the outrigger force, the forced intervention scheme of zero free clearance was put forward by calculating the technological parameters of the bearing surface clearance of the main outrigger. Aiming at the problem of insufficient motion accuracy of the curve leveling structure, through the three-state analysis of the curve leveling structure, the functions of each stage in the leveling process were accurately realized. According to the evaluation of process effect, the scheme effectively controls the correct conduction mode of the outrigger force, realizes the precise action of the curve leveling structure, reduces the assembly difficulty of the multi-outrigger underframe, and all the detection indicators meet the manufacturing requirements of the high-speed rescue railway crane products.