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2021 Vol. 43, No. 2

Display Method:
Abstract:
With the rapid population growth, economic development, and technological progress around the world today, energy consumption levels are becoming increasingly huge. Most of the energy consumed comes from coal, oil, natural gas, and other primary energy sources that lead to the greenhouse effect, acid rain, photochemical smog, and other environment problems. Therefore, the identification of greener energy resources has become humanity’s great challenge. To reduce the use of primary energy sources, new types of energy have been proposed that are associated with decreased environmental pollution. However, these new energy sources typically require effective storage equipment to facilitate the use of solar, wind or water-driven energy. Lithium-ion batteries (LIBs) were developed to store electrical energy, and due to their unique advantages, today they are widely used in portable devices, electric vehicles, and all kinds of electronic equipment. The advantages of LIBs include a high specific capacity, good cycle performance, and long lifespan. Although life on Earth is greener by the use of LIBs, with the rapidly increasing energy consumption, more spent LIBs are being produced, which contain a range of valuable metals (Cu, Al, Co, Mn, Ni, Li) and harmful substances (HF, organic substances). If these materials are not treated properly, much harm will result to both human beings and the natural environment, and this would also be a great waste of valuable metals. The recovery of spent LIBs has become a research hotspot among the scientific and business communities. To support the discovery of new methods and concepts in the recovery of spent LIBs, in this paper, we reviewed the various methods available and discussed their advantages and disadvantages in detail. Based on this review, we consider the approach that uses a combination of chemical and physical technologies for the recovery of spent LIBs to be the most promising.
Abstract:
In the 1990s, Ye, a scholar from China, broke the routine with a creative idea of the concept of high entropy alloys (HEAs). Since then, new alloys, which breached the traditional concept of “primary component”, have caught great attention of scientists at home and abroad. Due to their excellent properties such as high hardness, strength, wear resistance, corrosion resistance, thermal resistance, and irradiation resistance, HEAs have been considered as a new generation of thermal spray materials with immense potential for industrial applications. Previous studies show similar or even better properties of HEA coatings compared to those of the HEA block. The preparation of the coatings has become the key point since then. Spraying is one of the common methods on preparing HEA coatings, including conventional methods such as plasma spraying, supersonic flame spraying, high-velocity arc spraying, and cold spraying. With their own advantages and disadvantages, appropriate spraying methods and parameters should be selected according to different matrix and spraying materials, which will be discussed in this paper. First, the theoretical basis of the HEAs were introduced. Next, starting from different thermal spraying processes, the research and development status of plasma spraying, supersonic flame spraying, high-velocity arc spraying, and cold spraying on the preparation of HEA coatings were reviewed. Raw material selection, preparation process optimization, performance research, coating post-treatment, and other aspects of the above four thermal spraying techniques to prepare HEA coatings were systematically summarized. Finally, the three problems of limited existing thermal spraying techniques for preparing HEA coatings, limited thermal spraying materials, and aimless design of HEA coatings were proposed. Moreover, three future development issues of new thermal spraying techniques and optimization of existing techniques were discussed along with the development of high entropy ceramics, high entropy amorphous alloys, high entropy composite materials, and other new thermal spray materials. Finally, an HEA database was established to prepare HEA coatings using the concept of material genome to solve the three problems.
Abstract:
With the rapid improvement of exploration and monitoring technologies, the oil and gas industry has accumulated a large amount of data in the fields of seismic exploration, logging, production, and development. How to transform the huge “data resources” into “data assets” and fully utilize data and tap their real value to better serve society is a main concern in the oil and gas industry today. Therefore, the oil industry needs to complete the industrial upgrading of “Smart Oilfield” through digital and intelligent transformation. In recent years, the rise of big data technology and artificial intelligence have allowed international oil companies and oil service giants to accelerate the construction of digital and intelligent oil fields. The overall framework of the big data intelligent platform of oil and gas resources should be based on data resources with big data platform computing power as the support and artificial intelligence algorithms as the core. To meet the production needs of the oil and gas industry, it is of great urgency to build an oil and gas data resource pool that integrates exploration, development, and production data. The data quality can be improved via data cleaning and fusion. Physical simulations, data mining, and other approaches should be combined to achieve the modularization of service functions. Additionally, the goals of intelligent monitoring, early warning, and display on multi-dimensional platforms such as PC, control screen, and mobile apps can also be achieved. The analysis of artificial intelligence methods such as deep learning in the context of the oil and gas industry shows that these methods have good application prospects. In the future, oil companies should work together with scientific research institutes to tap the huge potential of oil industry data, achieve cost reduction and efficiency increase, and build a new smart oil and gas industrial ecosystem to complete industrial upgrading.
Abstract:
Path tracking control of articulated vehicles is a focus in the field of mine automation. Mathematical models and path tracking control methods are two key focal points of research in this area. For mathematical models of articulated vehicles, the classic kinematics model without side-slip is suitable as a reference model for low-speed autonomous driving control. However, when this model is used as the reference model, it may lead to an intensification of sliding. In any event, the four-degree-of-freedom dynamic model of articulated vehicles based on the Newton–Euler method meets the requirements of autonomous driving control in principle. However, this model cannot reflect both transient and steady steering characteristics. In the research of path tracking control methods, feedback linearization control, optimal control, sliding mode control, and other control methods without feedforward information cannot effectively solve the problem of a large error when vehicle tracking a reference path with large abrupt changes in curvature. Feedforward–feedback control can be used to solve the above problem, but when the reference path has diverse amplitudes of abrupt changes in curvature, it is necessary to automatically adjust the preview distance. Model predictive control, especially nonlinear model predictive control, can use feedforward information more effectively and does not need to consider the setting of the preview distance. This way, when the articulated vehicle tracks a reference path with large abrupt changes in curvature, accuracy can be effectively improved. Additionally, for the path tracking control of articulated vehicles based on nonlinear model predictive control, three aspects of research need to be deepened. First, for this control method, there is still a trend that the maximum value of the error increases as the reference velocity increases. Second, currently, this control method uses the kinematics model as the prediction model, so it cannot solve the twin problems of reduced accuracy and worsened safety, caused by the lateral velocity when the articulated vehicle runs at a higher reference velocity. Finally, real-time optimization research on this control method is needed.
Abstract:
The high mining costs of mines have led to the imbalance between the supply and demand of the total mineral resources in China and the dependence on imports to a large extent. Therefore, it is of great significance to expand the mining scale of mineral resources and reduce the mining costs to improve the self-sufficiency rate of mineral resources and strengthen social support and economic development in China. The caving mining method, especially the block caving method, has the following two main characteristics: one is that caved ores, surrounded by overlying rocks, are drawn from the drawpoint and the other one is that ground pressure is managed by filling goaf with overlying rocks. It is a low-cost and efficient large-scale underground mining method and has been widely used in metal mines around the world. To further reveal the far-field field migration and evolution mechanism of caved ore and rock in metal mine, through physical test, numerical simulation, and theoretical analysis, isolated-drawpoint draw models were constructed to study the flow characteristics of near/far-field flow characteristics of caved ore and rock. Based on the discrete element software PFC3D and rigid block model, the numerical draw model was constructed for the first time. The reliability and superiority of the rigid block model in the study of flow characteristics of caved ore and rock were proved by comparative analysis between near-field physical draw test results and simulated results. Moreover, the variation law of the IMZ (Isolated Movement Zone), the stress evolution law and its mechanical mechanism in the particle flow system under far-field conditions were quantitatively studied. The key research results prove that: 1) The shapes of IMZ under near/far-field conditions conform to the upside-down drop shape theory. In the initial draw stage, the maximum width of IMZ increases rapidly with the increase of height in the form of power function; while in the following draw stage, the maximum width of IMZ increases almost linearly with the height increase. 2) There is an obvious stress arch effect during the flow of caved ore and rock. With the range expansion of the caved ore and rock, the vertical stress in a certain range outside the IMZ decreases obviously, while the horizontal stress gradually increases and surges before the arrival of IMZ. Furthermore, the horizontal and vertical stresses within the IMZ drop sharply to a lower level.
Abstract:
The high-concentration slurry prepared from full tailings used for mine backfilling can effectively eliminate the disasters caused by underground voids and tailing ponds. Using pipelines to transport filling slurry is the most efficient way, and the pipe resistance is one of the most important parameters. Presently, the loop test method for studying the pipe transportation parameters of filling slurry is closest to engineering reality. To determine the influence of the cement-sand ratio, concentration, and flow velocity of the high-concentration filling slurry prepared from full tailings on the pipe resistance and predict the resistance of industrial filling pipelines, pilot-scale loop tests were performed. A pipe resistance prediction model was established based on the relationship between the shear stress and the shear rate at the pipe wall. The gray correlation method was used to analyze the influence of various factors on the pipe resistance, and the rheological parameters of filling slurry were obtained by linear regression. The results show that the pipe resistance is most sensitive to the mass concentration of filling slurry and increases quadratically. The flow velocity of filling slurry has the second-greatest effect on pipe resistance, and the resistance increases linearly with flow velocity in laminar flow. The cement-sand ratio of filling slurry has a dual effect on the pipe resistance. When the cement-sand ratio is less than 1∶8, the cohesion effect of the cementing material is dominant and increases the pipe resistance. On the contrary, the lubrication effect of the cementing material is dominant and reduces the pipe resistance. The rheological parameters of filling slurry obtained by the loop test are much smaller than those obtained by the rheometer, and the loop test method is more reliable. The error of the pipe resistance prediction model is within 10%.
Abstract:
The use of adsorbents such as activated coke to separate pollutants from flue gas is an effective flue gas treatment method. As a cheap carbon material, semi-carbon is a potential porous alternative material to the existing commercial activated coke. In this work, the effects of the carbonization time, carbonization temperature, and binder addition on the properties of prepared adsorbents from Shanxi semi-coke were studied. The microstructure changes were investigated, and the changes in the surface functional groups in the adsorption and desorption process were explored via X-ray photoelectron spectroscopy (XPS). The results show that the carbonization temperature has a significant effect on the wear resistance and compressive strength index, and the carbonization time has a significant effect on the saturated desulfurization value and the breakthrough desulfurization value. In addition, under the conditions of 50% coal tar addition ratio, 700 ℃ carbonization for 20 min, and 900 ℃ activation for 60 min, the modified semi-coke parameters were as follows: abrasion resistance 95.81%, compressive strength 536.1 N·cm?1, saturated desulfurization value per g of semi-carbon is 45.71 mg, and breakthrough desulfurization value per g of semi-carbon is 23.45 mg. When the first failure occurred in the adsorbents after 10 thermal regeneration processes, the activated carbon surface was etched over a large area with severe changes in the surface morphology under the above conditions. Some large granular activated carbons were etched and pulverized into small particles. The activated carbon surface structure was also etched out of pores, which may be caused by the C consumption resulting from the interaction of C and H2SO4. The results also show that the secondary activation could increase the adsorption capacity in a short time, but the activated carbon performance degradation is also significant. The amount and composition ratio of the oxygen-containing groups on the surface of the modified semi-coke affected the adsorption performance. The ratio of oxygen to carbon groups corresponded to the adsorption performance: the higher the proportion of oxygen-containing groups, the worse the adsorption performance. The proportion of oxygen-containing groups was changed by the second activation regeneration, and C=O decreased significantly, O?C=O increased significantly, while C?O changed slightly. Although the O?C=O functional group contains oxygen, it may not significantly inhibit adsorption. This study provides a new adsorbent-preparation method for industrial flue gas treatment and also provides a reference for the research on the surface modification of semi-coke and the adsorption and desorption mechanisms of sulfur dioxide.
Abstract:
Lubrication is the key in obtaining excellent products when zirconium alloys are hot extruded. Reasonable lubrication conditions are important to improve the product quality, reduce energy consumption, and prolong the service life of tools and dies. Presently, the glass lubricants commonly used in domestic industry are not very suitable for hot extrusion zirconium alloy, and they still need to be imported. In order to meet the requirements of lubrication and protection during hot extrusion of zirconium alloy, a protective lubricant for hot extrusion of zirconium alloy was trial manufactured in this paper. The main components of this protective lubricant include silicone resin, low softening point glass powder, aluminum oxide (Al2O3) powder, molybdenum disulfide, graphite powder, talcum powder, mica powder, and others. When the experimental temperature is in the range of 700?800 ℃, the friction factor of Zr-4 alloy coated with the lubricant is calculated to be 0.19?0.25 by the ring compression method, which shows good lubrication effect. The zirconium alloy with lubricant protection is not obviously oxidized after heating at 700 ℃, 800 ℃, and 900 ℃, respectively, for 1 h, indicating that the lubricant has good thermal protection effect. The relation curves between contact temperature and time at the interface of the Zr-4 alloy and H13 die steel are measured. The initial interface temperatures of the Zr-4 alloy and H13 steel are 700 ℃ and 350 ℃, respectively. Without the lubricant, the time for the surface temperature of the Zr-4 alloy to reach stability is 7.7 s, and the interfacial heat transfer coefficient increases from 250 W·m?2·℃?1 to 2700 W·m?2·℃?1. On the other and, when the lubricant was used, the time for the surface temperature of Zr-4 alloy to reach stability is prolonged to 12 s, and the interfacial heat transfer coefficient increases from 131 W·m?2·℃?1 to 1900 W·m?2·℃?1, indicating that the lubricant has good thermal barrier properties.
Abstract:
The preparation of graphene aerogel (GA) by the sol-gel method has wide application prospects. In this study, the sol-gel method was used to prepare GA composites using resorcinol (R), formaldehyde (F), and graphene oxide (GO) as precursor materials and sodium carbonate (C) as the catalyst. The effects of the pH value and GO in the precursor solution on the energy storage performance of GA materials were studied. The microstructure and morphology of the samples were characterized by X-ray powder diffraction (XRD), X-ray photoelectron spectroscopy (XPS), nitrogen desorption analysis, and scanning electron microscopy (SEM). Cyclic voltammetry (CV), constant current charge–discharge (CP) and electrochemical impedance spectroscopy (EIS) were used to measure the electrochemical properties of the samples in 1 mol?L?1 Na2SO4 electrolyte. The results show that different pH values and GO affect the size and number of cluster particles in GA and the three-dimensional structure of GA. When the pH value was 6.3 and the mass fraction of GO was 1% in the precursor solution, the obtained GA sample exhibited superior surface properties and electrochemical performance. At a current density of 1 A?g?1, the specific surface area of the GA was 530 m2?g?1, and the specific capacitance was 364 F?g?1. If the current density was increased to 10 A?g?1, the specific capacitance still reached 229 F?g?1, indicating that the GA sample had better multiplier performance. After 800 cycles at a current density of 1 A?g?1, the specific capacitance retention rate was 76%. In addition, the GA sample was utilized as a symmetrical supercapacitor with high coulomb efficiency. The specific capacitance of the capacitor remained at 98 F?g?1 in a constant current charge–discharge test at a current density of 1 A?g?1. After 800 cycles, a specific capacitance retention rate of 95.9% was maintained by the symmetrical supercapacitor. This study provides a method for improving the electrochemical properties of GA to realize supercapacitors with better performance.
Abstract:
Semisolid processing is a new near-net-shape manufacturing process suitable for fabricating components with complex shapes. Semisolid billet remelting is a key process performed prior to the subsequent semisolid thixoforming. Understanding the remelting behavior will provide significant theoretical guidance for the semisolid thixoforming process. In this study, during remelting, we investigated the microstructural evolution of a 9Cr18 semisolid billet prepared by the sloping plate method. The microstructures of 9Cr18 specimens for a semisolid billet and traditional casting ingot were discussed. The effects of the initial microstructure and remelting temperature on the remelting behavior were also clarified. The microstructural evolution and remelting behavior were observed via optical microscopy, scanning electron microscopy, X-ray diffraction, and differential scanning calorimetry. The results show that an excellent 9Cr18 semisolid billet can be obtained via the sloping plate method. Forced convection through the sloping plate was found to play a key role in breaking the continuous distribution of dendrites. The typical microstructure was found to exhibit a primary solid austenite globular grain (γ1) and a eutectic structure of secondary austenite (γ2) and M7C3 carbide. The average size of a globular grain was determined to be 93.5 μm and the shape factor was 0.69. The globular grains showed a smooth boundaries. The Fe, C, and Cr elements showed obviously different contents in the solid and liquid phases. The Cr and C elements were enriched in the liquid phase, whereas the Fe content was higher in the solid phase. Compared with the traditional casting ingot, the remelting microstructure of the 9Cr18 semisolid billet prepared by the sloping plate method was more suitable for subsequent semisolid thixoforming. A more even distribution of the chemical composition and more globular grains can be obtained after semisolid remelting. The solid/liquid interface was smooth on the remelted specimen. The width of the M7C3 carbide decreased to 0.5 μm after remelting and the morphology became nearly granular. The observed microstructural evolution during remelting of the 9Cr18 semisolid billet contributes to our understanding of the thixotropic behavior in the subsequent semisolid forming process.
Abstract:
Low-alloy engineering structural steel is widely used in many fields, because of its good mechanical and processing properties. The corrosion resistance of low-alloy engineering structural steel is related not only to chemical composition but also to microstructure, inclusions, grain size, and other factors. However, at present, the direct and fast criterion for evaluating the corrosion resistance of low-alloy structural steel, i.e., the corrosion resistance index I, in the ASTM Standard and China National Standards only involves the chemical composition of low-alloy structural steel and ignores the microstructure, inclusions, and grain size. In the literature on the corrosion resistance of low-alloy structural steel, the coupled effect of chemical composition and other material factors on corrosion resistance and the quantitative analysis of each factor have not been reported. Therefore, a new corrosion resistance index for low-alloy structural steel that includes more factors needs to be proposed. Through the neutral salt spray accelerated corrosion test of eight kinds of low-alloy engineering structural steels with similar composition and microstructure produced by different manufacturers or production lines, combined with the methods of composition test, microstructure analysis, corrosion product analysis, data statistics, and calculation fitting, a composite corrosion resistance index Y for low-alloy structural steel was proposed, and a quantitative index formula containing several factors, including chemical composition, inclusions, microstructure, and grain size, was established. Results show that the corrosion resistance of low-alloy structural steel is affected by the coupling of many material factors, not only the traditional corrosion resistance index I but also inclusions, microstructure, and grain size. The degree of influence is in the order of corrosion resistance index I determined by corrosion-resistant alloy elements, total inclusions, pearlite content, and grain size. The composite corrosion resistance index can be used as an effective criterion for the corrosion resistance of low-alloy structural steel and is of significance in engineering applications.
Abstract:
Increasing demands for lightweight manufacturing accelerate the application of lightweight materials in the transportation, aviation, and power industries. High-strength steel is a popular candidate among various lightweight materials. Transformation-induced plasticity (TRIP) steel, a high-strength, lightweight steel, is promising for forming processes owing to its high strength and toughness. However, the increase in the flow strength of metals will create big challenges for material formability and fracture issues for manufacturing processes. Ductile fracture is still the main failure form during the forming process of TRIP steel. Sheet metal is subject to complex stress states when it undergoes diverse loading paths. Failure modes in metal forming can be mainly classified into the following: tensile, compression, shear, tensile–shear, and compression–shear. Because the metal sheet is prone to buckling failure when it undergoes in-plane compression–shear deformation, it is difficult to induce fracture during the corresponding negative stress triaxiality range. To solve this issue, a novel experimental setup and a specimen were designed to analyze fracture behaviors of an advanced high-strength steel TRIP800 sheet. For the same specimen, the failure behaviors of diverse stress states could be achieved by adjusting the angles between the loading direction and specimen positions. The parallel numerical simulations of in-plane compression–shear deformations under three typical loading angles of 20°, 30°, and 45° were performed on the ABAQUS/Explicit platform. The predicted stress triaxiality in the local deformation region of the three cases was less than zero, and the lowest was up to ?0.485, which verifies that the fracture failure analysis of negative stress triaxiality range could be realized with the designed device. In addition, the fracture onset information and damage evolution were analyzed based on the modified Mohr–Coulomb (MMC) fracture criterion. Furthermore, the fracture strain at the fracture point decreased with the decrease in stress triaxiality when the stress triaxiality was less than ?1/3.
Abstract:
Considering the digital flexible extrusion sand mold as the research object, the surface quality of sand mold was studied by designing a single-factor experiment, and then the optimal parameter for the high-precision flexible forming of sand mold was obtained. The results show that there are differences in surface properties between the outside and inside of the sand mold, and the different types of sand mold had different surface properties. The angle coefficient of sand has a great influence on the sand mold surface properties. With the increase in the extrusion force, the distance between sand grains decreases and the parallel connection mode of sand grains increases. When the sand mold was cut, the number and extension depth of cracks of the sand mold were greatly reduced; thus, the sand mold surface properties increased. With the increase in the resin content, the coating thickness of sand grains increases, the bonding bridge of sand grains increases, the sand mold strength increases, the number of cracks of sand mold decreases, and the surface properties of sand mold increase. In this paper, a new method to obtain the surface quality of sand mold is provided, which can help popularize the precision forming technology of pattern-less casting. The method of sand-mold near-net forming with digital flexible extrusion makes the extrusion unit array pack form the sand-mold cavity. Moreover, in the digital precision forming technology without pattern casting, by filling the mold with molding sand, holding pressure, and hardening, the sand-mold near-net forming is obtained as a preform. This technology saves a lot of molding sand and reduces the amount of cut molding sand in the process of the digital precision forming technology without pattern casting. As the preliminary process of the sand-mold digital precision forming without pattern casting, the technology of sand-mold near-net forming with digital flexible extrusion effectively shortens the development cycle of castings. The basic research on sand mold efficiently achieves high-quality and near-net forming of sand molds with digital flexible extrusion. The research improves the digital level, eco-friendliness, and efficiency level of pattern-less casting technology.
Abstract:
The air separation plants of iron and steel enterprises are characterized by a high oxygen-emission rate and high comprehensive energy consumption. To solve this problem, a converter oxygen scheduling model was established based on particle swarm optimization (PSO) with the goal of reducing the fluctuation of the total oxygen consumption and saving system energy consumption in the converter. With the full consideration of constraints, such as the constant duration of blowing intervals, compliant starting time of each blowing interval, molten steel temperature above 1250 °C, and minimal variation before and after converter scheduling, PSO based on integer space was used to solve the hypothesis. With the air separation plant of a large domestic iron and steel enterprise as a case study, Pipeline Studio software was used to establish the oxygen transmission and distribution model, and the energy-saving performance of the converter oxygen scheduling was verified. The results show that the optimal scheduling of converter oxygen based on PSO can arrange oxygen for a single converter as much as possible during the study period; moreover, the optimal scheduling can effectively reduce the overlapping time of oxygen blowing in multiple converters, reduce the fluctuation of the total oxygen amount, and alleviate the contradiction between oxygen supply and demand. The oxygen emission of the pipeline transmission and distribution system before and after the dispatch is reduced from 1242.1 m3 to 0 within the 120 min simulation period; the corresponding air separation system oxygen production energy consumption saves 1192.42 kW·h; the compression energy consumption of the oxygen compressor increases by 41 kW·h; and the total energy saving of the system is 1151.42 kW·h. Based on comprehensive calculations, optimal scheduling of converter oxygen based on PSO is applied throughout the year. The oxygen transmission and distribution pipeline system is expected to reduce the total amount of oxygen emission by 5.44×106 m3 and save the total energy consumption by 5.22×106 kW·h.
Abstract:
To solve the problem of smooth turning of an autonomous underground load-haul-dump loader (LHD), in this paper, a method for turning trajectory planning of an LHD was proposed. This method is a type of hybrid trajectory planning method based on a bidimensional search. According to the characteristic of the problem, the longitudinal and lateral decomposition method was applied, and the basic algorithms are a sampling method and an optimization algorithm. The algorithm consists of three main steps that are parameter generation of the optimal model based on a bidimensional search strategy, trajectory calculation based on quadratic programming models, and determination of the optimal trajectory based on an articulated angle and collision avoidance constraints check. The novelty of this method lies in the proposed two-dimensional search strategy and trajectory optimization models. The two dimensions are the driving time and mileage of the trajectory in the turning area; the trajectory optimization model is based on the quadratic programming that can quickly generate the optimal trajectory in both dimensions according to the turning area entering speed and position of the LHD. This trajectory planning method is simple in structure and easy to implement. Moreover, it can satisfy the real-time requirement of the controller on the trajectory generation time by adjusting the key parameters. Based on the characteristics of the trajectory planning method, it is not only suitable for real-time trajectory planning but can also provide basic constraints for intelligent control and optimal scheduling of intelligent mines. A series of case studies was conducted to show the effectiveness and superiority of the proposed method. The case studies show that the optimal trajectories according to different entering speeds and positions can be obtained through the proposed method. A prototype experiment was performed to show the feasibility of the proposed trajectory planning method. This method generates trajectories that are easy to track and control because the velocity, articulated angle, and angular velocity change gently.
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