Designs, Volume 8, Issue 4 (August 2024) – 6 articles

In today’s era of heightened environmental awareness, industries and means of transport are under increasing pressure to minimize their ecological footprint. In particular, small-scale power plants for the marine sector pose environmental challenges due to their pollutant emissions. One promising technology to address this purpose is represented by small-scale gas turbines. In this work, the design of a radial turbine and a centrifugal compressor for a 5 MW engine to be employed onboard ships is developed. After a one-dimensional design, the project involves the aerodynamic and structural design optimization of the two machines using fluid dynamic and structural simulation software. The final configuration obtained by the optimization process and its performance are analyzed, demonstrating that the use of a radial architecture for the construction of a 5 MW small gas-turbine assembly for marine propulsion is feasible. Both the compressor and the turbine optimization procedures led to final values of polytropic efficiencies that were three percentage points larger than the first-guess design machine values, simultaneously allowing for reductions in stress usage factors by more than 38% and 32% for the compressor and the turbine, respectively. Full article

The automotive industry is currently transforming, primarily due to the rise of electric and hybrid vehicle technologies and the need to reduce vehicle mass and energy losses to decrease consumption, pollution, and raw material usage. Additionally, road surface manufacturers emphasize improving pavement durability and reducing rolling noise. This necessitates precise load condition definitions and drives the need for reliable wheel testing benches. Many current benches use abrasive-coated rollers or synthetic tapes, but devices capable of testing on actual road surfaces are rare. In this work, a novel device for testing tire-pavement interaction is proposed. The system features a cart moving along a closed-track platform, ensuring test repeatability and enabling structural durability tests on uneven surfaces with installed obstacles. The cart is equipped with a cantilever arm capable of supporting either a testing wheel with customizable dimensions and kinematic parameters or a tire integrated with a complete suspension system, moving along a customizable pavement surface. The system includes actuators and sensors for applying vertical loads and adjusting the alignment of the testing wheel (slip angle, camber angle, etc.), allowing the characterization of tire behavior such as wear, fatigue, rolling noise, and rolling resistance. Multibody simulations were performed to evaluate the bench’s feasibility in terms of kinematics, power requirements, and structural loads. Results confirmed how this novel test bench represents a promising advancement in tire testing capabilities, enabling comprehensive studies on tire performance, noise reduction, and the structural dynamics of vehicle subsystems. Full article

Glucose is a simple sugar molecule. The chemical formula of this sugar molecule is C₆H₁₂O₆. This means that the glucose molecule contains six carbon atoms (C), twelve hydrogen atoms (H), and six oxygen atoms (O). In human blood, the molecule glucose circulates as blood sugar. Normally, after eating or drinking, our bodies break down the sugars in food and use them to obtain energy for our cells. To execute this process, our pancreas produces insulin. Insulin “pulls” sugar from the blood and puts it into the cells for use. If someone has diabetes, their pancreas cannot produce enough insulin. As a result, the level of glucose in their blood rises. This can lead to many potential complications, including blindness, disease, nerve damage, amputation, stroke, heart attack, damage to blood vessels, etc. In this study, a non-invasive and therefore easily usable method for monitoring blood glucose was developed. With the experiment carried out, it was possible to measure glucose levels continuously, thus eliminating the disadvantages of invasive systems. Near-IR sensors (optical sensors) were used to estimate the concentration of glucose in blood; these sensors have a wavelength of 940 nm. The sensor was placed on a small black parallelepiped-shaped box on the tip of the finger and the output of the optical sensor was then connected to a microcontroller at the analogue input. Another sensor used, but only to provide more medical information, was the heartbeat sensor, inserted into an armband (along with the microprocessor). After processing and linear regression analysis, the glucose level was predicted, and data were sent via the Bluetooth network to a developed APP. The results of the implemented device were compared with available invasive methods (commercial products). The hardware consisted of a microcontroller, a near-IR optical sensor, a heartbeat sensor, and a Bluetooth module. Another objective of this experiment using low-cost and low-power hardware was to not carry out complex processing of data from the sensors. Our practical laboratory experiment resulted in an error of 2.86 per cent when compared to a commercial product, with a hardware cost of EUR 8 and a consumption of 50 mA. Full article

In battery systems, there are several established form factors targeting mass market applications, like D, C, AA, AAA series, lithium round cells, and coin cells. Besides these standardized batteries, in printed electronics, there are several approaches to realize flat batteries of different material systems fabricating primary and secondary battery types. For a dedicated application in agriculture, a sensor system requires a degradable primary battery. In this paper, the development of a dedicated zinc–carbon battery is described, supplying the sensor application with 4.5 V_nom. The battery has a 170 mm length and a 23 mm outer diameter. while the inner core is open for the antenna system of the application. The active area is up to 161 cm². The design and manufacturing aspects are described. The rolled-up battery system is fully charged after manufacturing and ready to operate. It may remain inside the degradable sensor system after use in the field. Full article

In the dynamic realm of sustainable energy storage technologies, the global research landscape presents myriad scientific and economic challenges. The erratic growth of renewable energies alongside the phasing out of conventional power plants poses a significant hurdle in maintaining a stable balance between energy supply and demand. Consequently, energy storage solutions play a pivotal role in mitigating substantial fluctuations in demand. Metal–air batteries, distinguished by their superior energy density and enhanced safety profile compared to other storage devices, emerge as promising solutions. Leveraging the well-established lead–acid battery technology, this study introduces a novel approach utilising open-cell foam manufactured through the Excess Salt Replication process as an anode for lead–air battery cells. This innovation not only conserves lead but also reduces battery weight. By employing a 25% antimonial lead alloy, open-cell foams with diameters ranging from 2 mm to 5 mm were fabricated for the antimonial lead–air battery. Preliminary findings suggest that the effective electrical conductivity of primary battery cells, measured experimentally, surpasses that of cells composed of the same dense, non-porous antimonial lead alloy. This improvement is primarily attributed to their extensive specific surface area, facilitating oxidation–reduction reactions. A correlation between effective electrical conductivity and cell diameter is established, indicating optimal conductivity achieved with a 5 mm cell diameter. These results underscore the feasibility of implementing such an electrical system. Full article