Guangke Qi
| Zhiliang Xia*
© 2023 IIETA. This article is published by IIETA and is licensed under the CC BY 4.0 license (http://creativecommons.org/licenses/by/4.0/).
OPEN ACCESS
With the evolution of industrial technology, the role of valves in multifarious systems has been accentuated. Traditional methodologies for valve design and fabrication predominantly depended on tangible laboratory tests to ascertain their hydrodynamic and thermodynamic properties. Such methodologies, although resource-intensive, often fall short in accurately predicting valve performance under genuine operational environments due to inherent experimental limitations. Presented in this study is a simulation system for valve design that seamlessly integrates virtual reality with fluid dynamics. This system's primary objective is the emulation and comprehensive assessment of valves' hydrodynamic and thermodynamic responses under a variety of operational conditions within a virtual environment. Such an approach considerably diminishes both the temporal and monetary costs of testing and provides design engineers with an intuitive, precise feedback mechanism. This, in turn, fosters enhanced design strategies ensuring the efficiency and safety of valve operations. Moreover, the amalgamation of thermodynamic principles with fluid dynamics models has been elucidated, proffering a more solid theoretical framework for the efficient design and pragmatic application of valves.
virtual reality integration, fluid dynamics, thermodynamics, valve design evaluation, simulation system, performance enhancement
In fluid control systems, the role of valves is universally recognised as pivotal; their efficiency, safety, and stability are directly linked to the overall system performance [1]. Historically, investigations into valves relied heavily on tangible experiments and mathematical modelling [2]. However, these methods have been noted to exhibit limitations, especially when addressing complex fluid dynamics challenges [3]. Such deficiencies have prompted a quest for alternative research modalities, a shift accelerated by considerable advancements in computational capabilities [4].
With the deepening of fluid dynamics research, an amalgamation of experimental, theoretical, and computational strategies was explored, with the aspiration of overcoming the impediments associated with traditional techniques [5]. The synergy of emerging technological needs and innovations led to the integration of virtual reality technology within fluid dynamics [6]. This incorporation offered engineers a platform for intuitive and real-time feedback [7].
In an endeavour to gain a nuanced understanding of fluid dynamics in valves, virtual reality technology has been harnessed for simulation purposes [8]. For example, the work of Davis and Stewart [9] focused on predicting the performance of globe control valves using Computational Fluid Dynamics (CFD) modeling. Similarly, Lin et al. [10] conducted a three-dimensional numerical investigation of solid particle erosion in gate valves. Through such methods, the accuracy of simulations was reportedly enhanced, and the duration and financial demands of research were concurrently diminished [11].
The intricate interplay between valve performance and thermodynamics cannot be overlooked [12]. Within valve design and functioning, significant effects are attributed to both temperature and pressure on fluid behaviour [13]. In a pioneering study by Saleem et al. [14], this interrelation was elucidated, paving the way for in-depth explorations into the thermodynamic facets of valves and broadening the scope of comprehensive valve performance assessments [15].
To encapsulate, the focus of the present study revolves around integrating cutting-edge computational approaches with fluid dynamics theories [16]. The aim is to furnish engineers with a refined analytical toolset, poised to revolutionise design, optimisation, and safety within fluid control systems [17].
2.1 Objectives and requirements for system design
Within modern industrial spheres, the paramount importance of valves in fluid control systems is universally acknowledged. Accordingly, the aim was set to conceive a simulation system integrating principles of both fluid dynamics and thermodynamics. The design requirements for such a system have been delineated as follows:
• Authenticity: It is imperative that the system demonstrates the capability to faithfully replicate the operation of valves and the associated thermodynamic state transitions of fluids. For instance, variations in fluid attributes, notably viscosity and compressibility, in response to fluctuations in temperature and pressure, must be precisely represented.
• Interactivity: The provision of an intuitive user interface by the system is essential. Such an interface should empower users to seamlessly modulate the thermodynamic parameters of fluids and directly perceive the resultant interplay between these fluids and the valves.
• Real-time Nature: A salient feature of the system is its ability to instantaneously simulate and display the dynamic interrelation between fluids and valves. Pertinent examples include adaptations in flow rate and the ensuing pressure drop.
• Scalability: Inherent flexibility within the system design is crucial to accommodate the incorporation of emerging fluid models or additional simulation functionalities in subsequent iterations.
2.2 System architecture and integral components
The proposed simulation system is bifurcated into hardware constituents and software applications, collaboratively synthesising a comprehensive, efficient, and user-intuitive experimental milieu. A detailed architectural representation is provided in Figure 1.
2.2.1 Hardware constituents
• Core Computer System: All simulation computations are centrally processed within this unit.
• Environmental Sensing Instruments: Monitoring of external physical magnitudes, including ambient temperature and pressure, is accomplished by these devices.
• VR Apparatus: Immersive experimental interactions are facilitated through this equipment.
• Specialised Thermodynamic Sensors: These are meticulously crafted to quantify thermodynamic parameters intrinsic to fluids.
2.2.2 Software applications
• Simulation Software Suite: By integrating fluid dynamics and thermodynamics models, essential algorithms for simulation experiments are delivered through this platform.
• Data Analytics Modules: These tools enable users to undertake intricate evaluations of resultant simulation data.
• Interactive User Dashboard: A seamless and user-congenial operating platform is ensured by this interface.
2.3 Features and attributes of the system
Grounded in an exhaustive comprehension of real-world application contexts and user requisites, the system's conceptualisation was initiated. Based on this foundational understanding, a myriad of cutting-edge technologies and tools were harnessed to actualise the desired simulation capabilities. A detailed depiction of the development trajectory is provided in Figure 2.
(1) Fluid-Thermodynamic Interaction Modelling:
Fluid behaviour under diverse thermodynamic conditions, influenced by external determinants such as ambient temperature and pressure, is simulated by the system.
(2) Diverse Operational Modalities:
Multiple operational schemes, encompassing manual, automatic, and hybrid modes, are offered by the system, catering to varied experimental stipulations.
(3) Comprehensive Data Examination:
Intricate reports encompassing fluid dynamic metrics and thermodynamic parameters are generated by the system. Moreover, intuitive visual tools are availed to users, augmenting the ease of data interpretation.
(4) Modularity and Scalability:
Future-oriented considerations were pivotal during the preliminary design phase, allowing for effortless integration of novel features or models as the need arises.
(5) Enhanced User Engagement:
An instinctual operating interface is complemented by exhaustive user guidance documents and digital support mechanisms, ensuring that assistance remains at the users' fingertips during system interaction.
Figure 1. Schematic of system architecture
Figure 2. Sequential overview of the system development
3.1 Hardware composition and device selection predicated on thermofluidic considerations
For the faithful representation of fluid dynamic and thermodynamic traits, meticulous care was taken during the hardware selection phase. Integral components incorporated into the system include:
(1) Central to the system, this component is tasked with managing extensive datasets, operating complex software modules, and conducting simulation computations pertinent to fluid dynamics and thermodynamics.
(2) Sensory Mechanisms:
Key thermodynamic attributes of the fluid, encompassing temperature, pressure, flow rate, and their respective temporal shifts, are monitored by these devices. Through this acquired data, heat transfer and fluid behaviours are authentically mirrored by the system.
(3) Virtual Reality (VR) Interface:
An immersive research environment is presented through this component, facilitating a nuanced understanding of fluid dynamics and thermic exchanges in a simulated milieu.
Throughout the hardware selection process, heightened emphasis was placed on the device's ability to capture fluid and thermal dynamics with precision. High-calibre temperature and pressure sensors, for instance, not only vouch for the veracity of the data but also register granular thermodynamic shifts in the fluid. Concurrently, the stability of actuators was identified as paramount, bearing influence on the continuous and stable state of fluid within the system.
3.2 Integration and synchronicity of hardware devices within thermodynamic and fluid dynamic parameters
For the system to function in an integrated manner, synchronised operation across all hardware devices, ensuring consistent delivery of thermofluidic data, is imperative.
(1) Communication Interfaces and Protocols:
The RS485 communication protocol is utilised to ensure the real-time and stable transmission of thermodynamic and fluid dynamic information. In contrast, devices equipped with USB interfaces offer expedited and efficient connection avenues, particularly tailored for the transmission of substantial data sets, be it high-definition video streams or comprehensive simulation data.
(2) Calibration Protocols:
Calibration is designed not merely to validate the operational integrity of the devices but also to certify the precision and continuity of data. For sensors, calibrations are tailored to encapsulate both fluid dynamic and thermodynamic parameters. Meanwhile, for actuators, calibration processes predominantly centre on their response rates and exactitude.
In synthesising the essence of fluid dynamics and thermodynamics, the system, through its meticulous design, not only exudes stability and reliability but also ensures that data of profound depth and accuracy is acquired by researchers.
4.1 Comprehensive design and deployment of the experimental system software
The software developed for this experimental system has been pivotal in facilitating the virtual simulation of fluid dynamics and thermodynamics within valve systems. A meticulous approach was adopted to reflect the nuances of fluid mechanics and heat exchange within these valves. As such, several core components were integrated into the software design:
(1) Virtual Reality Software:
Within this component, a three-dimensional model of the valve and fluid flow was constructed. Temperature distribution and heat exchange within the valve were simulated based on thermodynamic models. These models were employed to characterise heat interactions between the fluid and the valve materials, tracking temperature deviations. Essential metrics such as flow velocity and heat transfer were visually depicted. Moreover, functionalities facilitating interaction and rendering were embedded to amplify the user's intuitive grasp of the simulations.
(2) Data Acquisition Software:
Key parameters encompassing fluid dynamics and thermodynamics, including temperature, heat flux, and specific heat capacity, were extracted by this module from the overarching simulation system. Following extraction, the data were relayed to the data processing software for in-depth analysis.
(3) Data Processing Software:
This component was designed to integrate data derived from fluid dynamics and thermodynamics. It undertakes the task of gleaning pertinent insights from the data and subsequently visualising them. Such processes are instrumental in assisting researchers to comprehend the full spectrum of simulation results.
(4) Control Software:
A principal role of this software is to command the actuators. It is paramount for the simulation's fluid dynamics and heat exchanges to precisely echo real-world scenarios. By amalgamating data from fluid dynamics and thermodynamics, exacting control is delivered to the actuators, underscoring the simulation's veracity and precision.
4.2 Exploration and deployment of key software technologies for the experimental system
(1) Valve Model Determination:
In contemporary industrial settings, a surging demand is observed for the meticulous design and optimisation of valves. Addressing intricate design requisites, such as streamlined flow channel configurations and diminished fluid impedance, often necessitates an in-depth fluid dynamics evaluation. Such evaluations are instrumental in yielding insightful design and optimisation guidelines. For valves subjected to extreme operational conditions, characterised by elevated temperatures, pressures, and flow velocities, the interplay between fluid dynamic attributes and thermodynamic properties becomes notably complex. As a result, a unified approach, integrating both fluid dynamics and thermodynamic analyses, becomes indispensable to project the comprehensive performance, resilience, and thermal variances of the valve. Given these dual facets of analysis, valve types warranting scrutiny were discerned.
(2) Techniques in Virtual Reality Modelling:
• Three-dimensional Modelling and Heat Transference: The technique of virtual reality modelling proves instrumental in facilitating a virtual representation of fluid dynamics and thermodynamics within valve systems. A constructed three-dimensional model is necessitated not only to mirror the dynamic propensities of fluids with fidelity but also to emulate the heat transference interplay between the valve and the fluid, integrating thermodynamic variables such as thermal conductivity, convection, and radiation.
• Integration of Material Characteristics and Thermal Traits: The inherent material of an entity not only demarcates its mechanical attributes but also profoundly influences its heat transference capability. Upon the introduction of materials within a three-dimensional paradigm, it becomes imperative to embed thermodynamic properties germane to the material, encompassing aspects like thermal conduction, convection, and radiation.
• Illustration of Scenario Dynamics and Thermal Shifts: In the instantiation of scenario animations, the emphasis should extend beyond simulating the fluid's dynamic behaviour; it should concurrently manifest temperature gradients and heat exchange mechanics between the fluid and the valve.
• Scenario Fabrication and Thermally-Induced Visualisation: The scenic configuration ought to mimic authentic thermal dispersion. Such verisimilitude is achievable through adept rendering methodologies, leveraging dedicated engines to manipulate the three-dimensional blueprints and vistas, furnishing a vivid portrayal coupled with an intuitive exposition of temperature differentials.
• Model Refinement and Thermally-Driven Efficiency Augmentation: Model refinement manoeuvres contribute to bolstering the operational efficacy of the depicted scenario. In thermal contexts, such refinements further prove advantageous in illustrating the heat transference dynamics under stipulated conditions.
Upon transposition into a standardised three-dimensional template, the model seamlessly assimilates into virtual reality development platforms, thus mirroring laboratory manifestations as depicted in Figure 3.
Such a synthesis of methodologies guarantees that the simulation apparatus boasts unparalleled accuracy and veracity in its representation of both fluid dynamics and thermodynamics.
Figure 3. Visual representation of laboratory effects
(3) Integration of Interaction Mechanisms with Emphasis on Thermodynamic Factors:
Incorporating interactive mechanisms is pivotal within the framework of the virtual simulation system for valve fluid dynamics and thermodynamics. Such mechanisms grant users the capability to interface directly with the simulation model nested within the virtual ambit, facilitating real-time manipulation and assessment of fluid dynamic and thermodynamic parameters.
User Management Module: Within this framework, user registration is facilitated, granting individuals access to the system and the ability to execute simulation experiments. Further, this module empowers users to delineate distinct environmental variables, such as ambient and fluid initiation temperatures, and subsequently observe the ensuing perturbations in simulation results.
Simulation Experimentation Functional Module: This segment permits users to incorporate valve designs and delineate data for fluid dynamic and thermodynamic simulation environments. The resultant simulation is illustrated in Figure 4. Emphasis within this domain gravitates towards the application of foundational principles such as the continuity equation and Bernoulli's equation, with specific annotations pertaining to Young's modulus (E) and its fluctuation under diverse thermodynamic circumstances.
In contemplation of thermodynamic tenets, deliberations transcend mere fluid dynamism, encompassing thermal attributes. As exemplified, fluid transit within the valve may be contingent upon numerous factors including fluid temperature, valve material's thermal conductivity, and surrounding temperatures. Thus, computations and replications, concerning thermal conduction, convection, and radiation, are often imperative.
Enhancing comprehension, Figure 4 delineates the fluid simulation trajectory under an array of thermodynamic states, enabling users to discernibly apprehend both fluid movement and associated temperature modulations within the valve construct.
Figure 4. Depiction of simulated fluid dynamics
(4) Data Compilation and Analysis with Thermodynamic Emphasis:
Data acquisition technology, beyond its foundational role in the virtual simulation of valve fluid dynamics, is instrumental in thermodynamic analytical assessments. Specifically, the data collection software is equipped to assimilate fluid dynamic metrics from sensors and procure parameters intrinsically related to thermodynamics, encompassing aspects like temperature, heat flux, and efficiency of thermal conduction.
Post simulation experimentation, the derived data not only elucidates the fluidic behaviour within the valve but also highlights its responsiveness in multifarious thermal ambits. As an illustration, alterations in the temperature of fluid traversing a pre-heated valve might induce perturbations in both its flow rate and trajectory. Garnering such insights is integral for affirming the valve's operational efficiency and reliability.
Figure 5 delineates the analytical outcomes from the simulation experimentation. Through these results, the interplay between the fluid's passage within the valve and temperature modulations is discernibly captured. This collated data proffers pivotal diagnostic perspectives pertinent to the refinement and enhancement of valve configurations.
The role of data processing techniques is also paramount. Leveraging advanced algorithms and computational strategies, characteristics intertwined with fluid dynamics and thermodynamics are extricated from the amassed data. For instance, analysis facilitates the comprehension of the fluid's trajectory and flow rate within the valve under designated temperature scenarios. These evaluations fortify the endeavours directed towards valve optimisation and design.
In summation, an exhaustive appraisal of the simulation data permits a profound insight into the fluidic behaviours exhibited by the valve, whilst simultaneously elucidating its efficacy under diverse thermodynamic settings. Such insights pave the path for ensuing research ventures and pragmatic applications.
Figure 5. Analytical representation of valve dynamics
5.1 Progressive trajectories of the experimental system
In light of the incessant progress in virtual reality technology, sensor mechanisms, computational advancements, and thermodynamic analytical tools, anticipations regarding the evolution of the valve fluid dynamics and thermodynamic virtual simulation experimental system are outlined as follows:
(1) Refinement in Modelling Precision and Visual Realism: As advances in virtual reality unfold, forthcoming experimental systems are expected to not only encapsulate fluidic dynamics but also encapsulate meticulous renditions of thermodynamic repercussions, endowing users with an augmented verisimilar simulation experience.
(2) Expansion in Interactivity and Modus Operandi: Contrasting conventional fluid dynamics simulacra, those centred on thermodynamics are projected to command augmented interactive facets, embracing attributes like thermal modulation and calorific flux adjustments, thereby enriching the user's operational spectrum.
(3) Augmentation in Data Assimilation and Analytical Prowess: Surpassing mere fluidic dynamic datasets, the system's propensity to curate data embedded with thermodynamic nuances, such as thermal dispersion and calorific pathways, is poised to present users with more nuanced and holistic analytical outcomes.
(4) Escalation in Cognizance and Automation: By harnessing the potential of artificial intelligence, the system's capacity to autonomously discern fluidic and thermodynamic nuances is envisaged to burgeon. This will culminate in more astute simulation guidance, thus substantially amplifying the efficacy of simulation experiments.
5.2 Potential utilisations and intrinsic merit of the experimental system
The valve fluid dynamics and thermodynamic virtual simulation experimental system is endowed with a wide array of utilisation prospects and inherent value, characteristically evident in the subsequent domains:
(1) Refinement in Valve Modelling and Enhancement: Superseding mere fluidic dynamics, the system's aptitude to emulate thermodynamic repercussions, such as the influence of fluidic temperature on valve functionality, presents a more encompassing template for valve modelling and enhancement.
(2) Pedagogy and Capacitation within the Fluid Management Sphere: The experimental system avails a platform for pedagogical and capacitative endeavours, edifying scholars and professionals on the synergy between thermodynamics and fluid dynamics, facilitating a profound comprehension of their intertwined dynamics.
(3) Conception and Rectification of Fluid Governance Mechanisms: By integrating thermodynamic implications, system architects possess enhanced capability to ingeniously conceive and rectify fluid governance apparatuses, certifying their steadfast operation across a gamut of thermal scenarios.
(4) Manufacture and Assessment of Valves: In the realm of valve fabrication and evaluation, factoring in the thermodynamic properties of fluids elevates the precision in ascertaining valve performance metrics, guaranteeing the valve's dependability and constancy in tangible operational contexts.
In this study, an exploration into the development and application of a valve fluid dynamics and thermodynamic virtual simulation experimental system, predicated on virtual reality technology, was undertaken. Not solely limited to fluid dynamics, this system encapsulates facets of thermodynamics, exemplified by parameters like temperature and heat flow. Upon amalgamating these dual disciplines, a thorough investigation was conducted, encompassing the experimental system's holistic design, its hardware constituents, pivotal technologies, software realisations, evaluative assessments of application efficacy, and prospective development trajectories. From this investigation, the following deductions were drawn:
(1) The virtual reality-based valve fluid dynamics and thermodynamic simulation experimental system offers an enriched reference for valve design and optimisation, with particular emphasis on fluid temperature and heat flow considerations.
(2) In juxtaposition with conventional fluid dynamics simulations, this novel system extends a heightened realism in simulating thermodynamic phenomena. Nonetheless, challenges in model accuracy and visual rendering persist, signalling an exigency for further enhancements.
(3) The simulated system exhibits considerable promise in myriad domains: valve design, training within fluid control, system diagnostics, and evaluative manufacturing trials, especially when thermal implications are pivotal.
The inaugural exploration into this system evinces its latent value, yet avenues for further finesse and progression remain salient. In prospective endeavours, the underlisted areas warrant intensified scrutiny:
(1) The incorporation of refined thermodynamic models is imperative to facilitate a more authentic emulation of thermodynamic intricacies, thereby augmenting the fidelity of the simulation.
(2) Augmentation of the interactivity concerning thermodynamic variables is essential. Beyond mere fluid dynamics, the system should accommodate interactive nuances pertinent to thermodynamics, encompassing facets like temperature variances, pressure metrics, and heat transference phenomena.
(3) Emphasis on thermodynamic-focused data processing is paramount. Surpassing the realm of fluid dynamics, data attendant to thermodynamic phenomena, such as thermal gradients and heat fluxes, must be meticulously processed, providing users with profound analytical insights.
(4) The utilisation of artificial intelligence tailored for thermodynamics could spearhead predictive analytics on valve performance across disparate thermal conditions or auto-tune simulation metrics to ascertain thermally optimal outcomes.
The First Batch of Teaching Reform Projects in the "14th Five-Year Plan" for Higher Vocational Education in Zhejiang Province (Grant No.: jg20230066) Research and Practice Exploration of "Post-Course-Competition-Certificate" Integration Talent Cultivation Mode for Higher Vocational Virtual Reality Technology Application Specialties; Wenzhou Vocational and Technical College 2023 Research Project university-level major project (Grant No.: WZY2023005).
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