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Preliminary considerations on the form-finding of a tensegrity joint to be used in dynamic orthoses
(2024)
Isogeometric sheet metal forming simulation is a numerical simulation technique that is used to predict the behavior of sheet metal parts during the forming process [1] and tries to tighten the link with the Computer Aided Design (CAD) description. This technique uses the isogeometric analysis (IGA) approach, which combines the well-established framework of traditional finite element analysis (FEA) and the power of non-uniform rational B-splines (NURBS). In contrast to the approach in a “classical” FEA framework, IGA directly uses the ansatzspace of the CAD geometry for analysis, which opens the possibility to work directly on the exact geometry. Furthermore, the smoothness of the NURBS basis functions results in a more accurate simulation [2].
A powerful method to reduce the computational effort is adaptive mesh refinement, that has been developed and optimized for sheet metal forming applications over several years for standard Finite Elements. However, it remains an open question how an efficient local adaptive mesh refinement strategy can be implemented for complex industrial sheet metal forming simulations based on trimmed NURBS models, which are typically the description in Boundary Representation (B-Rep) CAD-models [3]. First investigations for explicit dynamics have been made in [4].
In this contribution, a detailed comparison between FEA and IGA sheet metal forming applications is conducted. The state of the art for FEA and IGA will be contrasted and the need for an efficient adaptive mesh refinement strategy will be discussed. The goal of our research is to develop an efficient adaptive mesh refinement strategy for isogeometric sheet metal forming simulations in LS-DYNA. This will contribute to closing the efficiency gap between IGA and FEA in explicit dynamics, accelerate the product development process and enable the application of IGA in industrial sheet metal forming simulations.
A factory has to adapt to a future production program and increasing volumes. The planning of new factories must therefore already take expansion stages and reconfigurations into account. This leads to an increase in the complexity of planning, as different variants have to be planned and put into a chronologically reasonable and cost-optimized sequence. A factory data model that covers expansion stages manages the planning data amount and reduces complexity. Based on existing models from the literature, a factory data model was developed and modeled in the Unified Modeling Language standard. The factory data model shows which classes are interdependent and how planning results are stored reusable for other variants. An example is used to explain the developed factory data model and highlighting its advantages. The aim is to enable factory planners to document variant sequences and expansion stages in a comprehensible way, which supports the interdisciplinarity of factory planning projects.
Effects of Deep Rolling on the Fatigue Behavior of Ti-6Al-4V at Ambient and Elevated Temperatures
(2003)
This paper presents a comprehensive analysis of a three-dimensional compliant tensegrity joint structure, examining its actuation, kinematics, and response to external loads. The study investigates a baseline configuration and two asymmetric variants of the joint. The relationship between the shape parameter and the parameters of the tensioned segments is derived, enabling the mathematical description of cable lengths for joint actuation. Geometric nonlinear static finite element simulations are performed to analyze the joint's response under various load conditions. The results reveal the joint's range of motion, the effect of different stiffness configurations, and its deformation behavior under external forces. The study highlights the asymmetric nature of the joint and its potential for targeted motion restriction. These findings advance the general understanding of the behavior of the considered tensegrity joint and provide valuable insights for their design and application in soft robotic systems.
Um die Leistungsfähigkeit von nachgiebigen Robotersystemen („Soft Robotics“) zu verbessern, werden immer neue Möglichkeiten zur Realisierung dieser Systeme gesucht. In vielen Anwendungen ist der Einsatz von mechanisch vorgespannten nachgiebigen Strukturen in diesen Systemen von Vorteil. Die Steifigkeit dieser Strukturen kann gezielt und gegebenenfalls reversibel variabel eingestellt werden. Die Formveränderung kann nur durch wenige Aktuatoren erzeugt werden.
Nachgiebige Tensegrity-Strukturen, die auf hochelastischen Materialien basieren, entsprechen einer speziellen Klasse von mechanisch vorgespannten Strukturen. Sie werden durch druck- und zugbelastete Segmente gebildet, wobei die druckbelasteten Segmente untereinander nicht direkt verbunden sind. Die resultierende Form dieser Strukturen wird durch ihre Vorspannung bestimmt. Weiche Roboter, die auf diesen Strukturen basieren, bieten mehrere vorteilhafte Eigenschaften, wie z. B. Faltbarkeit/Entfaltbarkeit, geringe Masse, hohes Festigkeits-Gewichts-Verhältnis und stoßdämpfende Fähigkeiten [1]. Diese Strukturen haben eine ausgeprägte Fähigkeit, sowohl ihre Form als auch ihre Steifigkeit zu verändern. In den letzten Jahren hat das Interesse an der Erforschung von Robotersystemen, die auf diesen Strukturen basieren, zugenommen. Aktuelle Arbeiten konzentrieren sich auf die Entwicklung von mobilen Robotern [2]–[7] und Manipulatoren, die auf diesen Strukturen basieren [8]–[10]. Tensegrity-Manipulatoren werden typischerweise durch Kaskadierung von gleichartigen elementaren Einheiten gebildet, die nach dem Tensegrity-Prinzip untereinander verbunden werden. Die elementaren Einheiten sind entweder selber konventionelle Tensegrity-Strukturen oder einteilige planare bzw. räumliche Strukturen. In klassischen Tensegrity-Manipulatoren werden starre Drucksegmente und nicht elastische Zugsegmente verwendet. Die Formänderung dieser Systeme wird durch Änderung der Längen ausgewählter Zugsegmente realisiert. Dem gegenübergestellt können nachgiebige Tensegrity-Manipulatoren realisiert werden, indem die Zugsegmente der Struktur eine hohe Nachgiebigkeit aufweisen. Um die mechanische Nachgiebigkeit und Formänderungsfähigkeit von diesen nachgiebigen Manipulatoren zusätzlich
zu erhöhen, ist auch der Einsatz von Tensegrity-Strukturen auf der Basis nachgiebiger Drucksegmente denkbar.
Im vorliegenden Beitrag werden zwei nachgiebige Tensegrity-Manipulatoren vorgestellt und in Hinblick auf ihre mechanischen Eigenschaften und Formänderungsfähigkeit gegenübergestellt. Sie unterscheiden sich in ihrer Topologie, in der Art der Aktuierung und auch in der mechanischen Nachgiebigkeit. Die mechanische Nachgiebigkeit des ersten Systems beruht auf der Elastizität der Zugsegmente, die Drucksegmente sind starr. Die elementaren Einheiten bilden einteilige Strukturen. Das zweite System beruht auf elementaren Einheiten, die selbst räumliche Tensegrity-Strukturen sind. In diesem System sind sowohl die Zug- als auch die Drucksegmente nachgiebig. Die Aktuierung des ersten Systems erfolgt durch Längenänderung der Zugsegmente. Im zweiten System wird die Formänderung des Gesamtsystems durch Änderung der Form der nachgiebigen Drucksegmente realisiert. Die theoretischen Untersuchungen erfolgen unter Anwendung
der statischen geometrisch nichtlinearen FE-Methode. Mit diesen Untersuchungen wird die Formveränderungsfähigkeit der beiden Systeme unter Variation ihrer Vorspannung untersucht und gegenübergestellt. Die experimentellen Untersuchungen an zwei Demonstratoren bestätigen die theoretischen Ergebnisse und zeigen die Anwendbarkeit von Systemen auf Basis dieser Strukturen als Manipulatoren auf.
Theoretical considerations on a 2D compliant tensegrity joint in context of a biomedical application
(2023)
In this paper, a two-dimensional compliant tensegrity joint was investigated for potential biomedical applications such as orthotics or exoskeletons. The structure consists of two compressed members connected by five compliant tensioned members. The concept is based on the tensegrity principle, which allows the realization of dynamic orthoses without conventional hinge joints. Another advantage is the adaptability to the individual needs of the patient through a suitable design of the structure and the careful selection of the characteristics of the elements. Using geometric nonlinear analysis, the mechanical behavior of the structure was investigated, focusing on mechanical compliance. The main objective was to determine the influence of the initial length and stiffness of the tensioned members and the influence of the magnitude of external forces on the overall stiffness of the movable member of the structure. The results highlight the significant impact of member parameters on the structure's stiffness and movability under varying load magnitudes. The research laid the foundation for future development of dynamic orthoses based on this structure.
In diesem Beitrag erfolgt die theoretische Untersuchung einer zweidimensionalen nachgiebigen Tensegrity-Struktur in Hinsicht auf ihre potenzielle Eignung als Basisstruktur für eine dynamische Handorthese. Translatorische und rotatorische relative Bewegungsmöglichkeiten zwischen den Drucksegmenten der Struktur sind möglich, da diese Segmente durch nachgiebige Zugsegmente miteinander verbunden sind. Die Form der Struktur und ihre Vorspannung in einer statisch stabilen Gleichgewichtskonfiguration werden mit Hilfe der Minimierung des Kräfte- und Momentenungleichgewichts, der Betrachtung der potentiellen Energie der Struktur und einem Ansatz mittels statischer Finite-Elemente-Methode (FEM) in Abhängigkeit der Segmentparameter untersucht.
In this paper, the movement behavior of amoeboid locomotion system is investigated and the theoretical proof of the locomotion of the system is provided with the finite element method. It is shown that not only the speed of locomotion but also its direction can be influenced by the drive frequency. Depending on the drive frequency, a movement from the home position and a subsequent movement in opposite directions can be achieved. In addition, high speeds of movement can be achieved in a limited frequency range.
Digital twins enable the digital representation of physical systems and provide comprehensive modelling and analysis capabilities. An online data exchange between the Digital twin and SAP is feasible, through integration of a transport control systems (SAP) via RESTful API. This interface allows decision making in resource allocation and furthermore the adaptation of the digital model if the real system changes. Despite the associated challenges in terms of data synchronisation, the integration has benefits such as a reduction in modelling effort and an increase in the lifetime of the digital twin. In the context of this work, the design of the interface between the simulation software and a SAP transport control system via RESTful API is described.
Current challenges in the planning and control of internal logistics systems are based on permanent changes in the requirements on the system, e.g., due to fluctuating order numbers or changes in their structure. For the representation and planning of in-house logistics processes, digital twins offer the possibility to verify different operational decisions such as predictive workforce scheduling. In this context, the quality of the results and their in-time presentation plays a decisive role. However, both target criteria are influenced by the detail-level of the digital representation. Based on a case study, this paper investigates the influence of the level of detail on the simulation runtime and result divergence to provide an evaluation for detail levels in the modelling of intralogistic transport systems.
Product sounds with clearly audible tonal components are often perceived as unpleasant or annoying. If different simultaneously operating aggregates are present in a system, for example vehicle engines and gearboxes, the interaction of tonal components, similar to music, can evoke additional sensations in human auditory perception. Supplementary to a pronounced tonality, such sounds can also yield distinct degrees of consonance or dissonance between tones. Previous studies showed that the perceived dissonance had a high impact on preference judgements for sounds with similar tonality. In experiments of the present study, sounds that differed in tonality were rated with respect to the auditory sensations sharpness, tonality and dissonance by one group of participants while another group only carried out a preference task. Thereout a model for predicting perceived preference is derived from the subjective judgements of auditory sensations. The performance of the preference predictions based on subjective udgements will be compared against purely model-based predictions using different algorithms for acoustic attributes.
Fused layer modeling (FLM) is widely used and is gaining more acceptance in the industry mainly due to its material variety and low costs. However, the usage is limited by a process-related anisotropy of the produced parts. The strength and ductility of the printed parts are significantly lower in the build-up direction than perpendicular to it. This is caused by insufficient interlayer bonding resulting from a reduced surface temperature in the process zone. To overcome this problem, a diode laser is integrated into the conventional FLM process to increase the surface temperature between the already printed surface and the newly applied substrate directly at the deposition zone. The investigations carried out show a significant improvement in the mesostructure, as well as a clear reduction in the anisotropy of the printed test specimens.
Absorber-free laser transmission welding enables clean and precise joining of plastics without additives or adhesives. It is therefore well suited to produce optical and medical devices, which place high demands on cleanliness and accuracy.
However, the weld usually has an undesirably large vertical expansion, causing bulges and distortion. To improve this, the intensity distribution of the laser beam as well as the processing strategy must be adapted. Due to the complexity, this is aided by process simulation. However, simulation parameter calibration and verification are usually done considering the seam width and height, which is of limited significance. To overcome this, we propose a new method for image processing of microtome sections, determining the spatially resolved geometry of the weld. Thus, the deviation between experiment and simulation can be calculated pixel by pixel. This spatially resolved value is predestined for the calibration of the simulation parameters: For a parameter field with 18 different settings, the total deviation between experiment and simulation is less than 11 % after calibration.
Mechanical surface treatments, such as deep rolling, shot peening and laser shock peening, can significantly improve the fatigue behavior of highly stressed metallic components. Deep rolling is an especially attractive technique since it is possible to generate deep, near-surface compressive residual stresses and work hardening while retaining a relatively smooth surface finish. Indeed, this technique is best known for increasing the fatigue strength and lifetime of steel components such as crankshafts. Although most work on deep rolling has been on steels, recently it has also been applied with reasonable success to titanium alloys. Accordingly, in this investigation, we examine the effect of deep rolling on the high-cycle fatigue behavior of Ti-6Al-4V, with particular emphasis on the thermal and mechanical stability of the residual stress states and near-surface microstructures. Preliminary results on laser shock peened Ti-6Al-4V are also presented for comparison. In addition, we examine whether these surface treatments are effective in retaining fatigue strength at the higher temperatures of 300 to 450C. Based on the cyclic deformation and stress/life behavior, together with the X-ray and microstructural observations, it is found that deep rolling can be quite effective in retarding the initiation and initial propagation of fatigue cracks in Ti-6Al-4V at such higher temperatures, despite the almost complete relaxation of the residual stresses at the surface. This clearly implies that, in addition to residual stresses, near-surface microstructures, which in Ti-6Al-4V consist of ultrafine near-surface nanostructures, play a critical role in the enhancement of fatigue lifetimes by mechanical surface treatments.
Dual front steering axles are quite common in multi-axled heavy duty trucks. In standard layouts of such axle combinations, the steer motions of the wheels depend not only on the rotation of the steering wheel but also on the movements of the axles. As a consequence, the model complexity of the steering system should match with the complexity of the suspension model. The development of new technologies like advanced driver assistance systems or autonomous driving can only be accomplished efficiently using extensive simulation methods. Such kind of applications demand for computationally efficient vehicle models. This paper presents a steering system model for dual front axles of heavy duty trucks which supplements the suspension model of the axles. The model takes the torsional compliance of the steering column as well as the stiffness of the tie rods and the coupling rod into account. A quasi-static solution provides a straight forward computation including the partial derivatives required for an efficient implicit solver. The steering system model matches perfectly with comparatively lean, but sufficiently accurate multibody suspension models.
A prototype of a thermal insulation system to offer high selectivity of the solar gain regarding the solar incidence angle (SATIS) was applied to a typical solid brick masonry for existing buildings in Germany. Light conducting elements (LCEs) inclined at 19 ° were incorporated in SATIS, which equals the average solar noon angle in southern Germany during winter. The entire wall construction was experimentally investigated in a differential climatic chamber test bench at four different irradiation angles according to a dynamic test procedure. In addition, a conventional wall construction (CWC) has been measured. At SATIS’ design angle of 19 °, the SATIS wall construction shows a solar gain (SG) of 394.5 Wh/m², while the SG of the CWC amounts to only 25.4 Wh/m². The validated transient model of the SATIS wall construction showed that, at the end of the irradiation period of the dynamic test procedure (8 h), the solar heat penetrates to a depth of 253 mm and 111 mm inside the 385 mm thick brick wall masonry at the irradiation angles of 19 ° and 50 °, respectively. During the same time, the stored solar energy at 50 ° amounts to only 24.4 % of that stored at 19 °.
Due to the complexity and the number of factors involved in factory layout planning, computers were identified as an efficient tool to support the process. However, so far no method for computer-aided layout planning has gained wide acceptance in practical application. One reason for this is that in present approaches either the user or the computer designs the layout, neglecting either the qualitative or the quantitative goals. To bridge this gap, this article introduces a concept for human-computer-integration based on evaluative feedback and inverse reinforcement learning. A key element of the concept is the interactive planning process in which user and computer alternately design and improve the layout until a satisfactory layout is found. The user evaluates the layouts according to qualitative criteria, adjusts them intuitively and specifies objectives and restrictions in an explorative way. The computer on the other hand – in form of a reinforcement algorithm – generates possible layouts and incorporates the user’s feedback into its policy. This synergy is expected to generate better results than an expert or an algorithm alone could. Furthermore, in the context of learning factories, it encourages critical thinking and allows students to develop a deeper understanding of the factors that contribute to efficient manufacturing processes. Both an architecture for the implementation is proposed and the requirements for the user interface are specified.
Produkt- bzw. Maschinengeräusche mit deutlich hörbaren tonalen Komponenten werden häufig als lästig empfunden. Wenn zusätzlich eine Interaktion mehrerer tonaler Komponenten in Geräuschen stattfindet, was in realen Szenarien beispielsweise durch die Überlagerung tonaler Komponenten durch verschiedene Aggregate, wie Motoren und Getrieben, stattfindet, dann können Geräusche unterschiedlich tonal, aber auch unterschiedlich konsonant und dissonant wahrgenommen werden. Vorangehende Hörexperimente haben gezeigt, dass die Dissonanz bei ähnlicher Tonhaltigkeit der Geräusche einen großen Einfluss auf die Präferenzurteile hat. Des Weiteren konnte bereits ein grundlegendes Empfindungsmodell für die ”Dissonanz” sowie ein Präferenz-Prädiktor entwickelt werden, die die Subjektivdaten in hoher Güte vorhersagen konnten. In den hier vorgestellten Versuchen wurde das Zusammenspiel zwischen der empfundenen Tonhaltigkeit und der sich aus mehreren Tonkomponenten ergebenden Dissonanz auf die Präferenzurteile untersucht. In der Analyse wird aufgezeigt, auf welche Weise und in welchem Umfang die wahrgenommene Ausgeprägtheit der Tonhaltigkeit durch Interaktion mehrerer Tonkomponenten die allgemeine Geräuschqualität beeinflusst. Da verschiedene Grade der Dissonanz nur durch die gleichzeitige Anwesenheit tonaler Komponenten entstehen können, ist das Zusammenspiel beider Größen bei der Bildung eines Präferenzurteils von einer speziellen Natur. Dies wird sowohl bei der Modellierung der Interaktion beider Größen als auch im Vorhersagemodell der Dissonanz berücksichtigt.
It is generally known that project-based learning is a very important part of engineering education to connect theoretical knowledge with practical work. Students learn to apply their knowledge to real-world challenges as it is the case in their later professional life. If students are not used to project work or the scientific topic is new and relatively complex, they may be overwhelmed. The consequence is that students achieve poor results, are frustrated, and therefore learning success is low. Semi-structured projects are introduced that combine the advantages of structured experiments with projects. The project work is structured into several parts with detailed descriptions of the tasks. In the end, students get similar results to doing a free project, but the success rate is higher due to higher guidance. Therefore, these semi-structured projects are seen to be an appropriate method to guide students to learn how to do project work. The feedback from most students is very positive. Some students with no previous lab experience complained about the project work and wished for more guidance to become familiar with lab work. In sum, the student feedback is encouraging to develop semi-structured projects further.
In the treatment of hand injuries in the context of orthopedic care, movable hand orthoses are used in many cases. Early motion therapy is in most cases advantageous for adequate, rapid, and successful long-term healing of the hand. Conventional mobile hand orthoses can only be used for movement therapy to a limited extent since they represent the wrist as a simple rotating joint and neglect the complexity of the movement possibilities of the hand. In this paper, a novel concept for movable hand orthoses based on prestressed compliant structures is presented. The advantage with this concept is that it replicates the multiaxial motion capabilities without the need for conventional joints. Besides the derivation and description of the concept, a first three-dimensional CAD design is shown. Additionally, the next planned steps in the development of such a novel dynamic hand orthosis are described.
In the treatment of hand injuries in the context of orthopedic care, movable wrist hand orthoses are used in numerous instances. Early motion therapy is in most cases advantageous for adequate, rapid and successful long-term healing of the hand. Conventional dynamic wrist hand orthoses can only be used for movement therapy to a limited extent since they represent the wrist as a simple rotating joint and neglect the complexity of the hand movement possibilities. In this paper, a preliminary concept for dynamic wrist hand orthoses based on prestressed compliant structures is presented. The distinctive feature of this concept lies in the enabling of multiaxial motion capabilities of the human hand without applying conventional joints. According to the concept the wrist region is surrounded by a prestressed compliant structure. Besides the derivation and description of the concept, a first three-dimensional computer-aided design is shown. Additionally, the necessary steps in the development of such a novel dynamic wrist orthosis are discussed.
Surgical Smoke is generated during the cauterization of tissue with high-frequency (HF) devices and consists of 95% water vapor and 5% cellular debris. When the coagulation tweezers, which are supplied with HF voltage by the HF device, touch tissue, the electric circuit is closed, and smoke is generated by the heat. In-vivo investigations are performed during tracheotomies where surgical smoke is produced during coagulation of tissue. Furthermore, in-vitro parametric studies to investigate the particle number and size distribution and the spatial distribution of surgical smoke with laser light sheet technique are conducted. With higher power of the HF device, the particles generated are larger in size and the total number of particles generated is also higher. Adding artificial saliva to the tissue shows even higher particle counts. The study by laser light sheet also confirms this. The resulting characteristic size distribution, which may include viruses and bacterial components, confirms considering the risk arising from surgical smoke. Furthermore, the experiments will provide the database for further numerical investigations.
High Spatial Resolution Tomo-PIV of the Trachea Focussing on the Physiological Breathing Cycle
(2023)
Investigations of complex patient-specific flow in the nasopharynx requires high resolution numerical calculations validated by reliable experiments. When building the validation base and the benchmark of computational fluid dynamics, an experimental setup of the nasal airways was developed. The applied optical measurement technique of tomo-PIV supplies information on the governing flow field in three dimensions.
This paper presents tomo-PIV measurements of the highly complex patient-specific geometry of the human trachea. A computertomographic scan of a person’s head builds the basis of the experimental silicone model of the nasal airways. An optimised approach for precise refractive index matching avoids optical distortions even in highly complex non-free-of-sight 3D geometries. A linear-motor-driven pump generates breathing scenarios, based on measured breathing cycles. Adjusting of the CCD cameras‘ double-frame-rate PIV-Δt enables the detailed analysis of flow structures during different cycle phases. Merging regions of interest enables high spatial resolution acquisition of the flow field.
In the context of production and factory planning, the expansion of the factory must already be taken into account during initial planning. This results in an increase in planning complexity, as the involved planners have to know the expansion stages of the factory in the different time periods and have to evaluate concept modifications across all time periods. This paper presents an idea for a planning tool, which takes expansion stages into consideration. The data model contains all relevant information to generate a simulation model of the factory in an almost automated way. The aim is to enable factory planners to quickly investigate concept changes with the help of simulation, for example, to identify bottlenecks.
To evaluate the performance of a ropeway in an urban environment, simulations of the dynamic passenger transport characteristics are required. Therefore, a modular simulation model for urban ropeway networks was developed, which can be flexibly adapted to any city and passenger volume. This simulation model was used to analyze the ropeway network concept of the German city Regensburg and to determine the expected operating conditions. The passenger volume, different types of persons, their occurrence probability and their destination distribution is depending on the location and daytime and can be defined for each individual station. In an initial analysis, the number of passengers currently occurring in bus traffic were projected onto the ropeway network. To enable climate-friendly and efficient operation, different strategies were developed to significantly reduce the number of gondolas. The best fitting strategies resulted in significant cost savings while passenger comfort, as represented by queue time, remained unchanged.
Simulation Based Approach for Reconfiguration and Ramp up Scenario Analysis in Factory Planning
(2022)
Structural changes in production entail a potential economic risk for manufacturing companies. It is necessary to identify a suitable strategy for the reconfiguration process and to continue to meet the demand during the change in the factory structure and ramp-up phase. A simulation offers the possibility to analyze different ramp-up scenarios for the factory structure and to select a suitable concept for the reconfiguration process. A discrete event simulation approach is presented that can be used to evaluate variants of structural changes and serves as a basis for deciding on a reconfiguration strategy. This approach is demonstrated using a specific production step of a plant producing hydrogen electrolyzers, the results and generalized conclusions are discussed.
BACKGROUND:
Shear-induced conformational changes of von Willebrand factor (vWF) may be responsible for coagulation disorder and clot formation inside membrane oxygenators (MOs) during extracorporeal membrane oxygenation (ECMO) therapy.
OBJECTIVE:
The aim was to identify vWF structures inside clinically used MOs and employ computational fluid dynamics to verify the corresponding flow conditions.
METHODS:
Samples from gas exchange membranes (GEM) from MOs were analysed for accumulations of vWF and P-selectin-positive platelets using immunofluorescence techniques. Streamlines and shear rates of the flow around GEMs were computed using a laminar steady Reynolds-Averaged-Navier-Stokes approach.
RESULTS:
Most samples were colonized with equally distributed leukocytes, integrated in thin cobweb-like vWF-structures. Only 25 % of the samples showed extended accumulations of vWF. Computed streamlines showed considerable cross flow between interconnected neighbouring channels. Stagnation points were non-symmetric and contact faces were washed around closely. The occurring maximum shear rates ranged from 2,500 to 3,000 1/s.
CONCLUSIONS:
If pronounced vWF structures are present, shape and extent match the flow computations well. Computed shear rates bear a critical degree of uncertainty due to the improper viscosity model. If flow conditions inside the MO were sufficient to affect vWF, a more consistent distribution of vWF across the samples should be present.
Internal transport systems are an essential part of intralogistics in production and distribution facilities. These are characterized by a variety of technologies as well as a multitude of interactions with other processes, such as warehouse, picking, and production processes. Therefore, resource planning and control of these systems is complex, especially for discontinuous conveyors. In this task, users can be supported by Digital Twins for decision-making, as they are suitable for investigating both future system states and possible actions. However, relevant use cases that are generally applicable across sectors as well as a generic system architecture for Digital Twins for resource planning and process control of in-plant transport systems have not yet been sufficiently investigated. In this paper, use cases are presented, relevant functions defined, and, finally, a generic functional and a logical reference architecture described. This is conducted with the design science in information systems research method together with a Systems Engineering approach. The use cases are determined at industrial partners of the research project TwInTraSys, which explores Digital Twins for the planning and control of internal transport systems. They are generalized and, thus, also applicable to other production and distribution facilities in different sectors. Further, the reference architecture can provide a basis for the successful implementation of the Digital Twin.
This paper addresses the problem of properly placing a given task in the manipulator workspace by a heuristic and numeric approach. Thus, the task is placed relatively to the manipulator for each element of the discretized workspace and the required joint torques are determined. The results are are by a torque-based optimization criterion. The modularity of this approach ensures general applicability on various systems and tasks while the high computational effort is treated by GPU parallelization. The method is presented for a given 6DOF manipulator and a highly dynamic trajectory. The resulting interactive map of the manipulator workspace gives an overview of the task dependent dynamic performance, detailed evaluation of certain solutions will show the dexterity of the proposed approach.
19F Gas Flow Measurement of C3F7H During Constant Flow and High Frequency Oscillatory Ventilation
(2013)
The aim of the current study is the development of MRI methods that enable the investigation of gas flow mechanisms during high frequency oscillatory ventilation. This work includes flow measurements during three constant flows (19.9, 30.6 and 41.4 L min-1) and the comparison to direct numerical simulations (DNS) using a second-order-acurate finite-volume method and to data measured with a volume flow meter. 19F-MRI, DNS and flow meter data are in good agreement. Flow measurements during HFOV of 4 Hz were successfully performed and velocity profiles could be recorded at different phases of the ventilation cycle.
Manual tasks in industrial production are often monotonous, leading to a decrease in concentration and motivation of the worker and thus to deficiencies in the products. With quality as well as performance requirements getting more and more stringent, workers need additional support by their work environment. We developed a novel approach providing worker assistance and inline quality assurance for manual workplaces. The prototypical system Smart Workbench (SWoB) uses a multimodal sensor interface consisting of a 3D depth sensor in combination with a 2D camera to control quality aspects of the product and track the work progress. The bidirectional flow of information is handled via an image processing driven gestural interface and the displaying of advice directly on the work surface. In this paper the developed system is introduced and the current state of evaluating its industrial usage with a manual quality control and packaging task reported.
Heutzutage werden Strukturen häufig aufwendig konstruiert und nachträglich mithilfe von numerischen Verfahren optimiert. Dennoch kommt es zu erheblichen Schäden infolge von Ermüdungsbrüchen bei wechselnd beanspruchten Bauteilen. Ein Großteil dieser Schäden hat den Ursprung in den im Inneren herrschenden Spannungszuständen, den sogenannten Eigenspannungen.
Diese Eigenspannungen heben sich innerhalb des Bauteils auf und führen zu keiner Formabweichung des Bauteils, weswegen diese Spannungen in Form und Lage nur schwer detektierbar sind und sich häufig negativ auf die Betriebsfestigkeit von Strukturen auswirken.
Mithilfe neuartiger numerischer Methoden können thermomechanische Simulationen angefertigt und Verformungen, sowie Spannungszustände abgeleitet werden. Durch diese Optionen ergeben sich neue Anwendungen, die das Potenzial von Fertigungsverfahren in Hinblick auf die Ausnutzung spezieller Eigenschaften neu eröffnen. Durch die geschickte Anwendung und Vernetzung der Simulation mit der Fertigung können Eigenspannungen gezielt in Lage und Richtung schon während der Produktion des Bauteils eingebracht werden. Im theoretischen Vergleich zu konventionell gefertigten Bauteilen entstehen Strukturen, die hinsichtlich ihrer Bauteillebensdauer optimiert sind.
Der vorliegende Artikel skizziert die neu entwickelte Prozesskette für detailgenaue Rekonstruktion von Geometrien anhand medizinischer Bilddaten sowie die Herstellung von transparenten Modellen für experimentelle Untersuchungen mit bildgebenden Strömungsmessverfahren. Die Geometriedaten und Modelle werden für systematische Untersuchungen der komplexen Transportvorgänge in den Atemwegen bei künstlicher Beatmung mittels Hochfrequenzoszillationsventilation (HFOV) verwendet.
Early meta-level: deeper understanding of connectivity-states and consequences for state definition
(2015)
Computational Fluid Dynamics (CFD) and experimental investigations on a generic model of the trachea have been carried out focusing on the impact of an endotracheal tube (ETT) on the resulting flow regime. It could be shown that detailed modelling of the airway management devices is essential for proper flow prediction, but secondary details as Murphy Eyes can be neglected. Models with bending and connector promote the formation of stronger secondary flows and disturbances which persist for a longer time.
The high frequency oscillation artificial respiration technique is often the last hope for patients to survive highly damaged lung tissue. The mortality can significantly be reduced. In
comparison to conventional artificial respiration the applied volume flow rate and pressure is significantly lowered in order to avoid further damaging of lung tissue and remaining intact alveolae. However, the physical mechanism of transport of oxygen to the aeriols under high frequency oscillation is not well understood. In the upper part of the lung convection is dominant, in contrast, the gas exchange in the lower parts of the lung is mainly driven by diffusion. It is not clear how associated gradients of concentrations of different molecular species are then achieved. Highly oscillating fluid flows has been a long research topic in fluid dynamics. It is known that oscillating pressure fluctuations are able to induce secondary flows, in particular, in curved ducts and pipes. The question is, whether the trachea enforces the generation of secondary flow by its kidney like cross section geometry. The influence of molecular species of different densities onto the formation of secondary flows and the convectional transport within the trachea is investigated. In order to clarify the physical mechanisms behind flow simulations have been conducted by using state of the art CFD techniques.
Aerospace and automotive industries employ three main techniques to set up joints between metal and fibre reinforced plastics parts (FRP); adhesive bonding, mechanical fastening with rives/bolts and a hybrid combination. A new joint technique has been developed to combine the two advantageous mechanisms form-closure and adhesion in a fibre-friendly way. Prior is established through metal structures (pins) which are perpendicularly welded onto metal surfaces with an arc-welding-process. They intrude into the FRP during lay-up and therefore set up a first connection. The composite-matrix is responsible for latter adhesive bonding and final form closure. Finite-element-analyses of cylindrically shaped joints are carried out to get detailed knowledge of the influence of parameters like pin-number, pin-position, pin-height, pin-form sleeve-geometry, and stiffness behaviour. Long calculation times of 3D-models lead to the introduction of a corresponding 2D-axisymmetric-model which is used to run parameter-studies within a reasonable time. For this novel technique the combination of fibre-friendly form closure and adhesive bonding of interface plays a major role. A well selected amount of vertical reinforcements, their placement and geometrical dimensions will lead to a stiffer joint. Goal is to minimize fibre-deletion and overlap length to improve load-transfer and joint-strength, to reduce weight in high-strength-applications as well as the avoidance of safety rivets.
Entwicklung eines Experimentalsystems zur Validierung adaptiver Regelungen mit einem OEM-Steuergerät
(2014)
Im Rahmen des Kooperationsprojektes "ACES" (Integrated Adaption of Linear Controllers for Embedded Systems) ist ein Prüfstand zur Validierung adaptiver Regelungen entwickelt und aufgebaut worden, der das dynamische Verhalten eines Kfz-Antriebstrangs aufweist. Ziel ist es, verschiedene Adaptionsverfahren auf ihre Einsetzbarkeit in OEM-Steuergeräten, die im Automotive-Bereich auf breiter Basis verwendet werden, kostengünstig testen zu können. Das Problem der aktiven Schwingungsdämpfung in Kfz-Antriebssträngen mit unbekannten und veränderlichen mechanischen Parametern stellt eine Pilotanwendung dar. Ein leicht anpassbarer mechanischer Prüfstand dient hierbei als vereinfachtes Modell eines Antriebstrangs. Dieser ist Bestandteil eitles Experimentalsystems mit einer informationstechnischen Architektur, die einen Betrieb engebetteter Regelungssysteme auf verschiedenen Plattformen gestattet. Das flexible mechanische und informationstechnische Design des Experimentalsystems gestattet die Variation von Parametern der zu regelnden Applikation durch leicht austauschbare mechanische Komponenten und gezielte Einbringung von Störgrößen. Zudem kann die Berechnung der Regelungsarchitektur auf einem Industrie-PC oder einem Steuergerät erfolgen. Weitere Vorteile des entwickelten Experimentalsystems sind die Berücksichtigung von Effekten, die aus dem Verhalten realer Sensoren und der CAN-basierten Signalübertragung entstehen. Insbesondere der Einfluss von Wortbreite und Latenz übertragener Signale auf die Adaption von Regelungen kann mit Hilfe des vorgestellten Experimentalsystems eingehend untersucht werden.
The cyclic deformation behavior of deep rolled and polished aluminium wrought alloy AlMg4,5Mn in the temperature range 20-300°C has been investigated. Results of quasistatic tension and compression tests of untreated specimens in the temperature range 20-300°C are presented. To characterize the fatigue behavior for stress-controlled tests as a function of test temperature, s-n curves, cyclic deformations curves and mean strains as a function of number of cycles are given. The residual stress- and work hardening states near the surface of deep rolled aluminium alloy AlMg4.5Mn before and after fatigue tests were investigated by X-ray diffraction methods. The investigated AlMn4.5Mn aluminium alloy shows cyclic hardening until fracture at all stress amplitudes in stress-controlled fatigue tests at 25-150°C. With increasing temperature the deformation behavior shifts from cyclic hardening to cyclic softening. Below a certain stress amplitude at a given temperature deep rolling led to a reduction of the plastic strain amplitude as compared to the untreated state through cyclically stable near-surface work hardening as indicated by stable FWHM-values. This reduction in plastic strain amplitude is associated with enhanced fatigue lives. The effectiveness of deep rolling is governed by the cyclic and thermal stability of near-surface work hardening rather than macroscopic compressive residual stresses. Since near-surface work hardening is known to retard crack initiation, deep rolling is also effective in temperature- and stress ranges where macroscopic compressive residual stresses have relaxed almost completely, but where near-surface work hardening prevails. Above certain stress amplitudes and temperatures, deep rolling has no beneficial effect on the fatigue behavior of AlMg4.5Mn. This is a consequence of instable near-surface microstructures, especially instable near-surface work hardening.
This paper briefly presents the challenges for order control and release of multi-zone order picking systems. On the one hand, the order control must ensure that all orders are processed on time, and on the other hand, the space requirements (buffer) and the utilisation of the zones must be considered.
Within the framework of a case study, different strategies for order release were developed. The paper shortly describes the ideas of the strategies and presents results of a case-based simulative evaluation of the strategies. The findings of the simulation study are the basis for the development of a digital twin for the operational control of multi-zone picking systems.
Bei Ottomotoren mit Direkteinspritzung besteht beim Kaltstart, den Warmlaufphasen und auch durch den Einfluss anderer Parameter wie z. B. des Einspritzzeitpunkts oder des Einspritzdrucks die Problematik, dass Kraftstoff an die Zylinderlaufbahn aufgetragen wird und sich mit dem Motoröl vermischen kann. Eine Verstärkung dieses Kraftstoffauftrags ist unter anderem der Verschiebung der Motorbetriebspunkte zu höheren Mitteldrücken und damit einem Wirkungsgrad optimaleren Betrieb geschuldet. Eine Veränderung der physikalischen und chemischen Eigenschaften des Motoröls durch die Verdünnung mit Kraftstoff ist die Folge. Durch die Verringerung der Viskosität des Motoröls kann es zu einer verminderten Schmierwirkung des Öls kommen, die im schlimmsten Fall zur Schädigung des Motors führt. Existierende Offline-Analysemethoden die zeitintensive Laboranalysen nach sich ziehen, als auch Online-Messverfahren die nicht den technischen Anforderungen hinsichtlich Genauigkeit und einer kurzen Messdauer entsprechen, stellen aktuell die einzigen Messmethoden zur Bestimmung der Schmierölverdünnung dar. Durch neue Entwicklungstrends bei Ottomotoren ist es jedoch unbedingt notwendig, die Mechanismen des Kraftstoffein- und -austrags in das und aus dem Motoröl genauer zu untersuchen. Mit der an der OTH Regensburg neu entwickelten Messtechnik wurde eine Vorgehensweise erarbeitet, mit der die zeitlichen Verläufe des Kraftstoffein- und -austragsverhaltens bei Ottomotoren quantitativ in kurzer Zeit bestimmt und optimiert werden können.
Especially at cold start and the warm-up operation GDI engines have an issue with oil dilution. Parameters such as injection timing and injection pressure impact the entry of fuel in the engine oil as well. With the adjustment of engine operating points to higher mean effective pressures resulting in downsizing concepts also an additional increase of fuel entry occurs. Fuel gets into the oil pan and is mixed with the engine oil so that the physical and chemical properties of the engine oil are changed. With the reduction of engine oil viscosity due to fuel entry a reduced lubricating effect can be caused. In the worst case damage to the engine occurs, To determine oil dilution online and offline measurement methods exist. A rather long analysis time in the laboratory is a disadvantage of the offline methods. Online methods are not correlating with technical requirements in terms of accuracy and a short measurement time. New trends in the development of gasoline engines require investigations of fuel in oil sorption and desorption processes. A new measurement technique which is developed at the OTH Regensburg enables to determine quantitative fuel in oil sorption and desorption processes. With this technique a procedure was generated to measure the oil dilution at gasoline engines and optimize them in a short time.
Planning a new logistics center is a quite difficult job. Depending on the requirements there are a great number of possible design versions. The planner has to consider not only the present but also the future requirements. Up to now, the planner decides on the basis of experience which system will perform the requested services best. This paper illustrates the redesign of a new order-picking system in industry supported by a simulation tool of our institute designed especially for the rough planning. With the described project the road capability of the applied simulation concept is underlined. Several versions based on the requirements were investigated and evaluated. Key figures are calculated and a recommendation depending on performance and arising expenses is given.
Production supermarkets are a system to ensure high-frequency, demand-oriented, in-plant production supply with low lot sizes. The paper presents methods to design and dimension these systems using qualitative design criteria and quantitative approaches based on well-known analytical methods for conventional order picking systems. The methods help to design layout, provision type and path strategy and to derive space consumption and the number of supermarket employees required to fulfill a defined demand.
Qualification and modification of new polymer powders for laser beam melting using Ulbricht spheres
(2014)
The restricted amount of available materials for Laser Beam Melting (LBM) of polymers is one of the main limitations for expanding the technology. Current qualification methods deal with problems like inadequate powder flowability or high part porosities among others but do not offer a detailed analysis of the important beam-matter-interaction between powder particles and electro-magnetic laser radiation. In this paper, polyethylene powder is qualified for the LBM process and specifically analyzed regarding the optical material properties of the powder for a wavelength of 10.6 μm. By admixing graphite as absorption intensifier the change of the optical material properties and the thereby connected processing parameters are analyzed. Furthermore an explanation approach is given to explain the relation between different transmittances of different powder particles and the optical material properties of the polymer powders.
By simultaneous laser beam melting (SLBM), different polymer powders can be processed to multi-material parts, which offers the potential to enlarge the field of application for conventional LBM. In a SLBM process, a powder bed consisting of different polymers and therefore with different melting and crystallization temperatures is deposited. Besides the use of infrared emitters for preheating the lower melting polymer, a CO2 laser distributes the necessary preheating temperature of the higher melting polymer. In the last step, a thulium fibre laser distributes the energy necessary for melting the two preheated powders simultaneously. In order to analyze the temperature gradients of the process on the powder surface and in deeper layers, a high-resolution thermal imaging system and thermocouples are used.
Die Energieeinbringung in Form von elektromagnetischer Strahlung in das Pulverbett beim selektiven Laserstrahlschmelzprozess von Kunststoffen wird maßgeblich durch das Absorptionsverhalten der Pulverwerkstoffe bestimmt. Aufgrund von Vielfachreflexionen an den einzelnen Pulverpartikeln in den Poren weisen Pulverwerkstoffe im Vergleich zu makroskopischen Festkörpern andere Absorptionseigenschaften auf. Im vorliegenden Beitrag wird daher ein geeigneter Messaufbau zur Bestimmung der optischen Materialeigenschaften von verschiedenen Pulverwerkstoffen vorgestellt. Mittels eines Ulbricht-Kugel-Messaufbaus wird der Reflexions-, der Transmissions- und der Absorptionsgrad von pulverförmigen Werkstoffen bei einer Wellenlänge von 10,6 µm eines CO2-Lasers und unterschiedlichen Schichtstärken ermittelt. Neben den Werkstoffen Polyamid 12 und Polyethylen im reinen Zustand werden Mischungen mit Additiven, wie beispielsweise Graphit, analysiert und verglichen. Durch die Beimischungen kann eine für den Schmelzprozess zu geringe Absorption des reinen Kunststoffes wie im Fall von Polyethylen-Pulver bei einer Wellenlänge von 10,6 µm gezielt erhöht werden, wodurch die Entwicklung neuer Pulverwerkstoffe erleichtert wird.
By using Additive Manufacturing technologies, like Laser Beam Melting (LBM) of polymers, parts can be realized within single days and necessary modifications can be quickly adapted. With increasing complexity, products are often made out of different polymer materials and the need for multi-material parts is an increasing industry requirement, which cannot be fulfilled by the single material parts realizable by LBM. Therefore, Simultaneous Laser Beam Melting (SLBM) as a new Additive Manufacturing technology offers the possibility to build parts consisting of different polymer materials. The realizable parts combine different material properties, like differing stiffness or chemical resistances, within a single part. Up to now, different materials are deposited next to each other on the building platform, thus the boundary surface between the different polymers is orientated perpendicular to the building direction. For this paper, the polymer powders are alternated in building direction. Thus, the boundary surface is orientated horizontally and is larger, both influencing the boundary surface and resulting part properties, which are analyzed by a high-resolution thermal imaging system and by cross sections.
In this paper, the use of electrostatic polymer powder transfer methods for the preparation of multi-material layers is discussed with respect to the application in Simultaneous Laser Beam Melting (SLBM). Therefore, the basic principles of the single process steps as well as the challenges in combination with SLBM are considered verifying the critical process steps. On that base, process concepts are developed which might enable the fabrication of high quality multi-material parts in the future. Moreover, since the polymer powders typically used with Laser Beam Melting differ strongly from common toners for e. g. electrophotographic printing, an experimental setup was built to study the powder transfer with an electrically chargeable transfer plate using polyamide 12 powder. The results of this study show that transfer of powders usable for Laser Beam Melting can be achieved, but depends on the electric field strength which is a function of the gap between transfer and substrate plate and the intermediate electric potential.
In former works, the optical material properties of different polymer powders used for Laser Beam Melting (LBM) at room temperature have been analyzed. With a measurement setup using two integration spheres, it was shown that the optical material properties of polymer powders differ significantly due to multiple reflections within the powder compared to solid bodies of the same material. Additionally, the absorption behavior of the single particles shows an important influence on the overall optical material properties, especially the reflectance of the powder bed. Now the setup is modified to allow measurements at higher temperatures. Because crystalline areas of semi-crystalline thermoplastics are mainly responsible for the absorption of the laser radiation, the influence of the temperature increase on the overall optical material properties is analyzed. As material, conventional polyamide 12 and polypropylene as new polymer powder material, is used. By comparing results at room temperature and at higher temperatures towards the melting point, the temperature-dependent optical material properties and their influence on the beam-matter interaction during the process are discussed. It is shown that the phase transition during melting leads to significant changes of the optical material properties of the analyzed powders.
In this report, the delivery of polyamide 12 (PA 12) powder and powder layer preparation by vibrating steel nozzles is investigated and discussed with respect to its application for laser beam melting. Therefore, a setup was realized which includes a steel nozzle attached to a piezo actor as well as a positioning system. In order t o investigate the mass flow characteristics in dependency on the applied vibration state, a weighing cell is used enabling time-resolved mass flow measurements. Moreover, single-layer patterns consisting of colored and uncolored polyamide 12 were created and characterized regarding surface homogeneity and selectivity before as well as after the melting of the powder layers by a hot plate.
By Laser Beam Melting of polymers (LBM), parts with almost any geometry can be built directly out of CAD files without the need for additional tools. Thus, prototypes or parts in small series production can be generated within short times. Up to now, no multi-material parts have been built by LBM, which is a major limitation of the technology. To realize multi-material parts, new mechanisms for depositing different polymer powders as well as a new irradiation strategy are needed, by which polymers with different melting temperatures can be warmed to their specific preheating temperatures and be molten simultaneously. This is achieved by simultaneous laser beam melting (SLBM). In the process, two different materials are deposited next to each other and preheated a few degrees below their melting temperatures by infrared emitters and laser radiation (λ = 10.60 µm), before in the last step the two preheated powders are molten simultaneously by an additional laser (λ = 1.94 µm). So far, multi-material tensile bars have been realized and analyzed regarding their boundary zone between both materials. The experiments showed that the temperature gradients in the boundary zone and along the building direction seem to be of great importance for the process stability and the resulting part properties. Therefore, a detailed analysis of the occurring temperature gradients during the process is needed to identify adequate process adjustments regarding the temperature controlling. To analyze the temperature gradients, thermocouples positioned inside the powder bed are used. By varying the temperature of the building platform, the influence of different temperature gradients on the resulting part properties is shown.
The generation of multi-material components using Laser beam melting (LBM) is a challenge which requires the invention of new coating devices for the preparation of arbitrary powder patterns. One solution is the usage of vibration-controlled nozzles for selective deposition of polymer powders. Powder flow can be initiated by vibration even when using powders with low flowability. In this report, the selective deposition of polymer powder by vibrating nozzles is investigated with respect to their application in LBM machines. Therefore, a steel nozzle attached to a piezo actor is applied, whereas the nozzle itself features internal channels which allow the precise control of the powder temperature using heat transfer oil. The setup is used to study the influence of temperature on the powder mass flow. The results show that, next to the vibration mode, the temperature strongly influences the powder mass flow which is done by affecting the moisture and thus the particle-particle adhesion forces. This shows that a precise control of the powder temperature inside the nozzle is required in order to achieve a constant mass flow and thus a successful application of vibrating nozzles inside LBM machines.
Im Rahmen dieses Beitrags wird das Schmelzeemulgieren als Verfahren zur Herstel-lung von Polymermikropartikeln vorgestellt. In diesem Prozess wird zunächst ein Polymergranulat in einer kontinuierlichen Phase in Gegenwart geeigneter Additive in einem Rührbehälter aufgeschmolzen, die Rohemulsion in einer Rotor-Stator-Einheit feinemulgiert und anschließend zu einer Suspension abgekühlt. Der Einfluss von Prozessparametern und Systemzusam-mensetzung auf das Emulgierergebnis wird diskutiert und die Anwendbarkeit des Verfahrens für polymere Mikropartikeln anhand von Polypropylen (PP) und Polyethylen (PE-HD) dargestellt. Die erhaltenen Suspensionen werden zur Überführung in Pulverform sprühgetrocknet und die Fließeigenschaften des Pulvers analysiert. Durch trockenes Beschichten mit pyrogener Kieselsäure kann die Fließfähigkeit der erhaltenen Partikeln weiter verbessert werden. Das Verfahren bietet somit einen neuen Zugang zur Herstellung neuer Ausgangsmaterialien für die Additive Fertigung.
Neue Prozessstrategien zur Herstellung von Multi- Material-Bauteilen und Gradientenwerkstoffen
(2012)
Das additive Fertigungsverfahren, dem gemeinhin die größten Potentiale zugesprochen werden, ist das Laserstrahlschmelzen im Pulverbett von Kunststoffen (LSS-K) und von Metallen (LSS-M). Wie bei anderen Techniken der additiven Fertigung werden Bauteile direkt aus CAD-Dateien ohne zusätzliche Werkzeuge bei enormer konstruktiver Freiheit gefertigt. Die resultierenden Werkstoffeigenschaften sind vergleichbar mit konventionelleren Prozessrouten wie etwa dem Spritzgießen thermoplastischer Polymere beziehungsweise auf der Seite der Metalle dem Schmieden oder Gießen. Derzeit wird der Einsatz des LSS zur Fertigung von Endprodukten in kleinen Stückzahlen erschwert von nicht ausreichender Prozessstabilität und, insbesondere bei Kunststoffen, von der eingeschränkten Werkstoffauswahl. Bisher werden für beide Werkstoffklassen Bauteile aus jeweils einem einzigen Ausgangsmaterial hergestellt. Näherungsweise erzeugt LSS also einheitliche Materialeigenschaften über das gesamte Bauteil hinweg. Ein Ansatz, der in den Teilprojekten A5 und B6 des Sonderforschungsbereichs 814 verfolgt wird, ist die Realisierung von Multi-Material-Bauteilen mittels LSS-K beziehungsweise LSS-M.
In the paper first results regarding the realisation of gradient and multi-material parts manufactured by Laser Beam Melting in powder bed of metals and polymers are published. Gradient properties of additively manufactured metal parts can be achieved by varying the composition of alloying components in the powder and adapting process strategies. As an alternative to atomizing pre-alloyed materials, mixtures of different powders are investigated. For realizing multi-material-parts from polymers, at first relevant material properties concerning compatibility have to be analysed. Therefore the paper shows the main requirements for compatibility between different materials and also first results regarding the compatibility of polymer powders and possible combinations for the manufacturing of multi-material components by laser beam melting of polymers.
Simultaneous laser beam melting (SLBM) allows the direct realization of multi-material components consisting of different polymer materials by a single Additive Manufacturing (AM) process. To achieve a high compound strength between different materials by adhesive bonding, a common boundary zone based on diffusion of the macromolecules is necessary and thus, both materials needs to be compatible regarding their specific adhesion compatibility. However, by SLBM also incompatible polymers can be processed to multi-material parts. If two incompatible polymers are processed, a positive locking between the different materials is necessary to achieve a connection between the materials. The positive locking results of a random mixture process of the different powder materials during the powder deposition process by a two chamber recoater system, which leads to the forming of undercuts of one material in the other during the melting and recrystallization. In this paper, thermoplastic elastomer (TPE) and polypropylene (PP) powders, which are incompatible, are processed to multi-material specimens. By qualifying basic material properties, their influence on the process and especially on the forming of undercuts in the boundary zone is analyzed. To also allow the analysis of the influence of both material and process parameters on the resulting part properties, tensile test specimens are built and their tensile strength is determined. Additionally, cross sections of the boundary zone are prepared and analyzed by microscope images.
Simultaneous Laser Beam Melting of polymers (SLBM) allows the generation of multi-material components,consisting of different thermoplastic polymers, within one additive building process. Besides the common advantagesof conventional Laser Beam Melting (LBM), multi-material components built by SLBM can fulfill different productrequirements like different chemical resistances or haptic material properties within a single part. To achieve suchparts, different powder materials are deposited next to each other and preheated a few degrees below their meltingtemperatures by infrared emitters and laser radiation (λ = 10.60 μm), before in the last step the preheated powdersare molten simultaneously by an additional laser source (λ = 1.94 μm). In this paper, different polymer powders likepolypropylene (PP) and polyamide 12 (PA12) are used for the generation of multi-material specimens. By varyingdifferent building parameters according to a specified design of experiments, their influence on the part properties isanalyzed. Important building parameters are the intensity and the irradiation time of the laser beam used for meltingthe preheated powders. Besides using tensile tests to determine the tensile strength and the elongation at break, theaverage part height in dependence of the energy input is analyzed. The overall aim is to specify the correlationbetween different building parameters regarding the energy deposition on the resulting part properties.
Das Forschungsprojekt ManuCyte konzentriert sich auf die Realisierung einer Plattform für die Kultivierung menschlicher Zellen und Gewebe im industriellen Maßstab. Für die Mensch-Roboter-Kolloboration ist die Robotersteuerung technologisch diversitär und redundant ausgeführt. Skizziert und analysiert wird ein prototypisches Robotersystem zum Erhalt von sicherer Mensch-Roboter-Kollaboration. Eine normgerechte Risikobeurteilung wird anhand der vorliegenden Anwendung Schritt für Schritt aufgezeigt. Wichtige Kenngrößen zur Bestimmung des sicherheitstechnischen Leistungsgrades sicherheitsrelevanter Steuerungsfunktionen werden exemplarisch berechnet und zusammengefasst. Die Vorgehensweise der Steuerungsentwicklung und die entwickelte Steuerungsarchitektur werden aufgezeigt. Außerdem werden die Sicherheitsanforderungen exemplarisch validiert und die Ergebnisse diskutiert. Aufgezeigt werden die Entwicklungsschritte zu einer möglichen Zertifizierung.
A prototypic robot system for Human-Robot Collaboration is sketched and analyzed in the article at hand. For the present application, the risk assessment according to the relevant standards is visualized step by step. Important parameters to determine the safety performance level of safety related control functions are calculated and summarized. The procedure to develop a safe control system and the developed control architecture are shown. Furthermore, the safety requirements are validated exemplarily and the results are discussed. Possible steps to carry the system to a certification complete the present article.
Beitrag und Praesentationsmaterial eines Vortrags ueber differenzierende Kohlenwasserstoffanalytik im Dieselabgas bei verschiedenen Motorbetriebszustaenden. Mit einem neu entwickelten, hochgenauen HC-Sensor werden unverbrannte HC im Abgas untersucht. Die differenzierende Untersuchung erfolgt an einem Massenspektrometer, das mit chemischer Ionisation arbeitet. Die Molekuele Ethin, Ethen und Propen wurden gezielt betrachtet. Es zeigt sich, dass bei kalten Betriebsbedingungen diese drei Komponenten etwa die Haelfte der gesamten HC Konzentration ergeben. Ein weiterer Punkt ist die Regeneration des Dieselpartikelfilters.
Es wird dargelegt, wie das Verhalten eines Manipulators durch die Vorsteuerung von Drehmomenten und die Anwendung von kinematischen Beziehungen zu einer Punktmasse vereinfacht werden kann. Der darauf aufbauende, vorgestellte Algorithmus zur Kopplung des Operators mit dem Teleoperator ist mathematisch beschrieben und hinsichtlich der Problematik von Differentiationen in der realen Anwendung angepasst. Die vorgestellte Simulation mit zwei Testsignalen sowie die Frequenzganganalyse eines Koppelterms zeigen, dass der Algorithmus vor allem bei niedrigen Frequenzen dem Bediener ein hohes Maß an Transparenz liefert. Eine Frequenzganganalyse bei Variation der parametrierbaren Übertragungsfunktionen kann die Transparenz bei hohen Frequenzen verbessern. Nächste Schritte konzentrieren sich auf die experimentelle Evaluierung einer vorgestellten Kraftregelungsarchitektur am Assistenzroboter CARo5X. Insbesondere wird geprüft, ob die Annahme eines linearisierten und entkoppelten Systems am Experimentalaufbau hinreichend zutrifft. Nach erfolgter Inbetriebnahme der vorgestellten Kraftregelung am Robotersystem SixAx, das von der Regensburg Robotics Research Unit (RRRU) entwickelt worden ist, werden beide Roboter durch den vorgestellten Ansatz gekoppelt und final experimentell bewertet.
Regelungsfunktionen für Automotive-Anwendungen werden dahingehend entworfen, dass ein bestmögliches Regelverhalten über die gesamte Lebensdauer der Applikation erzielt werden soll. Der Einfluss unterschiedlicher Umgebungsbedingungen und Bauteilvarianten sowie eine Alterung von Komponenten führt dazu, dass beim Entwurf von Regelungen Reserven vorgehalten werden müssen. Andernfalls besteht die Gefahr, dass eine Veränderung der geregelten Strecke zu einem ungewollten Regelverhalten - bis hin zur Instabilität des geregelten Systems - führt. Im Rahmen des Forschungsprojekts ACES (Integrated Adaption of Linear Controllers for Embedded Systems) entwickeln die Kooperationspartner AVL Software & Functions GmbH, Regensburg und die OTH Regensburg gemeinsam Algorithmen zum Entwurf von adaptiven Regelungen, bei denen die Parameter eines Reglers auf Basis identifizierter Streckenparameter eingestellt werden. Vorgestellt wird ein rekursiver und durch einen variablen Gewichtungsfaktor modifizierter Algorithmus, welcher in der Lage ist, auch unter nicht optimalen Schätzbedingungen zeitvariante physikalische Parameter eines realen Antriebstrangs zweiter Ordnung in Echtzeit zu ermitteln. Mit der Implementierung des Schätzverfahrens auf einem in der Automotive Branche verwendeten Steuergerät wurde die prinzipielle Tauglichkeit des Verfahrens im Hinblick auf die Anwendbarkeit für industrienahe Problemstellungen aufgezeigt. Die weitere Vorgehensweise besteht darin, den Algorithmus dahingehend anzupassen, dass auftretende nichtlineare Effekte wie Reibung berücksichtigt werden können. Ferner sollen auch Systeme höherer Ordnung identifiziert werden. Für den Fall von linearen Strecken zweiter Ordnung ist der Algorithmus bereits in der Lage, die notwendigen Parameter zur Auslegung adaptiver Regelungen zu liefern. Die Implementierung von solchen adaptiven Regelalgorithmen auf einem Steuergerät soll im Projekt ACES ebenfalls umgesetzt werden. Die Verwendung adaptiver Regler könnte somit eine effizientere Regelung von zeitvarianten Strecken ermöglichen.
Differenzierte Kohlenwasserstoffanalytik im Dieselabgas bei verschiedenen Motorbetriebszuständen
(2014)
Die für Dieselfahrzeuge gesetzlich vorgeschriebenen Grenzwerte bezüglich der Schadstoffkomponenten Kohlenwasserstoffe und Kohlenmonoxid können nur durch den Einsatz eines Diesel-Oxidationskatalysators erfüllt werden. Um erhöhte Emissionen infolge eines geschädigten Katalysators zu vermeiden, gilt es, dieses abgasrelevante Bauteil auch während des Betriebes zu überwachen. Die zukünftigen gesetzlichen Anforderungen an die Überwachung erfordern ein Verfahren das eine zuverlässige und hochgenaue Diagnose zulässt. Deshalb entwickelt eine Forschungsgemeinschaft aus Industrieunternehmen und Hochschulen einen neuartigen Kohlenwasserstoffsensor zur hochgenauen Analyse von unverbrannten Kohlenwasserstoffen im Abgasstrang. Hierfür ist die Kohlenwasserstoffzusammensetzung des Dieselabgases bei verschiedenen Motorbetriebszuständen zu ermitteln. Zur differenzierten Untersuchung der Kohlenwasserstoffkomponenten wurde in der Arbeit ein Massenspektrometer eingesetzt, das mit chemischer Ionisation arbeitet. Anhand eines Abgasscreenings konnte eine Reihe von Kohlenwasserstoffen (Alkane, Alkene, Alkine, Alkadiene und aromatische Kohlenwasserstoffe) identifiziert werden, die typisch für das Dieselabgas stehen. Die Moleküle Ethin, Ethen und Propen wurden gezielt betrachtet. Die Ergebnisse zeigen, dass bei kalten Betriebsbedingungen diese drei Komponenten etwa die Hälfte der Gesamtkohlenwasserstoffkonzentration ergeben. Ein weiterer Punkt der Untersuchungen war die Diesel-Partikelfilter-Regeneration. Wie erwartet, lassen sich Kohlenwasserstoffmoleküle mit höheren Massen feststellen, die auf unverbrannten Dieselkraftstoff zurückzuführen sind. Anhand der Ergebnisse zeigte sich.dass sich das mit chemischer Ionisation arbeitende Massenspektrometer hervorragend für ein Abgasscreening eignet. Zahlreiche Kohlenwasserstoffe konnten identifiziert werden, die repräsentativ für das Dieselabgas stehen. Es sollten Moleküle bei verschiedenen Motorbetriebsbedingungen untersucht werden, die einen möglichst großen Anteil an der Gesamtkohlenwasserstoffkonzentration besitzen. Die Auswahl fiel aufgrund der gemessenen Massenspektren, vor und nach dem Diesel-Oxidationskatalysator, auf die Komponenten Ethin, Ethen und Propen. Zudem kann bei diesen Molekülen eine Masseninterferenz mit anderen Abgaskomponenten ausgeschlossen werden. Im unteren Teillastbereich und kaltem Motor machen diese Kohlenwasserstoffe bis zu 50%, gemittelt über alle Messstellen vor, im und nach dem Diesel-Oxidationskatalysator, der Gesamtkohlenwasserstoffkonzentration aus. Bei betriebswarmem Motor reduziert sich ihr Anteil auf ein Drittel Die höchste Konzentration unter den drei Komponenten besitzt dabei Propen. Mit steigendem Drehmoment nimmt der Anteil dieser drei Komponenten fortlaufend ab,was dafür spricht, dass Moleküle mit höheren Massen einen höheren Anteil einnehmen. Die Kohlenwasserstoff-Emissionen bewegen sich bei diesen Motorbetriebspunkten mit betriebswarmem Katalysator jedoch bereits bei sehr niedrigen Werten. Während der untersuchten Diesel-Partikelfilter-Regeneration mit späten Nacheinspritzungen zur Abgastemperaturerhöhung lassen sich Moleküle mit höheren Massen nachweisen. Diese sind typisch für die Reinkomponente Dieselkraftstoff. Der Anteil von Ethin, Ethen und Propen an der THC-Konzentration beträgt dann ca. 40%.
In the forming tools for pressing car body parts, heavy blankholders are used to prevent buckling and wrinkling of the blank. During each press cycle, those large masses need to be lifted, raising thereby the structural dynamic load on the forming tool and on the press. Therefore a detailed knowledge about the forming tool dynamics is essential for an accurate and robust design of forming tools. In this paper, a dynamic finite element method (FEM) simulation of selected automotive forming tool is presented enabling identification of regions of critical stresses. For validation of the simulation results, the kinematic responses of the tool's components are compared with the measurements obtained in an experiment.
For the dynamic simulation of on-road vehicles, the model-element "tire/road" is of special importance, according to its influence on the achievable results. Sufficient description of the interaction between tire and road is one of the most challenging tasks of vehicle modeling. Two groups of tire models can be classified: handling models and structural or high-frequency models. Usually, various assumptions are made in modeling vehicles as multibody systems. Therefore, in the interest of balanced modeling, the precision of the complete vehicle model should stand in reasonable relation to the performance of the applied tire model. Handling tire models are characterized by a useful compromise between user friendliness, model complexity, and efficiency in computation time on the one hand, and precision in representation on the other hand. The present paper describes the general approach of the semi-physical tire model TMeasy for vehicle dynamics and handling simulation and its enhancement for bore torque simulation in Version TMeasy 5. A parameter fitting process realized by TESIS DYNAware and the validation of real tire behavior by simulation with DYNA4 is presented. Even with first guess parameters, the TMeasy tire model behaves in a realistic and plausible manner. Parameter estimation is intuitive and datasets from previous model versions can be easily migrated. After parameter fitting, the simulation results correlate well with both the tire test rig and full vehicle measurements. The enhancement of a three-dimensional slip calculation in the latest version does not modify the model behavior for high slip conditions, but improves the results not only for highly dynamic situations but also for low speed maneuvers such as parking.
The laminated steel core of transformers is one of the main sources of the generated sound, as it is excited by different electromagnetic effects during its normal operation. If the core is excited in its eigenfrequencies, the sound generated by a transformer will increase significantly. Therefore, knowledge of the core’s eigenmodes and -frequencies in an early design stage can decrease expenses by avoiding costly modifications that might be required to avoid the sound levels exceeding the specified values after the final factory acceptance test. The current study focuses on developing a core resonance model to determine the eigenmodes and -frequencies of a transformer core. The core’s geometry was simplified to a connected-beam structure and a numerical-based approach was applied. The accuracy of the developed model was validated against finite element method (FEM), using ANSYS on a reference core model.
During the factory acceptance test, the sound levels are measured. If the measured sound levels exceed pre-specified values, modifications on the transformer’s active part and/or tank need to be conducted. Tank resonance, if occurs, at twice main power frequency and its higher harmonics is one of the main reasons of amplifying the generated sound levels. Therefore, it is preferable to know already in the design stage about the occurrence of the tank resonance and propose reliable tank solutions. The current study presents a newly developed model for calculating the mode shapes and its corresponding eigenfrequencies of the tank.
The Twistbeam axle suspension is a cheap and robust layout for rear axles at front wheel driven midsize cars. Appropriate models have to take the elastic deformation of the torsion beam into account. A Finite Element approach requires detailed informations of the material properties and the shape which are usually only available in the final production stage. This paper presents a lumped mass model which can easily be integrated into a multibody vehicle model and can be used in the early stage of development. An approximation by the design kinematics further reduces the complexity of the model and considers only the kinematic properties of the Twistbeam suspension. Simulations using a nonlinear and three-dimensional vehicle model with different maneuvers, such as steady-state cornering, step steer input, and driving straight ahead on random road, demonstrate the performance and, in particular, the difference of the presented Twistbeam suspension models.
The TMeasy is a tyre model suitable for vehicle handling analyses and enables easy parametrisation. Recently, a convenient interface to Modelica was implemented by DLR to support the TMeasy also for vehicle modelling in multi-physical domains. This paper focuses especially on the particular problem of reliable reproduction of the tyre’s bore torque which occurs during parking manoeuvres. It outlines the theory behind it, discusses the Modelica interface implementation, and presents the results of parameter identification which were achieved based on real experiments with DLR’s research platform ROboMObil.
Independent component analysis (ICA), as a data driven method, has shown to be a powerful tool for functional magnetic resonance imaging (fMRI) data analysis. One drawback of this multivariate approach is, that it is naturally not convenient for analysis of group studies. Therefore various techniques have been proposed in order to overcome this limitation of ICA. In this paper a novel ICA based work-flow for extracting resting state networks from fMRI group studies is proposed. An empirical mode decomposition (EMD) is used to generate reference signals in a data driven manner, which can be incorporated into a constrained version of ICA (cICA), what helps to overcome the inherent ambiguities. The results of the proposed workflow are then compared to those obtained by a widely used group ICA approach. It is demonstrated that intrinsic modes, extracted by EMD, are suitable to serve as references for cICA to obtain typical resting state patterns, which are consistent over subjects. This novel processing pipeline makes it transparent for the user, how comparable activity patterns across subjects emerge, and also the trade-off between similarity across subjects and preserving individual features can be well adjusted and adapted for different requirements in the new work-flow.
Virtual testing procedures have become a standard in vehicle dynamics. The increasing complexity of driver assistance sys-
tems demand for more and more virtual tests, which are supposed to produce reliable results even in the limit range. As a consequence,
simplified vehicle models, like the classical bicycle model or 4-wheel vehicle models, have to be replaced by a fully three-dimensional
and nonlinear vehicle model, which also encompasses the details of the suspension systems. This paper presents a passenger car model,
where the chassis, the four knuckles, and the four wheels are described by rigid bodies, the suspension system is modeled by the generic
design kinematics, and the TMeasy tire model provides the tire forces and torques in all driving situations.
TMeasy 6.0, an extension to the standard TMeasy tire model of version 5.3, takes the relevant first two rigid body eigenmodes of the belt into consideration. These modes represent the in plane longitudinal and rotational movements of the belt relative to the rim. The dynamics of the longitudinal force is of higher order then and reproduces the tire wheel vibrations, required for indirect tire-pressure monitoring systems (iTPMS), sufficiently well. A tailored implicit solver, which takes the stiff coupling between the longitudinal force and the belt motions into account, still provides real-time performance in addition. Simulation examples show that a rigid body vehicle model equipped with TMeasy 6.0 makes it possible to investigate second generation indirect tire-pressure monitoring systems.
The present papers deals with the usability of an extended Maxwell model to describe the tyre dynamics during transient driving manoeuvres. In the present article, the para-metrisation process of a dynamic tyre model is investigated in a first step, using measurement data of tyre forces from a flat trac tyre test bench, (IABG 2016). Two tyre types of dimensions 255/50 R19 and 175/55 R15 are used. The practical applicability is discussed, considering the measurement procedure and the parameter optimisation process. In a second step, the performance of the dynamic tyre model is validated using measurements of manoeuvres under higher dynamic excitation. As a last step, an outlook is given on further research planned in which the presented model and parametrisation are adapted to a larger frequency range.
This article discusses the systematic design of the robot feedback for users in a stationary human-robot cooperation scenario. The design cycle starts with the analysis of related work and the capabilities of the human-robot system. It is followed by an online questionnaire with 100 participants to discover relevant information and modalities. A final experiment in the human-robot working cell with 13 subjects evaluates the usability of the robot feedback design.
Infolge neuer Zielsetzungen im Automobilbereich, wie z. B. der Weiterentwicklung von Fahrerassistenzsystemen hin zum hochautomatisierten Fahren (HAF), ergeben sich erhöhte Anforderungen an die Signalgüte der im Fahrzeug eingesetzten Inertialsensoren für Drehraten und Beschleunigungen. Da deren Erfüllung über einen hardwarebasierten Ansatz nicht immer möglich und sinnvoll ist, strebt die Firma Continental eine Software-Lösung zur modellbasierten Verbesserung dieser Sensorsignale an.
Recent developments in exhaust gas legislation make it necessary to focus the research at the particulate emissions from gasoline engines and technologies for their reduction. In addition to the particulates resulting from the combustion of the fuel, the oil emissions represent another possible source for particulate emissions. This paper presents a measurement method which can be used to quantify stationary as well as dynamic oil emissions of gasoline engines. Furthermore, the correlation between the oil emissions and the particulate emissions is the focus of the investigations. Conventional methods for the determination of the oil emissions, such as the gravimetric and the volumetric measurement, are unsuitable since they require long engine operation times to provide useful results. These methods therefore do not allow a fast online measurements during the dynamic operation. For this reason, a new measuring method was used, which allows for a time-resolved online measurement of the oil emissions. This measurement method is based on the sulfur tracer method, which uses the sulfur that is naturally contained in the engine oil as a tracer. The sulfur concentration in the exhaust gas is determined by using an Ion-Molecule-Reaction mass spectrometer. The determination of the particulate emissions corresponds to the PMP regulation. The studies carried out under steady state and dynamic conditions show a clear correlation between the oil consumption and the number of particulates in the exhaust gas. In the case of the dynamic measurements it could also be shown that time-resolved measurements of the oil consumption are possible with the used measurement setup. In addition, it was shown that the number of particulates does not influence the measurement of the SO2-concentration. Furthermore, the different effects of burned and unburned oil emissions have been evaluated by the dosing of the oil into the exhaust gas. The overall conclusion of the measurements shows a strong influence of the oil emissions on the particulate emissions. Therefore, it is crucial to reduce the oil emissions. Possible approaches for this reduction can be improved turbocharger sealing concepts, new piston ring designs or more efficient oil separators for the crankcase ventilation system.
In this work, an integrated vehicle control system (IC) is tested in run-off-road scenarios. The integrated approach was employed in order to coordinate vehicle control systems, i.e. the Anti-Lock Brake System (ABS), Four-wheel Steering (4WS) and the Electronic Stability Program (ESP). To perform a run-off-road maneuver, a fuzzy virtual test driver was designed. By receiving the lateral position of an obstacle and the vehicle’s relative yaw angle, the virtual test driver is capable of following a reference trajectory. Furthermore, to test the performance of the standalone controllers, i.e. ABS, ESP and 4WS, individual maneuvers are performed using a multibody vehicle model. The vehicle without any coordination between the control systems is used as reference. For the simulation results, it is concluded that the IC improves the vehicle stability and maneuverability in comparison with the non-integrated approach.
Motorische Untersuchung einer Doppelstromturbine bei gezielter Variation von Einflussparametern
(2018)
Um die Leistungsmerkmale moderner Ottomotoren, hohe Nennleistung bei niedrigem Kraftstoffverbrauch einerseits und hohes Low End Torque bei dynamischem Ansprechverhalten andererseits, zu erreichen, stehen Abgasturbolader mit verschiedenen Turbinentypen zur Verfügung. Dabei wird zwischen den Ausführungen ein- und mehrflutige Turbine unterschieden. Je nach geometrischer Ausführung der Flutentrennung wird bei den mehrflutigen Turbinen zwischen den Bauformen Zwillingsstrom- und Doppelstromturbine differenziert.
Efficient earthquake simulation of stiff and high DOF bridge expansion joint models with Python
(2021)
Various types of seismic protection devices has been developed to protect structures like bridges from collapse during an earthquake event, such as hydraulic or metallic hysteresis dampers and spherical pendulum bearings. The expansion joints however, which are already included in most large-span bridges, are not considered as an
earthquake protection device regardless of the significant friction forces they produce. These friction forces can be seen as damping forces between the shaking environment and the oscillating bridge. To investigate the effect of those damping forces during different earthquake loads, a multibody dynamics simulation model of the expansion joints will be created. This model should be accurate enough to represent the generation of the damping forces and effects of the geometric setup of the expansion joints. Because large expansion joints for large-span bridges are of special interest, the number of degrees of freedom (DOF) becomes very high. Because this models include stiff bushings, implicit solvers need to be used to gain a stable simulation. Expansion joints are almost unique constructions for every specific bridge, which requires a automated model generation. Because of its excellent modules for numerical mathematics, the scripting language Python is used. To create an efficient simulation model, several optimization techniques such as Just-In-Time (JIT) compilation and parallelization are implemented and tested.
A comprehensive experimental program is carried out to determine material parameters for fracture initiation and propagation in X100 pipeline steels. The quadratic Hill’48 yield function along with an isotropic hardening are used to describe plastic flow at large deformation and a phenomenological fracture criterion to predict fracture initiation. Fracture mechanics SENT specimens are used to calibrate post-initiation softening parameters necessary for ductile crack propagation in thick components. Once the material model parameters set is complete a final comparison is conducted with ring expansion test on same material.
The use of compliant tensegrity structures in robotic applications offers several advantageous properties. In this work the dynamic behaviour of a planar tensegrity structure with multiple static equilibrium configurations is analysed, with respect to its further use in a two-finger-gripper application. In this application, two equilibrium configurations of the structure correspond to the opened and closed states of the gripper. The transition between these equilibrium configurations, caused by a proper selected actuation method, is essentially dependent on the actuation parameters and on the system parameters. To study the behaviour of the dynamic system and possible actuation methods, the nonlinear equations of motion are derived and transient dynamic analyses are performed. The movement behaviour is analysed in relation to the prestress of the structure and actuation parameters.
This paper deals with the locomotion by tilting sequences of shape-variable compliant tensegrity structures. The shape of these structures is controlled by manipulating their prestress state. The tensegrity structure is tilting as consequence of a suitable variation of its shape. By multiple repetition of such tilting sequences a motion is generated. Quasi-static considerations for the considered structures are presented in order to estimate the actuation parameters. For a proper number of actuators this quasi-static approach enables an analytical calculation of the actuation parameters of the structure in order to control the geometrical configuration as required. As an example a two-dimensional tensegrity structure which is in contact with a horizontal plane due to gravity is considered. By successive tilting sequences a uniaxial motion results. The excitation of the structure is calculated for a given change of shape with the quasi-static analysis. The according results are compared with transient dynamic simulations. Qualitative conclusions about the motion behavior and the usability of the quasi-static approach are given.
Mobile cranes are regularly operated in regions which experience ultra deep operating temperatures of down to -60?C (-76?F). In safety regulated work environments crane operations will be suspended simply because the lowest wire rope working temperature stated in the applicable standards is -40?C/F. Examples of ultra deep temperature wire rope application are shown in Figure 1.1 and 1.3. It should be noted that this paper is written in conjunction with a paper written by the co-author Ulrich Briem titled “Fatigue Behaviour of Rope Wires”, presented and published in unison with this one. In order to analyze the behaviour under ultra deep temperature conditions, tests on wire rope as well as on rope wires were carried out. In the following, static tensile and bending test results with rope and rope wires will be reported, which were carried out in conditions of down to -95?C (-139?F) as well as at room temperature. The conclusion is that the results of these tests can be adopted to crane wire rope as well.
The rope curve line of a tensioned rope can be described by means of the catenary curve. Opposed to that, the curved line of a free bent rope cannot be described by an analytical function. Practical applications of free bending are for example at tail ropes at the bottom of shaft in rope drives with traction sheaves. The question whether the maximum diameter of rope loop is small enough for the diameter of the shaft is highly interesting. In [1] a method was presented to calculate the curved line of free bent ropes numerically by help of energy methods. An analytical description of rope curve line would be very helpful. Beginning with the structure of a rope curve line of tensioned rope (catenary curve) and considering the influence of bending stiffness, the structure of an analytical equation for the curve line of a free bent rope will be developed. The main focus of this paper is to develop and to describe the structure of such an analytical equation. To get a first idea about the values of the constants in that analytical equation a few test results were evaluated. But these equations consider the static rope behavior only. Due to dynamic effects in the rope while running through the loop at the bottom of a shaft, pendulousness of the tail rope occurs.
The rope curve line of a tensioned rope can be described by means of the catenary curve. Opposed to that, the curved line of a free bent rope cannot be described by an analytical function. Practical applications of free bending are for example at tail ropes at the bottom of shaft in rope drives with traction sheaves. The question whether the maximum diameter of rope loop is small enough for the diameter of the shaft is highly interesting. In [1] a method was presented to calculate the curved line of free bent ropes numerically by help of energy methods. An analytical description of rope curve line would be very helpful. Beginning with the structure of a rope curve line of tensioned rope (catenary curve) and considering the influence of bending stiffness, the structure of an analytical equation for the curve line of a free bent rope will be developed. The main focus of this paper is to develop and to describe the structure of such an analytical equation. To get a first idea about the values of the constants in that analytical equation a few test results were evaluated. But these equations consider the static rope behavior only. Due to dynamic effects in the rope while running through the loop at the bottom of a shaft, pendulousness of the tail rope occurs.
In this paper, first results regarding the realization of laser-based hot-melt bonding of additive manufactured plastics parts to metal sheets for strong and tight multi-material joints are presented. Compared to earlier investigations, in which nearly solely extruded plastic materials were applied, the use of additive manufactured plastics complements the research field with a promising approach. Besides the typical advantages of multi-material joints regarding weight reduction and high strengths, such parts can meet the needs of constructional freedom and the avoiding of tool costs. Materials used for this paper are aluminum (AlMg3), stainless steel (1.4301) and polyamide 12 (PA12). The performed experiments resulting in multi-material joints between metal and polyamide. The realized specimens undergo a tensile shear test and a tightness test, in which the characteristics of the joints are determined.
The use of thermoplastics in lightweight construction is continuing to grow. This implies the need for suitable joining techniques to combine thermoplastics with other materials, such as metals, to gain tailored multi-material parts. In this paper latest results of experimental investigations on laser-based hot-melt bonding and injection molding for laser-structured metal plastic hybrids are presented. As materials stainless steel and short-fiber reinforced polyamide are used. The stainless steel surface is structured with a nanosecond pulse laser before joining to improve the mechanical adhesion between the dissimilar materials. Thereby, different structure depths in the range between 16.6 ± 1.2 µm and 66.5 ± 2.5 µm as well as different hatch distances between 70 and 300 µm are realized. The laser-based joining process is carried out irradiating the metallic surface multiple times. Positioned below the metal in T-joint configuration, the thermoplastic melts as a result of heat transfer and acts as hot-melt cohesive. Besides, hybrid joints are manufactured using injection molding. For experiments, the mold temperature as well as the melt temperature are varied. Regardless of the joining process, the hybrid joints are mechanically characterized by tensile tests. The results demonstrate that for both joining processes strong laser-structured metal plastic hybrids can be realized.
Decision-making in supply chain management is complex because of the relations between planning tasks from different stages and planning levels. Uncertainties such as unpredictable supplier lead times and supply chain disruptions further complicate decision-making. Considering the case study of a company in printed circuit board assembly, a three-level concept is proposed that includes a decision support system. The global single-source supply network is characterized by highly variable lead times. Hence, the company maintains high inventory levels to prevent running out of stock. The decision support system considers the purchasing and scheduling decision problems in an integrated way. The prototypical implementation of the purchasing algorithm uses a genetic algorithm that recommends reorder days and order quantities using a simulation model. In addition, it evaluates the risks of the recommended solution by calculating the probability of stockouts for each order cycle.
In this paper, a new method for a minimum-error pose estimation of cylinder axes based on apparent contour line features from multiple views is presented. Novel model equations for both single and particularly multiple views are derived, and based upon these, an algorithm for least squares fitting the model to imaged cylinder contour line features is introduced. The good performance of the proposed algorithm is shown by solving an exemplary fitting problem.
The present paper deals with the experimental validation of tyre dynamics approaches as it is widely applied in tyre models for vehicle dynamics and handling. Firstly it gives a brief derivation of two modelling principles regarding the deflection velocity in the considered direction of the tyre’s deformation. This is than followed by a brief description of the performed measurement procedure. From the measurements, a set of model parameters of the considered tyre, depending on different manoeuvre speeds and frequencies, is identified, where no particular fitting parameters for the tyre dynamics are needed. Based on these model parameters, the related dynamic simulations are carried out. The comparisons show that the applied first-order model describes the behaviour quite well within a certain operation range, whereas the second-order approach cannot deliver better results in spite of the longer computational time. However, for investigations within an enlarged frequency range of the steer input and at high slip angles, a more detailed model is recommended.
Lines are one of the basic features that are used to characterise the content of an image and to detect objects. Unlike edges or segmented blobs, lines are not only an accumulation of certain feature pixels but can also be described in an easy and exact mathematical way. Besides a lot of different detection methods, the Hough transform has gained much attention in recent years. With increasing processing power and continuous development, computer vision algorithms get more powerful with respect to speed, robustness and accuracy. But there still arise problems when searching for the best parameters for an algorithm or when characterising and evaluating the results of feature detection tasks. It is often difficult to estimate the accuracy of an algorithm and the influences of the parameter selection. Highly interdependent parameters and preprocessing steps continually lead to only hardly comprehensible results. Therefore, instead of pure trial and error and subjective ratings, a systematic assessment with a hard, numerical evaluation criterion is suggested. The paper at hand deals with the latter ones by using a human-generated ground truth to approach the problem. Thereby, the accuracy of the surveyed Kernel-based Hough transform algorithm was improved by a factor of three. These results are used for the tracking of cylindrical markers and to reconstruct their spatial arrangement for a biomedical research application.