Fakultät Maschinenbau
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The paper deals with the investigation of magneto-sensitive elastomers(MSE) and their application in technical actuator systems. MSE consist of an elasticmatrix containing suspended magnetically soft and/or hard particles. Additionally,they can also contain silicone oil, graphite particles, thermoplastic components, etc.,in various concentrations in order to tune specific properties such as viscosity, con-ductivity and thermoelasticity, respectively. The focuses of investigations are thebeneficial properties of MSE in prototypes for locomotion and manipulation purposesthat possess an integrated sensor function. The research follows the principle of amodel-based design, i.e. the working steps are ideation, mathematical modelling,material characterization as well as building first functional models (prototypes). Thedeveloped apedal (without legs) and non-wheeled locomotion systems use the inter-play between material deformations and the mechanical motion in connection with theissues of control and stability. Non-linear friction phenomena lead to a monotonousforward motion of the systems. The aim of this study is the design of such mechanicalstructures, which reduce the control costs. The investigations deal with the movementand control of‘intelligent’mechanisms, for which the magnetically field-controlledparticle-matrix interactions provide an appropriate approach. The presented grippersenclose partially gripped objects, which is an advantage for handling sensitive objects.Form-fit grippers with adaptable contour at the contact area enable a uniform pressuredistribution on the surface of gripped objects. Furthermore, with the possibility ofactive shape adaptation, objects with significantly differing geometries can be gripped.To realise the desired active shape adaptation, the effect of field-induced plasticity ofMSE is used. The first developed prototypes mainly confirm the functional principles assuch without direct application. For this, besides the ability of locomotion andmanipulation itself, further technological possibilities have to be added to the systems.
The tightening of the emission legislation and political and social demands for sustainable mobility are forcing the automotive industry to develop complex, high precision mechatronic drive systems. The increasing precision of mechatronic components generally leads to an increase in structural excitation and thus to a rise in noise. The so-called ticking of the fuel injection system has a rather low sound pressure level compared to the residual engine noise. Nevertheless, the impulsive and high frequency noise character leads to a decline concerning the perception of comfort and sound quality. In order to identify the sound quality of fuel injection systems as a frontloading measure, a system test bench has been developed which represents the structure-borne and airborne sound radiation of the stand-alone injection system in a close to series configuration. In this paper, measures for the acoustic optimization of injection systems and their effects on the robustness of the system are discussed. The focus is on engine idling, since at this operating point the ticking of the injectors and high-pressure pump can be perceived most clearly due to the low masking effects of other noise sources. For this purpose, the injection parameters were measured during full engine operation and transferred to the system test bench. By using a special development control unit, it was possible to modify the parameters, quantify their influence on the acoustic behavior and, based on this, define NVH optimized control strategies. For the robustness evaluation of the NVH optimized control strategies, key functions of the injection system were analyzed under varying boundary conditions in system operation on an injection rate test bench.
The Arbitrary-Lagrangian-Eulerian-Method (ALE-Method) offers the possibility to model the quasi-simultaneous laser transmission welding of plastics, in which a squeeze-flow of molten plastic occurs. It is of great interest to get a deeper understanding of the fluid-structure-interactions in the welding zone, since the occurring squeeze-flow transports heated material out of the joining zone, causinga temperature decrease inside.In addition, the numerical modelling offers the possibility to investigate the flow conditions in the joining zone. The aim of this article is to show the potentials of the ALE-Method to simulatethe quasi-simultaneous laser transmission welding with the commercially available software LS-DYNA. The central challenge is to realize a bi-directionalthermo-mechanically coupled simulation,which considers the comparatively high thermal expansion and calculates the interactions of solid and melted plastic correctly. Finally, the potentials of the ALE element formulations for the mathematical description of welding processesare shown, especially for those with a squeeze-flow.