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Basics for inline measurement of tribological conditions in series production of car body parts
(2019)
The quality of car body parts in series production is strongly dependent on the tribological behavior. Fluctuating material properties such as the sheet roughness and the amount of lubricant have an influence on the forming process. On the basis of large amounts of data it is possible to investigate the friction behavior in series production and to make process adjustments if required. Therefore, inline measurement systems have a great potential to detect the sheet roughness during the cutting process of blanks in the coil line. Furthermore, contactless systems are advantageous as they do not damage the surface. Nevertheless, the optical measuring is influenced by the lubricant layer on top of the surface. Therefore, the previously unknown impact of the lubricant on the measuring result is investigated.
Within this study, stationary optical roughness measurements have been conducted using different amounts of lubricant on hot-dip galvanized EDT steel. The results demonstrate the influence of different amounts of lubricant on the sheet roughness measurement. Hence, it is possible to correct the inline measuring results and gain knowledge of fluctuating surface roughness. In addition, strip drawing test has been carried out to investigate the effect of fluctuating tribological conditions.
To reduce particulate emissions, the use of particulate filters in diesel engines is meanwhile state of the art, while the integration of such systems in gasoline engines is now also necessary in order to comply with today's regulations. Over its lifetime, a gasoline particulate filter (GPF) collects ash components of fuel, lubrication oil, and materials originating from the catalytic coating and from engine abrasion. In the development and application process, synthetic ashing from GPFs is challenging. The ash of the lubrication oil can be increased in various ways, like oil-doped fuel, a separate oil burner, or changes in the piston-cylinder system of the engine. However, these methods show major disadvantages. For this reason, an improved approach is presented in this study, which allows a quick response to changes in combustion (e.g., engine knocking) and producing ash, which is more realistic due to its primary particle size and the density of ash plugs, in a shorter time. Therefore, an approach to accelerate ash loading by active oil injection using a multi-point injection (MPI) system is introduced. With the help of this methodology, an ashing capacity of 1.21 g/h is implemented, which is a high rate compared to other investigations. The primary particle size (evaluated by means of a transmission electron microscope), is in the same size range as those detected at the full-load curve during regular operation. A computer tomographic (CT) analysis of the incinerated particulate filter also shows that a very high density of ash plugs can be realized, which has also been found in the literature for real applications. In addition, with the help of a mass spectrometer (MS) and an intermediate weighing of the particulate filter, the current ash loading of the GPF could be determined with an accuracy of 1%.
Avoiding ice accumulation on aerodynamic components is of enormous importance to flight safety. Novel approaches utilizing surface dielectric barrier discharges (SDBDs) are expected to be more efficient and effective than conventional solutions for preventing ice accretion on aerodynamic components. In this work, the realization of SDBDs based on thin-film substrates by means of micro-electro-mechanical-systems (MEMS) technology is presented. The anti-icing performance of the MEMS SDBDs is presented and compared to SDBDs manufactured by printed circuit board (PCB) technology. It was observed that the 35 mu m thick electrodes of the PCB SDBDs favor surface icing with an initial accumulation of supercooled water droplets at the electrode impact edges. This effect was not observed for 0.3 mu m thick MEMS-fabricated electrodes indicating a clear advantage for MEMS-technology SDBDs for anti-icing applications. Titanium was identified as the most suitable material for MEMS electrodes. In addition, an optimization of the MEMS-SDBDs with respect to the dielectric materials as well as SDBD design is discussed.
To support a rational and efficient use of electrical energy in residential and industrial environments, Non-Intrusive Load Monitoring (NILM) provides several techniques to identify state and power consumption profiles of connected appliances. Design requirements for such systems include a low hardware and installations costs for residential, reliability and high-availability for industrial purposes, while keeping invasive interventions into the electrical infrastructure to a minimum. This work introduces a reference hardware setup that allows an in depth analysis of electrical energy consumption in industrial environments. To identify appliances and their consumption profile, appropriate identification algorithms are developed by the NILM community. To enable an evaluation of these algorithms on industrial appliances, we introduce the Laboratory-measured IndustriaL Appliance Characteristics (LILAC) dataset: 1302 measurements from one, two, and three concurrently running appliances of 15 appliance types, measured with the introduced testbed. To allow in-depth appliance consumption analysis, measurements were carried out with a sampling rate of 50 kHz and 16-bit amplitude resolution for voltage and current signals. We show in experiments that signal signatures, contained in the measurement data, allows one to distinguish the single measured electrical appliances with a baseline machine learning approach of nearly 100% accuracy.
The purpose of this study was to investigate the characteristic of nanoparticles under consideration of sub-23-nm particles from a 1.8-l direct injection (DI) gasoline engine under stoichiometric air/fuel conditions in the exhaust gas system. For future CO2 challenges, the usage of DI-instead of port fuel injection (PFI)-gasoline engines is unavoidable. Therefore, a state of the art particle management program-particle number (PN) system, the Horiba SPCS (2100) with an integrated CPC (condensation particle counter), was recalibrated from a 50% cutoff (D-50%) at 23 nm down to a cutoff at 10 nm and the PCRF (particle concentration reduction factor) for sizes smaller than 23 nm was checked. Two different modal points, out of a representative Real Driving Emission (RDE) cycle, were investigated with both calibrations, D-50%=10 nm and D-50%=23 nm. For these different load points, the fuel pressure (FUP) and the start of injection (SOI) were varied, to represent the difference in the structure and the ratio conc((10 nm))/conc((23 nm)) of the nanoparticle emissions. The particle characterization includes the particle number (PN), the particle size distribution (PSD), and the particle mass (PM). The particle number was measured with Horiba SPCS (2100). The particle size distribution was analyzed with a Grimm differential mobility analyzer (DMA) in combination with a Faraday cup electrometer (FCE). Micro Soot and Pegasor were used to determine the PM, and an optical characterization was done with a 120-kV Phillips CM12 transmission electron microscope (TEM). The position of all particle measurement systems was downstream the three-way catalyst (TWC). The results of this investigation showed that a higher injection pressure decreases the PN (without consideration of sub-23-nm particles) in general. The ratio conc((10 nm))/conc((23 nm)) was therefore higher, because smaller particles, especially ash particles, were less reduced from the FUP. This means higher FUP tends to a higher ratio. For the SOI, the main reasons of the ratio differences were explained by an encroachment between the injection jet and the piston, the valve and the wall.
Insulation of thermal energy storage tanks is fundamental to reduce heat losses and to achieve high energy storage efficiency. Although water tanks were extensively studied in the literature, the enhancement of the insulation quality is often overlooked. The use of vacuum insulation has the potential to significantly reduce heat losses without affecting the dimension of the storage system. This paper shows for the first time the results of the heat losses tests done for a 0.535 m3 water tank for residential building applications built with a double wall vacuum insulation. The different tests show that the rate of heat losses strictly depends on the temperature distribution inside the tank at the beginning of the experiment. Compared to a conventional water tank insulated with conventional materials, the U-value of the lateral surface was reduced by almost three times (from 1.05 W/K·m2 to 0.38 W/K·m2) using vacuum insulation. However, the bottom part, which is usually used to place the support parts and the piping, is the critical design part of those tanks acting as a thermal bridge with the ambient and enhancing heat losses.
A numerical parameter sensitivity analysis of the design parameters of the recently published solar selective thermal insulation system (SATIS) has been carried out to enhance its thermal and optical properties. It turned out that the insulation properties of SATIS can be effectively improved by reducing the length of the glass closure element. Increasing the area share of the light conducting elements (LCEs) and decreasing their length-to-diameter (L/D) ratio were identified as key parameters in order to increase the solar gain. Two SATIS variants were compared with the same wall insulation without SATIS in a yearly energetic performance assessment. The SATIS variant with 10 mm length of the closure element, 44.2% area share of LCE, as well as front and rear diameters of 12 mm/9 mm shows an 11.8% lower transmission heat loss over the heating period than the wall insulation without SATIS. A new methodology was developed to enable the implementation of the computed solar gains of SATIS in 1D simulation tools. The result is a radiant heat flow map for integration as a heat source in 1D simulation models. A comparison between the 1D and 3D models of the inside wall heat fluxes showed an integral yearly agreement of 98%.
Method of Measuring Deformations of Magnetoactive Elastomers under the Action of Magnetic Fields
(2019)
The hydrogen gas-to-liquid mass transfer is the limiting factor in biological methanation. In trickle-bed reactors, mass transfer can be increased by high flow velocities in the liquid phase, by adding a packing material with high liquid hold-up or by using methanogenic archaea with a high methane productivity. This study developed a polyphasic approach to address all methods at once. Various methanogenic strains and packings were investigated from a microbial and hydrodynamic perspective. Analyzing the ability to produce high-quality methane and to form biofilms, pure cultures of Methanothermobacter performed better than those of the genus Methanothermococcus. Liquid and static hold-up of a packing material and its capability to facilitate attachment was not attributable to a single property. Consequently, it is recommended to carefully match organism and packing for optimized performance of trickle-bed reactors. The ideal combination for the ORBIT system was identified as Methanothermobacter thermoautotrophicus IM5 and DuraTop (R).
he hydrogen gas-to-liquid mass transfer is the limiting factor in biological methanation. In a trickle-bed reactor, mass transfer can be increased by high flow velocities in the liquid phase, by adding a packing material with high liquid hold-up, or by choosing methanogenic archaea with a high methane productivity. This study analyzed various packings and methanogenic strains from a hydrodynamic and microbial perspective. By analyzing twelve pure cultures of thermophilic methanogens for their ability to produce high quality methane and to form biofilms on different packings, strains of Methanothermobacter were found to perform better than thus of the genus Methanothermococcus. Best methane production and adherence was observed on DuraTop®, Bioflow 9, and filter foam. DuraTop® and Bioflow 9 had also a high dynamic liquid hold-up, but the maximum hold-up was determined for expanded clay. The ideal combination for use in the ORBIT-trickle-bed reactor was identified as Methanothermobacter thermoautotrophicus IM5 and DuraTop®.