On the application of meshfree methods to the nonlinear dynamics of multibody systems

Esta tesis propone una completa formulación termo-mecánica para la simulación no-lineal de mecanismos flexibles basada en métodos libres de malla. El enfoque se basa en tres pilares principales: la formulación de Lagrangiano total para medios continuos, la discretización de Bubnov-Galerkin, y las funciones de forma libres de malla. Los métodos sin malla se caracterizan por la definición de un conjunto de funciones de forma en dominios solapados, junto con una malla de integración de las ecuaciones discretas de balance. Dos tipos de funciones de forma se han seleccionado como representación de las familias interpolantes (Funciones de Base Radial) y aproximantes (Mínimos Cuadrados Móviles). Su formulación se ha adaptado haciendo sus parámetros compatibles, y su ausencia de conectividad predefinida se ha aprovechado para interconectar múltiples dominios de manera automática, permitiendo el uso de mallas de fondo no conformes. Se propone una formulación generalizada de restricciones, juntas y contactos, válida para sólidos rígidos y flexibles, siendo estos últimos discretizados mediante elementos finitos (MEF) o libres de malla. La mayor ventaja de este enfoque reside en que independiza completamente el dominio con respecto de las uniones y acciones externas a cada sólido, permitiendo su definición incluso fuera del contorno. Al mismo tiempo, también se minimiza el número de ecuaciones de restricción necesarias para la definición de uniones realistas. Las diversas validaciones, ejemplos y comparaciones detalladas muestran como el enfoque propuesto es genérico y extensible a un gran número de sistemas. En concreto, las comparaciones con el MEF indican una importante reducción del error para igual número de nodos, tanto en simulaciones mecánicas, como térmicas y termo-mecánicas acopladas. A igualdad de error, la eficiencia numérica de los métodos libres de malla es mayor que la del MEF cuanto más grosera es la discretización. Finalmente, la formulación se aplica a un problema de diseño real sobre el mantenimiento de estructuras masivas en el interior de un reactor de fusión, demostrando su viabilidad en análisis de problemas reales, y a su vez mostrando su potencial para su uso en simulación en tiempo real de sistemas no-lineales. A new complete formulation is proposed for the simulation of nonlinear dynamic of multibody systems with thermo-mechanical behaviour. The approach is founded in three main pillars: total Lagrangian formulation, Bubnov-Galerkin discretization, and meshfree shape functions. Meshfree methods are characterized by the definition of a set of shape functions in overlapping domains, and a background grid for integration of the Galerkin discrete equations. Two different types of shape functions have been chosen as representatives of interpolation (Radial Basis Functions), and approximation (Moving Least Squares) families. Their formulation has been adapted to use compatible parameters, and their lack of predefined connectivity is used to interconnect different domains seamlessly, allowing the use of non-conforming meshes. A generalized formulation for constraints, joints, and contacts is proposed, which is valid for rigid and flexible solids, being the later discretized using either finite elements (FEM) or meshfree methods. The greatest advantage of this approach is that makes the domain completely independent of the external links and actions, allowing to even define them outside of the boundary. At the same time, the number of constraint equations needed for defining realistic joints is minimized. Validation, examples, and benchmarks are provided for the proposed formulation, demonstrating that the approach is generic and extensible to further problems. Comparisons with FEM show a much lower error for the same number of nodes, both for mechanical and thermal analyses. The numerical efficiency is also better when coarse discretizations are used. A final demonstration to a real problem for handling massive structures inside of a fusion reactor is presented. It demonstrates that the application of meshfree methods is feasible and can provide an advantage towards the definition of nonlinear real-time simulation models.

Simulation model for the study of overhead rail current collector systems dynamics, focused on the design of a new conductor rail

Overhead rigid conductor arrangements for current collection for railway traction have some advantages compared to other, more conventional, energy supply systems. They are simple, robust and easily maintained, not to mention their flexibility as to the required height for installation, which makes them particularly suitable for use in subway infrastructures. Nevertheless, due to the increasing speeds of new vehicles running on modern subway lines, a more efficient design is required for this kind of system. In this paper, the authors present a dynamic analysis of overhead conductor rail systems focused on the design of a new conductor profile with a dynamic behaviour superior to that of the system currently in use. This means that either an increase in running speed can be attained, which at present does not exceed 110 km/h, or an increase in the distance between the rigid catenary supports with the ensuing saving in installation costs. This study has been carried out using simulation techniques. The ANSYS programme has been used for the finite element modelling and the SIMPACK programme for the elastic multibody systems analysis.

Dynamic Response Optimization of Vehicles through Efficient Multibody Formulations and Automatic Differentiation Techniques

El diseño y desarrollo de sistemas de suspensión para vehículos se basa cada día más en el diseño por ordenador y en herramientas de análisis por ordenador, las cuales permiten anticipar problemas y resolverlos por adelantado. El comportamiento y las características dinámicas se calculan con precisión, bajo coste, y recursos y tiempos de cálculo reducidos. Sin embargo, existe una componente iterativa en el proceso, que requiere la definición manual de diseños a través de técnicas “prueba y error”. Esta Tesis da un paso hacia el desarrollo de un entorno de simulación eficiente capaz de simular, analizar y evaluar diseños de suspensiones vehiculares, y de mejorarlos hacia la solución optima mediante la modificación de los parámetros de diseño. La modelización mediante sistemas multicuerpo se utiliza aquí para desarrollar un modelo de autocar con 18 grados de libertad, de manera detallada y eficiente. La geometría y demás características de la suspensión se ajustan a las del vehículo real, así como los demás parámetros del modelo. Para simular la dinámica vehicular, se utiliza una formulación multicuerpo moderna y eficiente basada en las ecuaciones de Maggi, a la que se ha incorporado un visor 3D. Así, se consigue simular maniobras vehiculares en tiempos inferiores al tiempo real. Una vez que la dinámica está disponible, los análisis de sensibilidad son cruciales para una optimización robusta y eficiente. Para ello, se presenta una técnica matemática que permite derivar las variables dinámicas dentro de la formulación, de forma algorítmica, general, con la precisión de la maquina, y razonablemente eficiente: la diferenciación automática. Este método propaga las derivadas con respecto a las variables de diseño a través del código informático y con poca intervención del usuario. En contraste con otros enfoques en la bibliografía, generalmente particulares y limitados, se realiza una comparación de librerías, se desarrolla una formulación híbrida directa-automática para el cálculo de sensibilidades, y se presentan varios ejemplos reales. Finalmente, se lleva a cabo la optimización de la respuesta dinámica del vehículo citado. Se analizan cuatro tipos distintos de optimización: identificación de parámetros, optimización de la maniobrabilidad, optimización del confort y optimización multi-objetivo, todos ellos aplicados al diseño del autocar. Además de resultados analíticos y gráficos, se incluyen algunas consideraciones acerca de la eficiencia. En resumen, se mejora el comportamiento dinámico de vehículos por medio de modelos multicuerpo y de técnicas de diferenciación automática y optimización avanzadas, posibilitando un ajuste automático, preciso y eficiente de los parámetros de diseño. ABSTRACT Each day, the design and development of vehicle suspension systems relies more on computer-aided design and computer-aided engineering tools, which allow anticipating the problems and solving them ahead of time. Dynamic behavior and characteristics are thus simulated accurately and inexpensively with moderate computational times and resources. There is, however, an iterative component in the process, which involves the manual definition of designs in a trialand-error manner. This Thesis takes a step towards the development of an efficient simulation framework capable of simulating, analyzing and evaluating vehicle suspension designs, and automatically improving them by varying the design parameters towards the optimal solution. The multibody systems approach is hereby used to model a three-dimensional 18-degrees-of-freedom coach in a comprehensive yet efficient way. The suspension geometry and characteristics resemble the ones from the real vehicle, as do the rest of vehicle parameters. In order to simulate vehicle dynamics, an efficient, state-of-the-art multibody formulation based on Maggi’s equations is employed, and a three-dimensional graphics viewer is developed. As a result, vehicle maneuvers can be simulated faster than real-time. Once the dynamics are ready, a sensitivity analysis is crucial for a robust optimization. To that end, a mathematical technique is introduced, which allows differentiating the dynamic variables within the multibody formulation in a general, algorithmic, accurate to machine precision, and reasonably efficient way: automatic differentiation. This method propagates the derivatives with respect to the design parameters throughout the computer code, with little user interaction. In contrast with other attempts in the literature, mostly not generalpurpose, a benchmarking of libraries is carried out, a hybrid direct-automatic differentiation approach for the computation of sensitivities is developed, and several real-life examples are analyzed. Finally, a design optimization process of the aforementioned vehicle is carried out. Four different types of dynamic response optimization are presented: parameter identification, handling optimization, ride comfort optimization and multi-objective optimization; all of which are applied to the design of the coach example. Together with analytical and visual proof of the results, efficiency considerations are made. In summary, the dynamic behavior of vehicles is improved by using the multibody systems approach, along with advanced differentiation and optimization techniques, enabling an automatic, accurate and efficient tuning of design parameters.

Application of virtual certification techniques to vehicle design and track maintenance

Virtual certification partially substitutes by computer simulations the experimental techniques required for rail vehicle certification. In this paper, several works were these techniques were used in the vehicle design and track maintenance processes are presented. Dynamic simulation of multibody systems was used to virtually apply the EN14363 standard to certify the dynamic behaviour of vehicles. The works described are: assessment of a freight bogie design adapted to meter-gauge, assessment of a railway track layout for a subway network, freight bogie design with higher speed and axle load, and processing of the data acquired by a track recording vehicle for track maintenance.

Methodologies for Designing and Developing New Concepts in Vertical Transportation

Escalator and moving walkway are multibody systems with a design of more than a century. Developed methodology allows studying and improving any subsystem of both systems. In addition, new concepts can be developed and tested without the necessity and cost of a real construction. CITEF (Railway Technologies Research Centre) has been modelling escalators for more than four years. Several complex and innovative models has been developed to characterize static, kinematic and dynamic escalator behaviour. The high number of mechanical elements that are part of escalators complicate modelling task. In this way, methodologies and tools have been developed in order to automate these task and saving computational and time costs. Developed methodologies have been validated with the results of comparing real measurements and simulated outputs from a dynamic model.

Tratamiento consistente de restricciones e impacto en dinámica de sistemas multicuerpo

Esta tesis está enmarcada en el estudio de diferentes procedimientos numéricos para resolver la dinámica de un sistema multicuerpo sometido a restricciones e impacto, que puede estar compuesto por sólidos rígidos y deformables conectados entre sí por diversos tipos de uniones. Dentro de los métodos numéricos analizados se presta un especial interés a los métodos consistentes, los cuales tienen por objetivo que la energía calculada en cada paso de tiempo, para un sistema mecánico, tenga una evolución coherente con el comportamiento teórico de la energía. En otras palabras, un método consistente mantiene constante la energía total en un problema conservativo, y en presencia de fuerzas disipativas proporciona un decremento positivo de la energía total. En esta línea se desarrolla un algoritmo numérico consistente con la energía total para resolver las ecuaciones de la dinámica de un sistema multicuerpo. Como parte de este algoritmo se formulan energéticamente consistentes las restricciones y el contacto empleando multiplicadores de Lagrange, penalización y Lagrange aumentado. Se propone también un método para el contacto con sólidos rígidos representados mediante superficies implícitas, basado en una restricción regularizada que se adaptada adecuadamente para el cumplimiento exacto de la restricción de contacto y para ser consistente con la conservación de la energía total. En este contexto se estudian dos enfoques: uno para el contacto elástico puro (sin deformación) formulado con penalización y Lagrange aumentado; y otro basado en un modelo constitutivo para el contacto con penetración. En el segundo enfoque se usa un potencial de penalización que, en ausencia de componentes disipativas, restaura la energía almacenada en el contacto y disipa energía de forma consistente con el modelo continuo cuando las componentes de amortiguamiento y fricción son consideradas. This thesis focuses on the study of several numerical procedures used to solve the dynamics of a multibody system subjected to constraints and impact. The system may be composed by rigid and deformable bodies connected by different types of joints. Within this framework, special attention is paid to consistent methods, which preserve the theoretical behavior of the energy at each time step. In other words, a consistent method keeps the total energy constant in a conservative problem, and provides a positive decrease in the total energy when dissipative forces are present. A numerical algorithm has been developed for solving the dynamical equations of multibody systems, which is energetically consistent. Energetic consistency in contacts and constraints is formulated using Lagrange multipliers, penalty and augmented Lagrange methods. A contact methodology is proposed for rigid bodies with a boundary represented by implicit surfaces. The method is based on a suitable regularized constraint formulation, adapted both to fulfill exactly the contact constraint, and to be consistent with the conservation of the total energy. In this context two different approaches are studied: the first applied to pure elastic contact (without deformation), formulated with penalty and augmented Lagrange; and a second one based on a constitutive model for contact with penetration. In this second approach, a penalty potential is used in the constitutive model, that restores the energy stored in the contact when no dissipative effects are present. On the other hand, the energy is dissipated consistently with the continuous model when friction and damping are considered.

Simulación en tiempo real de vehículos industriales con modelos multicuerpo de gran complejidad

El objetivo de esta Tesis ha sido la consecución de simulaciones en tiempo real de vehículos industriales modelizados como sistemas multicuerpo complejos formados por sólidos rígidos. Para el desarrollo de un programa de simulación deben considerarse cuatro aspectos fundamentales: la modelización del sistema multicuerpo (tipos de coordenadas, pares ideales o impuestos mediante fuerzas), la formulación a utilizar para plantear las ecuaciones diferenciales del movimiento (coordenadas dependientes o independientes, métodos globales o topológicos, forma de imponer las ecuaciones de restricción), el método de integración numérica para resolver estas ecuaciones en el tiempo (integradores explícitos o implícitos) y finalmente los detalles de la implementación realizada (lenguaje de programación, librerías matemáticas, técnicas de paralelización). Estas cuatro etapas están interrelacionadas entre sí y todas han formado parte de este trabajo. Desde la generación de modelos de una furgoneta y de camión con semirremolque, el uso de tres formulaciones dinámicas diferentes, la integración de las ecuaciones diferenciales del movimiento mediante métodos explícitos e implícitos, hasta el uso de funciones BLAS, de técnicas de matrices sparse y la introducción de paralelización para utilizar los distintos núcleos del procesador. El trabajo presentado en esta Tesis ha sido organizado en 8 capítulos, dedicándose el primero de ellos a la Introducción. En el Capítulo 2 se presentan dos formulaciones semirrecursivas diferentes, de las cuales la primera está basada en una doble transformación de velocidades, obteniéndose las ecuaciones diferenciales del movimiento en función de las aceleraciones relativas independientes. La integración numérica de estas ecuaciones se ha realizado con el método de Runge-Kutta explícito de cuarto orden. La segunda formulación está basada en coordenadas relativas dependientes, imponiendo las restricciones por medio de penalizadores en posición y corrigiendo las velocidades y aceleraciones mediante métodos de proyección. En este segundo caso la integración de las ecuaciones del movimiento se ha llevado a cabo mediante el integrador implícito HHT (Hilber, Hughes and Taylor), perteneciente a la familia de integradores estructurales de Newmark. En el Capítulo 3 se introduce la tercera formulación utilizada en esta Tesis. En este caso las uniones entre los sólidos del sistema se ha realizado mediante uniones flexibles, lo que obliga a imponer los pares por medio de fuerzas. Este tipo de uniones impide trabajar con coordenadas relativas, por lo que la posición del sistema y el planteamiento de las ecuaciones del movimiento se ha realizado utilizando coordenadas Cartesianas y parámetros de Euler. En esta formulación global se introducen las restricciones mediante fuerzas (con un planteamiento similar al de los penalizadores) y la estabilización del proceso de integración numérica se realiza también mediante proyecciones de velocidades y aceleraciones. En el Capítulo 4 se presenta una revisión de las principales herramientas y estrategias utilizadas para aumentar la eficiencia de las implementaciones de los distintos algoritmos. En primer lugar se incluye una serie de consideraciones básicas para aumentar la eficiencia numérica de las implementaciones. A continuación se mencionan las principales características de los analizadores de códigos utilizados y también las librerías matemáticas utilizadas para resolver los problemas de álgebra lineal tanto con matrices densas como sparse. Por último se desarrolla con un cierto detalle el tema de la paralelización en los actuales procesadores de varios núcleos, describiendo para ello el patrón empleado y las características más importantes de las dos herramientas propuestas, OpenMP y las TBB de Intel. Hay que señalar que las características de los sistemas multicuerpo problemas de pequeño tamaño, frecuente uso de la recursividad, y repetición intensiva en el tiempo de los cálculos con fuerte dependencia de los resultados anteriores dificultan extraordinariamente el uso de técnicas de paralelización frente a otras áreas de la mecánica computacional, tales como por ejemplo el cálculo por elementos finitos. Basándose en los conceptos mencionados en el Capítulo 4, el Capítulo 5 está dividido en tres secciones, una para cada formulación propuesta en esta Tesis. En cada una de estas secciones se describen los detalles de cómo se han realizado las distintas implementaciones propuestas para cada algoritmo y qué herramientas se han utilizado para ello. En la primera sección se muestra el uso de librerías numéricas para matrices densas y sparse en la formulación topológica semirrecursiva basada en la doble transformación de velocidades. En la segunda se describe la utilización de paralelización mediante OpenMP y TBB en la formulación semirrecursiva con penalizadores y proyecciones. Por último, se describe el uso de técnicas de matrices sparse y paralelización en la formulación global con uniones flexibles y parámetros de Euler. El Capítulo 6 describe los resultados alcanzados mediante las formulaciones e implementaciones descritas previamente. Este capítulo comienza con una descripción de la modelización y topología de los dos vehículos estudiados. El primer modelo es un vehículo de dos ejes del tipo chasis-cabina o furgoneta, perteneciente a la gama de vehículos de carga medianos. El segundo es un vehículo de cinco ejes que responde al modelo de un camión o cabina con semirremolque, perteneciente a la categoría de vehículos industriales pesados. En este capítulo además se realiza un estudio comparativo entre las simulaciones de estos vehículos con cada una de las formulaciones utilizadas y se presentan de modo cuantitativo los efectos de las mejoras alcanzadas con las distintas estrategias propuestas en esta Tesis. Con objeto de extraer conclusiones más fácilmente y para evaluar de un modo más objetivo las mejoras introducidas en la Tesis, todos los resultados de este capítulo se han obtenido con el mismo computador, que era el top de la gama Intel Xeon en 2007, pero que hoy día está ya algo obsoleto. Por último los Capítulos 7 y 8 están dedicados a las conclusiones finales y las futuras líneas de investigación que pueden derivar del trabajo realizado en esta Tesis. Los objetivos de realizar simulaciones en tiempo real de vehículos industriales de gran complejidad han sido alcanzados con varias de las formulaciones e implementaciones desarrolladas. ABSTRACT The objective of this Dissertation has been the achievement of real time simulations of industrial vehicles modeled as complex multibody systems made up by rigid bodies. For the development of a simulation program, four main aspects must be considered: the modeling of the multibody system (types of coordinates, ideal joints or imposed by means of forces), the formulation to be used to set the differential equations of motion (dependent or independent coordinates, global or topological methods, ways to impose constraints equations), the method of numerical integration to solve these equations in time (explicit or implicit integrators) and the details of the implementation carried out (programming language, mathematical libraries, parallelization techniques). These four stages are interrelated and all of them are part of this work. They involve the generation of models for a van and a semitrailer truck, the use of three different dynamic formulations, the integration of differential equations of motion through explicit and implicit methods, the use of BLAS functions and sparse matrix techniques, and the introduction of parallelization to use the different processor cores. The work presented in this Dissertation has been structured in eight chapters, the first of them being the Introduction. In Chapter 2, two different semi-recursive formulations are shown, of which the first one is based on a double velocity transformation, thus getting the differential equations of motion as a function of the independent relative accelerations. The numerical integration of these equations has been made with the Runge-Kutta explicit method of fourth order. The second formulation is based on dependent relative coordinates, imposing the constraints by means of position penalty coefficients and correcting the velocities and accelerations by projection methods. In this second case, the integration of the motion equations has been carried out by means of the HHT implicit integrator (Hilber, Hughes and Taylor), which belongs to the Newmark structural integrators family. In Chapter 3, the third formulation used in this Dissertation is presented. In this case, the joints between the bodies of the system have been considered as flexible joints, with forces used to impose the joint conditions. This kind of union hinders to work with relative coordinates, so the position of the system bodies and the setting of the equations of motion have been carried out using Cartesian coordinates and Euler parameters. In this global formulation, constraints are introduced through forces (with a similar approach to the penalty coefficients) are presented. The stabilization of the numerical integration is carried out also by velocity and accelerations projections. In Chapter 4, a revision of the main computer tools and strategies used to increase the efficiency of the implementations of the algorithms is presented. First of all, some basic considerations to increase the numerical efficiency of the implementations are included. Then the main characteristics of the code’ analyzers used and also the mathematical libraries used to solve linear algebra problems (both with dense and sparse matrices) are mentioned. Finally, the topic of parallelization in current multicore processors is developed thoroughly. For that, the pattern used and the most important characteristics of the tools proposed, OpenMP and Intel TBB, are described. It needs to be highlighted that the characteristics of multibody systems small size problems, frequent recursion use and intensive repetition along the time of the calculation with high dependencies of the previous results complicate extraordinarily the use of parallelization techniques against other computational mechanics areas, as the finite elements computation. Based on the concepts mentioned in Chapter 4, Chapter 5 is divided into three sections, one for each formulation proposed in this Dissertation. In each one of these sections, the details of how these different proposed implementations have been made for each algorithm and which tools have been used are described. In the first section, it is shown the use of numerical libraries for dense and sparse matrices in the semirecursive topological formulation based in the double velocity transformation. In the second one, the use of parallelization by means OpenMP and TBB is depicted in the semi-recursive formulation with penalization and projections. Lastly, the use of sparse matrices and parallelization techniques is described in the global formulation with flexible joints and Euler parameters. Chapter 6 depicts the achieved results through the formulations and implementations previously described. This chapter starts with a description of the modeling and topology of the two vehicles studied. The first model is a two-axle chassis-cabin or van like vehicle, which belongs to the range of medium charge vehicles. The second one is a five-axle vehicle belonging to the truck or cabin semi-trailer model, belonging to the heavy industrial vehicles category. In this chapter, a comparative study is done between the simulations of these vehicles with each one of the formulations used and the improvements achieved are presented in a quantitative way with the different strategies proposed in this Dissertation. With the aim of deducing the conclusions more easily and to evaluate in a more objective way the improvements introduced in the Dissertation, all the results of this chapter have been obtained with the same computer, which was the top one among the Intel Xeon range in 2007, but which is rather obsolete today. Finally, Chapters 7 and 8 are dedicated to the final conclusions and the future research projects that can be derived from the work presented in this Dissertation. The objectives of doing real time simulations in high complex industrial vehicles have been achieved with the formulations and implementations developed.

Nonlinear models for lateral dynamics of railway vehicles on bridges subject to wind action

The study of lateral dynamics of running trains on bridges is of importance mainly for the safety of the traffic, and may be relevant for laterally compliant bridges. These studies require threedimensional coupled vehicle-bridge models, wheree consideration of wheel to rail contact is a key aspect. Furthermore, an adequate evaluation of safety of rail traffic requires nonlinear models. A nonlinear coupled model is proposed here for vehicle-structure vertical and lateral dynamics. Vehicles are considered as fully three-dimensional multibody systems including gyroscopic terms and large rotation effects. The bridge structure is modeled by means of finite elements which may be of beam, shell or continuum type and may include geometric or material nonlinearities. The track geometry includes distributed track alignment irregularities. Both subsystems (bridge and vehicles) are described with coordinates in absolute reference frames, as opposed to alternative approaches which describe the multibody system with coordinates relative to the base bridge motion. The wheelrail contact employed is a semi-Hertzian model based on realistic wheel-rail profiles. It allows a detailed geometrical description of the contact patch under each wheel including multiple-point contact, flange contact and uplift. Normal and tangential stresses in each contact are integrated at each time-step to obtain the resultant contact forces. The models have been implemented within an existing finite element analysis software with multibody capabilities, Abaqus (Simulia Ltd., 2010). Further details of the model are presented in Antolín et al. (2012). Representative applications are presented for railway vehicles under lateral wind action on laterally compliant viaducts, showing the relevance of the nonlinear wheel-rail contact model as well as the interaction between bridge and vehicle.

Co-simulation Methodologies for Hybrid and Electric Vehicle Dynamics

In recent decades, full electric and hybrid electric vehicles have emerged as an alternative to conventional cars due to a range of factors, including environmental and economic aspects. These vehicles are the result of considerable efforts to seek ways of reducing the use of fossil fuel for vehicle propulsion. Sophisticated technologies such as hybrid and electric powertrains require careful study and optimization. Mathematical models play a key role at this point. Currently, many advanced mathematical analysis tools, as well as computer applications have been built for vehicle simulation purposes. Given the great interest of hybrid and electric powertrains, along with the increasing importance of reliable computer-based models, the author decided to integrate both aspects in the research purpose of this work. Furthermore, this is one of the first final degree projects held at the ETSII (Higher Technical School of Industrial Engineers) that covers the study of hybrid and electric propulsion systems. The present project is based on MBS3D 2.0, a specialized software for the dynamic simulation of multibody systems developed at the UPM Institute of Automobile Research (INSIA). Automobiles are a clear example of complex multibody systems, which are present in nearly every field of engineering. The work presented here benefits from the availability of MBS3D software. This program has proven to be a very efficient tool, with a highly developed underlying mathematical formulation. On this basis, the focus of this project is the extension of MBS3D features in order to be able to perform dynamic simulations of hybrid and electric vehicle models. This requires the joint simulation of the mechanical model of the vehicle, together with the model of the hybrid or electric powertrain. These sub-models belong to completely different physical domains. In fact the powertrain consists of energy storage systems, electrical machines and power electronics, connected to purely mechanical components (wheels, suspension, transmission, clutch…). The challenge today is to create a global vehicle model that is valid for computer simulation. Therefore, the main goal of this project is to apply co-simulation methodologies to a comprehensive model of an electric vehicle, where sub-models from different areas of engineering are coupled. The created electric vehicle (EV) model consists of a separately excited DC electric motor, a Li-ion battery pack, a DC/DC chopper converter and a multibody vehicle model. Co-simulation techniques allow car designers to simulate complex vehicle architectures and behaviors, which are usually difficult to implement in a real environment due to safety and/or economic reasons. In addition, multi-domain computational models help to detect the effects of different driving patterns and parameters and improve the models in a fast and effective way. Automotive designers can greatly benefit from a multidisciplinary approach of new hybrid and electric vehicles. In this case, the global electric vehicle model includes an electrical subsystem and a mechanical subsystem. The electrical subsystem consists of three basic components: electric motor, battery pack and power converter. A modular representation is used for building the dynamic model of the vehicle drivetrain. This means that every component of the drivetrain (submodule) is modeled separately and has its own general dynamic model, with clearly defined inputs and outputs. Then, all the particular submodules are assembled according to the drivetrain configuration and, in this way, the power flow across the components is completely determined. Dynamic models of electrical components are often based on equivalent circuits, where Kirchhoff’s voltage and current laws are applied to draw the algebraic and differential equations. Here, Randles circuit is used for dynamic modeling of the battery and the electric motor is modeled through the analysis of the equivalent circuit of a separately excited DC motor, where the power converter is included. The mechanical subsystem is defined by MBS3D equations. These equations consider the position, velocity and acceleration of all the bodies comprising the vehicle multibody system. MBS3D 2.0 is entirely written in MATLAB and the structure of the program has been thoroughly studied and understood by the author. MBS3D software is adapted according to the requirements of the applied co-simulation method. Some of the core functions are modified, such as integrator and graphics, and several auxiliary functions are added in order to compute the mathematical model of the electrical components. By coupling and co-simulating both subsystems, it is possible to evaluate the dynamic interaction among all the components of the drivetrain. ‘Tight-coupling’ method is used to cosimulate the sub-models. This approach integrates all subsystems simultaneously and the results of the integration are exchanged by function-call. This means that the integration is done jointly for the mechanical and the electrical subsystem, under a single integrator and then, the speed of integration is determined by the slower subsystem. Simulations are then used to show the performance of the developed EV model. However, this project focuses more on the validation of the computational and mathematical tool for electric and hybrid vehicle simulation. For this purpose, a detailed study and comparison of different integrators within the MATLAB environment is done. Consequently, the main efforts are directed towards the implementation of co-simulation techniques in MBS3D software. In this regard, it is not intended to create an extremely precise EV model in terms of real vehicle performance, although an acceptable level of accuracy is achieved. The gap between the EV model and the real system is filled, in a way, by introducing the gas and brake pedals input, which reflects the actual driver behavior. This input is included directly in the differential equations of the model, and determines the amount of current provided to the electric motor. For a separately excited DC motor, the rotor current is proportional to the traction torque delivered to the car wheels. Therefore, as it occurs in the case of real vehicle models, the propulsion torque in the mathematical model is controlled through acceleration and brake pedal commands. The designed transmission system also includes a reduction gear that adapts the torque coming for the motor drive and transfers it. The main contribution of this project is, therefore, the implementation of a new calculation path for the wheel torques, based on performance characteristics and outputs of the electric powertrain model. Originally, the wheel traction and braking torques were input to MBS3D through a vector directly computed by the user in a MATLAB script. Now, they are calculated as a function of the motor current which, in turn, depends on the current provided by the battery pack across the DC/DC chopper converter. The motor and battery currents and voltages are the solutions of the electrical ODE (Ordinary Differential Equation) system coupled to the multibody system. Simultaneously, the outputs of MBS3D model are the position, velocity and acceleration of the vehicle at all times. The motor shaft speed is computed from the output vehicle speed considering the wheel radius, the gear reduction ratio and the transmission efficiency. This motor shaft speed, somehow available from MBS3D model, is then introduced in the differential equations corresponding to the electrical subsystem. In this way, MBS3D and the electrical powertrain model are interconnected and both subsystems exchange values resulting as expected with tight-coupling approach.When programming mathematical models of complex systems, code optimization is a key step in the process. A way to improve the overall performance of the integration, making use of C/C++ as an alternative programming language, is described and implemented. Although this entails a higher computational burden, it leads to important advantages regarding cosimulation speed and stability. In order to do this, it is necessary to integrate MATLAB with another integrated development environment (IDE), where C/C++ code can be generated and executed. In this project, C/C++ files are programmed in Microsoft Visual Studio and the interface between both IDEs is created by building C/C++ MEX file functions. These programs contain functions or subroutines that can be dynamically linked and executed from MATLAB. This process achieves reductions in simulation time up to two orders of magnitude. The tests performed with different integrators, also reveal the stiff character of the differential equations corresponding to the electrical subsystem, and allow the improvement of the cosimulation process. When varying the parameters of the integration and/or the initial conditions of the problem, the solutions of the system of equations show better dynamic response and stability, depending on the integrator used. Several integrators, with variable and non-variable step-size, and for stiff and non-stiff problems are applied to the coupled ODE system. Then, the results are analyzed, compared and discussed. From all the above, the project can be divided into four main parts: 1. Creation of the equation-based electric vehicle model; 2. Programming, simulation and adjustment of the electric vehicle model; 3. Application of co-simulation methodologies to MBS3D and the electric powertrain subsystem; and 4. Code optimization and study of different integrators. Additionally, in order to deeply understand the context of the project, the first chapters include an introduction to basic vehicle dynamics, current classification of hybrid and electric vehicles and an explanation of the involved technologies such as brake energy regeneration, electric and non-electric propulsion systems for EVs and HEVs (hybrid electric vehicles) and their control strategies. Later, the problem of dynamic modeling of hybrid and electric vehicles is discussed. The integrated development environment and the simulation tool are also briefly described. The core chapters include an explanation of the major co-simulation methodologies and how they have been programmed and applied to the electric powertrain model together with the multibody system dynamic model. Finally, the last chapters summarize the main results and conclusions of the project and propose further research topics. In conclusion, co-simulation methodologies are applicable within the integrated development environments MATLAB and Visual Studio, and the simulation tool MBS3D 2.0, where equation-based models of multidisciplinary subsystems, consisting of mechanical and electrical components, are coupled and integrated in a very efficient way.

A time-domain finite element method for seakeeping and wave resistance problems

El objetivo de la tesis es la investigación de algoritmos numéricos para el desarrollo de herramientas numéricas para la simulación de problemas tanto de comportamiento en la mar como de resistencia al avance de buques y estructuras flotantes. La primera herramienta desarrollada resuelve el problema de difracción y radiación de olas. Se basan en el método de los elementos finitos (MEF) para la resolución de la ecuación de Laplace, así como en esquemas basados en MEF, integración a lo largo de líneas de corriente, y en diferencias finitas desarrollados para la condición de superficie libre. Se han desarrollado herramientas numéricas para la resolución de la dinámica de sólido rígido en sistemas multicuerpos con ligaduras. Estas herramientas han sido integradas junto con la herramienta de resolución de olas difractadas y radiadas para la resolución de problemas de interacción de cuerpos con olas. También se han diseñado algoritmos de acoplamientos con otras herramientas numéricas para la resolución de problemas multifísica. En particular, se han realizado acoplamientos con una herramienta numérica basada de cálculo de estructuras con MEF para problemas de interacción fluido-estructura, otra de cálculo de líneas de fondeo, y con una herramienta numérica de cálculo de flujos en tanques internos para problemas acoplados de comportamiento en la mar con “sloshing”. Se han realizado simulaciones numéricas para la validación y verificación de los algoritmos desarrollados, así como para el análisis de diferentes casos de estudio con aplicaciones diversas en los campos de la ingeniería naval, oceánica, y energías renovables marinas. ABSTRACT The objective of this thesis is the research on numerical algorithms to develop numerical tools to simulate seakeeping problems as well as wave resistance problems of ships and floating structures. The first tool developed is a wave diffraction-radiation solver. It is based on the finite element method (FEM) in order to solve the Laplace equation, as well as numerical schemes based on FEM, streamline integration, and finite difference method tailored for solving the free surface boundary condition. It has been developed numerical tools to solve solid body dynamics of multibody systems with body links across them. This tool has been integrated with the wave diffraction-radiation solver to solve wave-body interaction problems. Also it has been tailored coupling algorithms with other numerical tools in order to solve multi-physics problems. In particular, it has been performed coupling with a MEF structural solver to solve fluid-structure interaction problems, with a mooring solver, and with a solver capable of simulating internal flows in tanks to solve couple seakeeping-sloshing problems. Numerical simulations have been carried out to validate and verify the developed algorithms, as well as to analyze case studies in the areas of marine engineering, offshore engineering, and offshore renewable energy.

Dynamic analysis of road vehicle-bridge systems under turbulent wind by means of Finite Element Models

When an automobile passes over a bridge dynamic effects are produced in vehicle and structure. In addition, the bridge itself moves when exposed to the wind inducing dynamic effects on the vehicle that have to be considered. The main objective of this work is to understand the influence of the different parameters concerning the vehicle, the bridge, the road roughness or the wind in the comfort and safety of the vehicles when crossing bridges. Non linear finite element models are used for structures and multibody dynamic models are employed for vehicles. The interaction between the vehicle and the bridge is considered by contact methods. Road roughness is described by the power spectral density (PSD) proposed by the ISO 8608. To consider that the profiles under right and left wheels are different but not independent, the hypotheses of homogeneity and isotropy are assumed. To generate the wind velocity history along the road the Sandia method is employed. The global problem is solved by means of the finite element method. First the methodology for modelling the interaction is verified in a benchmark. Following, the case of a vehicle running along a rigid road and subjected to the action of the turbulent wind is analyzed and the road roughness is incorporated in a following step. Finally the flexibility of the bridge is added to the model by making the vehicle run over the structure. The application of this methodology will allow to understand the influence of the different parameters in the comfort and safety of road vehicles crossing wind exposed bridges. Those results will help to recommend measures to make the traffic over bridges more reliable without affecting the structural integrity of the viaduct