Development of a simulation tool for torsional vibration of branched power transmission system

In this master's thesis a mechanical model that is driven with variable speed synchronous machine was developed. The developed mechanical model simulates the mechanics of power transmission and its torsional vibrations. The mechanical model was developed for the need of the branched mechanics of a rolling mill and the propulsion system of a tanker. First, the scope of the thesis was to clarify the concepts connected to the mechanical model. The clarified concepts are the variable speed drive, the mechanics of power transmission and the vibrationsin the power transmission. Next, the mechanical model with straight shaft line and twelve moments of inertia that existed in the beginning was developed to be branched considering the case of parallel machines and the case of parallel rolls. Additionally, the model was expanded for the need of moreaccurate simulation to up to thirty moments of inertia. The model was also enhanced to enable three phase short circuit situation of the simulated machine. After that the mechanical model was validated by comparing the results of the developed simulation tool to results of other simulation tools. The compared results are the natural frequencies and mode shapes of torsional vibration, the response of the load torque step and the stress in the mechanical system occurred by the permutation of the magnetic field that is arisen from the three phase short circuit situation. The comparisons were accomplished well and the mechanical model was validated for the compared cases. Further development to be made is to develop the load torque to be time-dependent and to install two frequency converters and two FEM modeled machines to be simulated parallel.

Torque vibration model of axial-flux surface-mounted permanent magnet synchronous machine

In order that the radius and thus ununiform structure of the teeth and otherelectrical and magnetic parts of the machine may be taken into consideration the calculation of an axial flux permanent magnet machine is, conventionally, doneby means of 3D FEM-methods. This calculation procedure, however, requires a lotof time and computer recourses. This study proves that also analytical methods can be applied to perform the calculation successfully. The procedure of the analytical calculation can be summarized into following steps: first the magnet is divided into slices, which makes the calculation for each section individually, and then the parts are submitted to calculation of the final results. It is obvious that using this method can save a lot of designing and calculating time. Thecalculation program is designed to model the magnetic and electrical circuits of surface mounted axial flux permanent magnet synchronous machines in such a way, that it takes into account possible magnetic saturation of the iron parts. Theresult of the calculation is the torque of the motor including the vibrations. The motor geometry and the materials and either the torque or pole angle are defined and the motor can be fed with an arbitrary shape and amplitude of three-phase currents. There are no limits for the size and number of the pole pairs nor for many other factors. The calculation steps and the number of different sections of the magnet are selectable, but the calculation time is strongly depending on this. The results are compared to the measurements of real prototypes. The permanent magnet creates part of the flux in the magnetic circuit. The form and amplitude of the flux density in the air-gap depends on the geometry and material of the magnetic circuit, on the length of the air-gap and remanence flux density of the magnet. Slotting is taken into account by using the Carter factor in the slot opening area. The calculation is simple and fast if the shape of the magnetis a square and has no skew in relation to the stator slots. With a more complicated magnet shape the calculation has to be done in several sections. It is clear that according to the increasing number of sections also the result will become more accurate. In a radial flux motor all sections of the magnets create force with a same radius. In the case of an axial flux motor, each radial section creates force with a different radius and the torque is the sum of these. The magnetic circuit of the motor, consisting of the stator iron, rotor iron, air-gap, magnet and the slot, is modelled with a reluctance net, which considers the saturation of the iron. This means, that several iterations, in which the permeability is updated, has to be done in order to get final results. The motor torque is calculated using the instantaneous linkage flux and stator currents. Flux linkage is called the part of the flux that is created by the permanent magnets and the stator currents passing through the coils in stator teeth. The angle between this flux and the phase currents define the torque created by the magnetic circuit. Due to the winding structure of the stator and in order to limit the leakage flux the slot openings of the stator are normally not made of ferromagnetic material even though, in some cases, semimagnetic slot wedges are used. In the slot opening faces the flux enters the iron almost normally (tangentially with respect to the rotor flux) creating tangential forces in the rotor. This phenomenon iscalled cogging. The flux in the slot opening area on the different sides of theopening and in the different slot openings is not equal and so these forces do not compensate each other. In the calculation it is assumed that the flux entering the left side of the opening is the component left from the geometrical centre of the slot. This torque component together with the torque component calculated using the Lorenz force make the total torque of the motor. It is easy to assume that when all the magnet edges, where the derivative component of the magnet flux density is at its highest, enter the slot openings at the same time, this will have as a result a considerable cogging torque. To reduce the cogging torquethe magnet edges can be shaped so that they are not parallel to the stator slots, which is the common way to solve the problem. In doing so, the edge may be spread along the whole slot pitch and thus also the high derivative component willbe spread to occur equally along the rotation. Besides forming the magnets theymay also be placed somewhat asymmetric on the rotor surface. The asymmetric distribution can be made in many different ways. All the magnets may have a different deflection of the symmetrical centre point or they can be for example shiftedin pairs. There are some factors that limit the deflection. The first is that the magnets cannot overlap. The magnet shape and the relative width compared to the pole define the deflection in this case. The other factor is that a shifting of the poles limits the maximum torque of the motor. If the edges of adjacent magnets are very close to each other the leakage flux from one pole to the other increases reducing thus the air-gap magnetization. The asymmetric model needs some assumptions and simplifications in order to limit the size of the model and calculation time. The reluctance net is made for symmetric distribution. If the magnets are distributed asymmetrically the flux in the different pole pairs will not be exactly the same. Therefore, the assumption that the flux flows from the edges of the model to the next pole pairs, in the calculation model from one edgeto the other, is not correct. If it were wished for that this fact should be considered in multi-pole pair machines, this would mean that all the poles, in other words the whole machine, should be modelled in reluctance net. The error resulting from this wrong assumption is, nevertheless, irrelevant.

Vibration free machining tools

Appearance of the vibration is the very important problem in long tool turning and milling. Current solutions of minimizing vibrations provided by different tool suppliers are very expensive. This Master’s Thesis is presenting the new type of vibration free machining tools produced by Konepaja ASTEX Gear Oy that have cheaper production costs compare to competitors’ products. Vibration problems in machining and their today’s solutions are analyzed in this work. The new vibration damping invention is presented and described. Moreover, the production, laboratory experimental modal analysis and practical testing of the new vibration free prototypes are observed and analyzed on the pages of this Thesis. Based on the testing results the new invention is acknowledged to be successful and approved for further studies and developments.

Bus bar aeolian vibration field tests

Large amplitude bus bar aeolian vibration may lead to post insulator damage. Different damping applications are used to decrease the risk of large amplitude aeolian vibration. In this paper the post insulator load caused by the bus bar aeolian vibration and the effect of damping methods are evaluated. The effects of three types of bus bar connectors and three types of primary structures are studied. Two actual damping devices, damping cable and their combinations are studied. The post insulator loads are studied with strain gage based custom made force sensors installed on the both ends of the post insulator and with the displacement sensor installed on the midpoint of the bus bar. The post insulator loads are calculated from the strain values and the damping properties are determined from the displacement history. The bus bar is deflected with a hanging weight. The weight is released and the bus bar is left to free damped vibration. Both actual bus bar vibration dampers RIBE and SBI were very effective against the aeolian vibration. Combining vibration damper with damping cable will increase the damping ratio but it may be unnecessary considering the extra effort. Bus bar connector type or primary structure have no effect on the vertical load. The bending moment at the post insulator with double sided bus bar connector is significantly higher than at the post insulator with single sided bus bar connector. No reliable conclusions about bus bar connector type effect can be done, but the roller bearing type or central bearing type connector may reduce the bending moment. The RHS steel frame as primary structure may increase the bending moment peak values since it is the least rigid primary structure type and it may start to vibrate as a response to the awakening force of the vibrating bus bar.

Stiffness based trajectory planning and feedforward based vibration suppression control of parallel robot machines

The dissertation proposes two control strategies, which include the trajectory planning and vibration suppression, for a kinematic redundant serial-parallel robot machine, with the aim of attaining the satisfactory machining performance. For a given prescribed trajectory of the robot's end-effector in the Cartesian space, a set of trajectories in the robot's joint space are generated based on the best stiffness performance of the robot along the prescribed trajectory. To construct the required system-wide analytical stiffness model for the serial-parallel robot machine, a variant of the virtual joint method (VJM) is proposed in the dissertation. The modified method is an evolution of Gosselin's lumped model that can account for the deformations of a flexible link in more directions. The effectiveness of this VJM variant is validated by comparing the computed stiffness results of a flexible link with the those of a matrix structural analysis (MSA) method. The comparison shows that the numerical results from both methods on an individual flexible beam are almost identical, which, in some sense, provides mutual validation. The most prominent advantage of the presented VJM variant compared with the MSA method is that it can be applied in a flexible structure system with complicated kinematics formed in terms of flexible serial links and joints. Moreover, by combining the VJM variant and the virtual work principle, a systemwide analytical stiffness model can be easily obtained for mechanisms with both serial kinematics and parallel kinematics. In the dissertation, a system-wide stiffness model of a kinematic redundant serial-parallel robot machine is constructed based on integration of the VJM variant and the virtual work principle. Numerical results of its stiffness performance are reported. For a kinematic redundant robot, to generate a set of feasible joints' trajectories for a prescribed trajectory of its end-effector, its system-wide stiffness performance is taken as the constraint in the joints trajectory planning in the dissertation. For a prescribed location of the end-effector, the robot permits an infinite number of inverse solutions, which consequently yields infinite kinds of stiffness performance. Therefore, a differential evolution (DE) algorithm in which the positions of redundant joints in the kinematics are taken as input variables was employed to search for the best stiffness performance of the robot. Numerical results of the generated joint trajectories are given for a kinematic redundant serial-parallel robot machine, IWR (Intersector Welding/Cutting Robot), when a particular trajectory of its end-effector has been prescribed. The numerical results show that the joint trajectories generated based on the stiffness optimization are feasible for realization in the control system since they are acceptably smooth. The results imply that the stiffness performance of the robot machine deviates smoothly with respect to the kinematic configuration in the adjacent domain of its best stiffness performance. To suppress the vibration of the robot machine due to varying cutting force during the machining process, this dissertation proposed a feedforward control strategy, which is constructed based on the derived inverse dynamics model of target system. The effectiveness of applying such a feedforward control in the vibration suppression has been validated in a parallel manipulator in the software environment. The experimental study of such a feedforward control has also been included in the dissertation. The difficulties of modelling the actual system due to the unknown components in its dynamics is noticed. As a solution, a back propagation (BP) neural network is proposed for identification of the unknown components of the dynamics model of the target system. To train such a BP neural network, a modified Levenberg-Marquardt algorithm that can utilize an experimental input-output data set of the entire dynamic system is introduced in the dissertation. Validation of the BP neural network and the modified Levenberg- Marquardt algorithm is done, respectively, by a sinusoidal output approximation, a second order system parameters estimation, and a friction model estimation of a parallel manipulator, which represent three different application aspects of this method.

Vibration analysis of a power take-off line

Gear rattle is a phenomenon that occurs when idling or lightly loaded gears collide due to engine’s torque fluctuations. This behaviour is related to vibration behaviour of the transmission system. Aim of this master’s thesis is to evaluate Adams and Adams/Machinery as a simulation tools for modelling the rattle e ect in a transmission system. A case study of tractor’s power take-o driveline, suspected to be prone to rattle, is performed in this work. Modelling methods used by Adams in this type of study are presented in the theory section while simulation model build with the software during this work is presented in the results. The Machinery toolbox is used to create gears and bearings while other model components are created with standard Adams tool set. Geometries and excitations are exported from other softwares. Results were obtained from multiple variations of a base model. These result sets and literature review suggest that Adams/Machinery may not be the most suitable tool for rattle analysis. While the system behaviour was partially captured, for accurate modelling user-written routines must be used which may be more easily performed with other tools. Further research about this topic is required.

Avaruusinstrumentin mekaniikkasuunnittelu

Tämän insinöörityön tarkoituksena on kehittää avaruusinstrumentti, joka on osa Euroopan avaruusjärjestön ESA:n ja Japanin avaruusjärjestön JAXA:n BepiColombo-yhteistyöhanketta. Satelliitti lähetetään Merkurius-planeetan kiertoradalle vuonna 2013. Avaruusaluksen matka Merkuriukseen kestää yhteensä kuusi vuotta ja on perillä vuonna 2019. Yksi BepiColombo-satelliitin tieteellisistä instrumenteista on Oxford Instruments Analytical Oy:n kehittämä SIXS-instrumentti (Solar Intensity X-ray and particle Spectrometer). Instrumentin tarkoituksena on mitata auringosta tulevaa röntgen- ja partikkelisäteilyä. Se toimii yhteistyössä Merkuriuksen pintaa mittaavan MIXS-instrumentin (Mercury Imaging X-ray Spectrometer) kanssa. Tuloksista pystytään analysoimaan ne alkuaineet, joista Merkuriuksen pinta koostuu. Työn alussa esitellään teoriataustaa alkuaineiden mittauksesta niiltä osin, kuin se tämän työn kannalta on tarpeellista. Työssä syvennytään tarkemmin auringosta tulevan säteilyn mittauksesta vastaavan instrumentin tekniikkaan ja mekaniikkasuunnitteluun. Instrumentin lämpöteknisestä suunnittelusta, värähtelymittauksista ja lujuusanalyysista on työhön sisällytetty pääasiat. Työn tuloksena on kehitetty instrumenttiin tulevan partikkelidetektorin prototyyppi sekä instrumenttikotelon malli. Lopullisen koon instrumenttikotelolle määrittää vaadittavan elektroniikan viemä tila. Mittalaitteen kehitystyö jatkuu Oxford Instruments Analytical Oy:ssä vuoteen 2011 saakka.

Raideliikennetärinä

Ratahallintokeskuksella (RHK) on ympäristöstrategia, joka toimii vuosittain päivitettävän ympäristöohjelman lähtökohtana. Ympäristöstrategia koostuu osastrategioista, joita ovat muun muassa melun ja tärinän osastrategiat. Ympäristöohjelman keskeisiä tavoitteita ovat esimerkiksi uusien ympäristöhaittojen ehkäiseminen, ympäristökuormituksen vähentäminen ja haittojen poistaminen. Ympäristöohjelmassa painotetaan muun muassa rautatieliikenteen melu- ja tärinäongelmien vähentämistä. Tässä työssä tehty tärinäkohteiden kartoitus on olennainen osa ympäristöohjelman toimeenpanoa. Työn päätavoite oli koota Ratahallintokeskuksessa oleva tärinäkohteisiin liittyvä materiaali ja viedä se paikkatieto-ohjelmaan sekä luoda tärinäkohteista digitaalinen paikkatietokartta ArcView-ohjelman avulla. Työ voidaan jakaa neljään osaan. Teoriaosuuden ensimmäisessä osassa paneudutaan tärinän kokemiseen ja sen haittavaikutuksiin sekä tärinän fysikaalisiin perusteisiin ja maaperän vaikutuksiin tärinän leviämisessä ja siirtymisessä. Toisessa osassa selvitetään raideliikennetärinän erityispiirteitä sekä sitä, miten raideliikennetärinän leviämistä tutkitaan matemaattisesti. Toisessa osassa käsitellään myös tärinän mittaamiseen liittyvät ja siinä vaadittavat erityispiirteet. Työn kolmannessa osassa kerrotaan, miten työn päätavoite toteutettiin eli tärinäkohteiden nykytila kartoitettiin. Neljännessä osassa tarkastellaan liikennetärinän kansainvälisiä standardeja ja ohjeita. Työn tuloksena syntynyt paikkatietoaineisto on Ratahallintokeskukselle tärkeä työkalu tärinäkohteiden tiedonhallintaan. Tietokanta luotiin sellaiseksi, että uusien tärinäkohteiden vieminen järjestelmään on mahdollista. Paikkatietomuotoinen aineisto on yleistymässä tärkeänä tiedonhallinnan välineenä RHK:ssa. Tärinäkohteisiin liittyvä paikkatietoaineisto tulee olemaan osa Ratahallintokeskuksen laajempaa tietojärjestelmää. Raideliikennetärinän tiedonhallinnan parantamiseksi voidaan paikkatietoaineistoon esimerkiksi yhdistää pehmeikkörekisteritiedot ja asukasmäärät. Näiden tietojen avulla uusia asuinalueita kaavoitettaessa voidaan paremmin tunnistaa, mitkä alueet ovat tärinän kannalta mahdolliset riskialueet. Tässä työssä RHK:n kanssa määritetyt ominaisuustiedot ja tietojen kuvaukset tulisi jatkossa ottaa käyttöön uusissa tärinään liittyvissä selvityksissä. Ominaisuustietojen avulla tullaan tekemään ohjeet jossa määritetään uusissa tärinään liittyvissä raporteissa esitettävät tiedot.