Entwicklung textiler Maschinenelemente für den Einsatz in Windkraftanlagen und Seilwinden

Es sollen hochfeste, gewichtreduzierte Zug- und Tragmittel aus hochmodularen (HM) und hochfesten (HT) Fasern validiert und dabei sowohl runde als auch flache, riemenartige Strukturen untersucht werden. Dadurch sind effizientere Fördersysteme und die Überwindung technischer Grenzen möglich. Darüber hinaus soll das Hauptkriterium für ein breites Anwendungsspektrum geschaffen werden: ein anerkanntes, zerstörungsfreies Prüfverfahren, mit dem der Austausch- bzw. Wartungszeitpunkt des textilen Tragmittels bestimmt werden kann. Können die o. g. Punkte erfolgreich bearbeitet werden, erfolgt eine Ausdehnung der textilen Strukturen in den Bereich kraftübertragender Maschinenelemente. Anhand von Feldversuchen in fördertechnischen Anlagen im Bergbau/ Intralogistik soll erstmals der vollständige Nachweis geführt werden, dass derartige textile Strukturen in technischen Anwendungen eingesetzt werden können. Der Nachweis umfasst die Validierung einer Vielzahl von Einzelschwerpunkten wie die Entwicklung einer Endlos-Herstellungstechnologie bzw. Endverbindung, die Tragmitteldimensionierung, die Erbringung von Festigkeitsnachweisen, die Erarbeitung von Vorschriften und die Erprobung der Verfahren zur Zustandsüberwachung.

Beitrag einer nutzungsabhängigen Instandhaltung zur Planung von Leistungsverfügbarkeit

Stets darauf bedacht, die Anlagen- und Maschinenverfügbarkeit bei möglichst geringem Ressourceneinsatz zu gewährleisten, wird die Rolle der Instandhaltung als unternehmerischer Wertschöpfungsfaktor immer bedeutsamer. Voraussetzung für eine Nutzbarmachung bestehender Potentiale sind neue Werkzeuge und Ansätze, deren Umsetzung eine effiziente Sicherstellung von Verfügbarkeit ermöglicht. Vor diesem Hintergrund wurde im Teilprojekt C3 des DFG Paketantrags 672 ein Konzept zur nutzungsabhängigen Instandhaltung entwickelt. Auf Grundlage des bestehenden Zusammenhangs von Nutzung und Abnutzung risikobehafteter Bauteile intralogistischer Systeme können damit die durch zukünftige Systemlasten hervorgerufenen Beanspruchungen antizipiert werden. Instandhaltungsmaßnahmen und technische Verfügbarkeiten werden dadurch anforderungsgerecht und ressourcen-optimal planbar.

Maintenance strategies affecting equipment performance

Proper maintenance of plant items is crucial for the safe and profitable operation of process plants, The relevant maintenance policies fall into the following four categories: (i) preventivejopportunistic/breakdown replacement policies, (ii) inspection/inspection-repair-replacernent policies, (iii) restorative maintenance policies, and (iv) condition based maintenance policies, For correlating failure times of component equipnent and complete systems, the Weibull failure distribution has been used, A new powerful method, SEQLIM, has been proposed for the estimation of the Weibull parameters; particularly, when maintenance records contain very few failures and many successful operation times. When a system consists of a number of replaceable, ageing components, an opporturistic replacernent policy has been found to be cost-effective, A simple opportunistic rrodel has been developed. Inspection models with various objective functions have been investigated, It was found that, on the assumption of a negative exponential failure distribution, all models converge to the same optimal inspection interval; provided the safety components are very reliable and the demand rate is low, When deterioration becomes a contributory factor to same failures, periodic inspections, calculated from above models, are too frequent, A case of safety trip systems has been studied, A highly effective restorative maintenance policy can be developed if the performance of the equipment under this category can be related to some predictive modelling. A novel fouling model has been proposed to determine cleaning strategies of condensers, Condition-based maintenance policies have been investigated. A simple gauge has been designed for condition monitoring of relief valve springs. A typical case of an exothermic inert gas generation plant has been studied, to demonstrate how various policies can be applied to devise overall maintenance actions.

Fibre-based devices for next generation photonics communication systems

The future broadband information network will undoubtedly integrate the mobility and flexibility of wireless access systems with the huge bandwidth capacity of photonics solutions to enable a communication system capable of handling the anticipated demand for interactive services. Towards wide coverage and low cost implementations of such broadband wireless photonics communication networks, various aspects of the enabling technologies are continuingly generating intense research interest. Among the core technologies, the optical generation and distribution of radio frequency signals over fibres, and the fibre optic signal processing of optical and radio frequency signals, have been the subjects for study in this thesis. Based on the intrinsic properties of single-mode optical fibres, and in conjunction with the concepts of optical fibre delay line filters and fibre Bragg gratings, a number of novel fibre-based devices, potentially suitable for applications in the future wireless photonics communication systems, have been realised. Special single-mode fibres, namely, the high birefringence (Hi-Bi) fibre and the Er/Yb doped fibre have been employed so as to exploit their merits to achieve practical and cost-effective all-fibre architectures. A number of fibre-based complex signal processors for optical and radio frequencies using novel Hi-Bi fibre delay line filter architectures have been illustrated. In particular, operations such as multichannel flattop bandpass filtering, simultaneous complementary outputs and bidirectional nonreciprocal wavelength interleaving, have been demonstrated. The proposed configurations featured greatly reduced environmental sensitivity typical of coherent fibre delay line filter schemes, reconfigurable transfer functions, negligible chromatic dispersions, and ease of implementation, not easily achievable based on other techniques. A number of unique fibre grating devices for signal filtering and fibre laser applications have been realised. The concept of the superimposed fibre Bragg gratings has been extended to non-uniform grating structures and into Hi-Bi fibres to achieve highly useful grating devices such as overwritten phase-shifted fibre grating structure and widely/narrowly spaced polarization-discriminating filters that are not limited by the intrinsic fibre properties. In terms of the-fibre-based optical millimetre wave transmitters, unique approaches based on fibre laser configurations have been proposed and demonstrated. The ability of the dual-mode distributed feedback (DFB) fibre lasers to generate high spectral purity, narrow linewidth heterodyne signals without complex feedback mechanisms has been illustrated. A novel co-located dual DFB fibre laser configuration, based on the proposed superimposed phase-shifted fibre grating structure, has been further realised with highly desired operation characteristics without the need for costly high frequency synthesizers and complex feedback controls. Lastly, a novel cavity mode condition monitoring and optimisation scheme for short length, linear-cavity fibre lasers has been proposed and achieved. Based on the concept and simplicity of the superimposed fibre laser cavities structure, in conjunction with feedback controls, enhanced output performances from the fibre lasers have been achieved. The importance of such cavity mode assessment and feedback control for optimised fibre laser output performance has been illustrated.

Fibre Bragg gratings in polymer optical fibre for applications in sensing

This thesis presents the potential sensing applications of fibre Bragg gratings in polymer optical fibres. Fibre Bragg gratings are fabricated in different kinds of polymer optical fibres, including Poly methyl methacrylate (PMMA) and TOPAS cyclic olefin copolymer based microstructured polymer optical fibres and PMMA based step-index photosensitive polymer optical fibre, using the 325nm continuous wave ultraviolet laser and phase mask technique. The thermal response of fabricated microstructured polymer optical fibre Bragg gratings has been characterized. The PMMA based single mode microstructured polymer optical fibre Bragg gratings exhibit negative non-linear Bragg wavelength shift with temperature, including a quasi-linear region. The thermal sensitivity of such Bragg gratings in the linear region is up to -97pm/°C. A permanent shift in the grating wavelength at room temperature is observed when such gratings are heated above a threshold temperature which can be extended by annealing the fibre before grating inscription. The largest positive Bragg wavelength shift with temperature in transmission is observed in TOPAS based few moded microstructured polymer optical fibre Bragg gratings and the measured temperature sensitivity is 250±0.5pm/°C. Gluing method is developed to maintain stable optical coupling between PMMA based single mode step index polymer optical fibre Bragg gratings and single mode step index silica optical fibre. Being benefit from this success, polymer optical fibre Bragg gratings are able to be characterised for their temperature, humidity and strain sensitivity, which are -48.2±1pm/°C, 38.3±0.5pm per %RH and 1.33±0.04 pm/µ??respectively. These sensitivities have been utilised to achieve several applications. The strain sensitivity of step index polymer optical fibre Bragg grating devices has been exploited in the potential application of the strain condition monitoring of heavy textiles and when being attached to textile specimens with certain type of adhesives. These polymer fibre Bragg grating devices show better strain transfer and lower structure reinforcement than silica optical fibre Bragg grating devices. The humidity sensitivity of step index polymer optical fibre Bragg grating devices is applied to detecting water in jet fuel and is proved to be able to measure water content of less than 20 ppm in Jet fuel. A simultaneous temperature and humidity sensor is also made by attaching a polymer fibre Bragg grating to a silica optical fibre Bragg grating and it shows better humidity measurement accuracy than that of electronic competitors.

Composite materials impact damage detection using neural networks

This thesis considers two basic aspects of impact damage in composite materials, namely damage severity discrimination and impact damage location by using Acoustic Emissions (AE) and Artificial Neural Networks (ANNs). The experimental work embodies a study of such factors as the application of AE as Non-destructive Damage Testing (NDT), and the evaluation of ANNs modelling. ANNs, however, played an important role in modelling implementation. In the first aspect of the study, different impact energies were used to produce different level of damage in two composite materials (T300/914 and T800/5245). The impacts were detected by their acoustic emissions (AE). The AE waveform signals were analysed and modelled using a Back Propagation (BP) neural network model. The Mean Square Error (MSE) from the output was then used as a damage indicator in the damage severity discrimination study. To evaluate the ANN model, a comparison was made of the correlation coefficients of different parameters, such as MSE, AE energy, AE counts, etc. MSE produced an outstanding result based on the best performance of correlation. In the second aspect, a new artificial neural network model was developed to provide impact damage location on a quasi-isotropic composite panel. It was successfully trained to locate impact sites by correlating the relationship between arriving time differences of AE signals at transducers located on the panel and the impact site coordinates. The performance of the ANN model, which was evaluated by calculating the distance deviation between model output and real location coordinates, supports the application of ANN as an impact damage location identifier. In the study, the accuracy of location prediction decreased when approaching the central area of the panel. Further investigation indicated that this is due to the small arrival time differences, which defect the performance of ANN prediction. This research suggested increasing the number of processing neurons in the ANNs as a practical solution.

Rolling bearing vibrations: the effects of varying compliance, manufacturing tolerances and wear

In this study some common types of Rolling Bearing vibrations are analysed in depth both theoretically and experimentally. The study is restricted to vibrations in the radial direction of bearings having pure radial load and a positive radial clearance. The general vibrational behaviour of such bearings has been investigated with respect to the effects of varying compliance, manufacturing tolerances and the interaction between the bearing and the machine structure into which it is fitted. The equations of motion for a rotor supported by a bearing in which the stiffness varies with cage position has been set up and examples of solutions,obtained by digital simulation. is given. A method to calculate amplitudes and frequencies of vibration components due to out of roundness of the inner ring and varying roller diameters has been developed. The results from these investigations have been combined with a theory for bearing/machine frame interaction using mechanical impedance technique, thereby facilitating prediction of the vibrational behaviour of the whole set up. Finally. the effects of bearing fatigue and wear have been studied with particular emphasis on the use of vibration analysis for condition monitoring purposes. A number of monitoring methods have been tried and their effectiveness discussed. The experimental investigation was carried out using two purpose built rigs. For the purpose of analysis of the experimental measurements a digital mini computer was adapted for signal processing and a suite of programs was written. The program package performs several of the commonly used signal analysis processes and :include all necessary input and output functions.

A strategy formulation process for the delivery of technology enabled service delivery systems

The Product Service Systems, servitization, and Service Science literature continues to grow as organisations seek to protect and improve their competitive position. The potential of technology applications to deliver service delivery systems facilitated by the ability to make real time decisions based upon ‘in the field’ performance is also significant. Research identifies four key questions to be addressed. Namely: how far along the servitization continuum should the organisation go in a single strategic step? Does the organisation have the structure and infrastructure to support this transition? What level of condition monitoring should it employ? Is the product positioned correctly in the value chain to adopt condition monitoring technology? Strategy consists of three dimensions, namely content, context, and process. The literature relating to PSS, servitization, and strategy all discuss the concepts relative to content and context but none offer a process to deliver an aligned strategy to deliver a service delivery system enabled by condition based management. This paper presents a tested iterative strategy formulation methodology which is the result of a structured development programme.

Support-mediated alkane activation over Pt-SO4/Al2O3 catalysts

The development of catalytic materials for the efficient combustion of light alkanes is fundamentally important for both automotive pollution control and the control of emissions produced from bio-fuel combustion. The presence of trace gas-phase SO2 is known to promote low temperature propane combustion over conventional Pt/Al2O3 combustion catalysts, however, there have been no systematic efforts to isolate the respective roles of support and metal, and it remains unclear, which plays the dominant role in this unusual phenomenon. Light alkane combustion over Pt/Al2O3 using pre-sulfated alumina supports to tune the physicochemical catalyst properties was presented. Support sulfation significantly enhanced ethane combustion, and improved methane and propane light-off. Catalyst activity increased with Pt loading, while the magnitude of sulfate promotion scales with alkane chain length. This is an abstract of a paper presented at the 228th ACS National Meeting (Philadelphia, PA 8/22-26/2004).

Real-time temperature estimation for power MOSFETs considering thermal ageing effects

This paper presents a novel real-time power-device temperature estimation method that monitors the power MOSFET's junction temperature shift arising from thermal aging effects and incorporates the updated electrothermal models of power modules into digital controllers. Currently, the real-time estimator is emerging as an important tool for active control of device junction temperature as well as online health monitoring for power electronic systems, but its thermal model fails to address the device's ongoing degradation. Because of a mismatch of coefficients of thermal expansion between layers of power devices, repetitive thermal cycling will cause cracks, voids, and even delamination within the device components, particularly in the solder and thermal grease layers. Consequently, the thermal resistance of power devices will increase, making it possible to use thermal resistance (and junction temperature) as key indicators for condition monitoring and control purposes. In this paper, the predicted device temperature via threshold voltage measurements is compared with the real-time estimated ones, and the difference is attributed to the aging of the device. The thermal models in digital controllers are frequently updated to correct the shift caused by thermal aging effects. Experimental results on three power MOSFETs confirm that the proposed methodologies are effective to incorporate the thermal aging effects in the power-device temperature estimator with good accuracy. The developed adaptive technologies can be applied to other power devices such as IGBTs and SiC MOSFETs, and have significant economic implications.

Physics-based modeling of power system components for the evaluation of low-frequency radiated electromagnetic fields

The low-frequency electromagnetic compatibility (EMC) is an increasingly important aspect in the design of practical systems to ensure the functional safety and reliability of complex products. The opportunities for using numerical techniques to predict and analyze system's EMC are therefore of considerable interest in many industries. As the first phase of study, a proper model, including all the details of the component, was required. Therefore, the advances in EMC modeling were studied with classifying analytical and numerical models. The selected model was finite element (FE) modeling, coupled with the distributed network method, to generate the model of the converter's components and obtain the frequency behavioral model of the converter. The method has the ability to reveal the behavior of parasitic elements and higher resonances, which have critical impacts in studying EMI problems. For the EMC and signature studies of the machine drives, the equivalent source modeling was studied. Considering the details of the multi-machine environment, including actual models, some innovation in equivalent source modeling was performed to decrease the simulation time dramatically. Several models were designed in this study and the voltage current cube model and wire model have the best result. The GA-based PSO method is used as the optimization process. Superposition and suppression of the fields in coupling the components were also studied and verified. The simulation time of the equivalent model is 80-100 times lower than the detailed model. All tests were verified experimentally. As the application of EMC and signature study, the fault diagnosis and condition monitoring of an induction motor drive was developed using radiated fields. In addition to experimental tests, the 3DFE analysis was coupled with circuit-based software to implement the incipient fault cases. The identification was implemented using ANN for seventy various faulty cases. The simulation results were verified experimentally. Finally, the identification of the types of power components were implemented. The results show that it is possible to identify the type of components, as well as the faulty components, by comparing the amplitudes of their stray field harmonics. The identification using the stray fields is nondestructive and can be used for the setups that cannot go offline and be dismantled

Tribologische Echtzeitüberwachung in Fördersystemen

Echtzeitbasierte Anlagenüberwachung gewinnt in industrieller Umgebung zunehmend an Bedeutung. Die frühzeitige Erfassung von Störungen ermöglicht es Unternehmen Anlagen punktgenau zu warten und somit deren Stillstandszeiten zu reduzieren. Auch im Bereich der Fördertechnik sind diese Systeme er-wünscht, aber aufgrund des beengten Bauraums ge-staltet sich ihre Integration oftmals schwierig. Im Fol-genden wird eine Baugruppe vorgestellt, welche das Reibwert- und Schmierstoffverhalten fördertechni-scher Anlagen in Echtzeit erfassen kann.

Caractérisation des propriétés mécaniques de la pâte de carbone à 150°C dans le but d’optimiser la mise en forme des anodes utilisées dans les cuves Hall-Héroult

Les anodes de carbone sont des éléments consommables servant d’électrode dans la réaction électrochimique d’une cuve Hall-Héroult. Ces dernières sont produites massivement via une chaine de production dont la mise en forme est une des étapes critiques puisqu’elle définit une partie de leur qualité. Le procédé de mise en forme actuel n’est pas pleinement optimisé. Des gradients de densité importants à l’intérieur des anodes diminuent leur performance dans les cuves d’électrolyse. Encore aujourd’hui, les anodes de carbone sont produites avec comme seuls critères de qualité leur densité globale et leurs propriétés mécaniques finales. La manufacture d’anodes est optimisée de façon empirique directement sur la chaine de production. Cependant, la qualité d’une anode se résume en une conductivité électrique uniforme afin de minimiser les concentrations de courant qui ont plusieurs effets néfastes sur leur performance et sur les coûts de production d’aluminium. Cette thèse est basée sur l’hypothèse que la conductivité électrique de l’anode n’est influencée que par sa densité considérant une composition chimique uniforme. L’objectif est de caractériser les paramètres d’un modèle afin de nourrir une loi constitutive qui permettra de modéliser la mise en forme des blocs anodiques. L’utilisation de la modélisation numérique permet d’analyser le comportement de la pâte lors de sa mise en forme. Ainsi, il devient possible de prédire les gradients de densité à l’intérieur des anodes et d’optimiser les paramètres de mise en forme pour en améliorer leur qualité. Le modèle sélectionné est basé sur les propriétés mécaniques et tribologiques réelles de la pâte. La thèse débute avec une étude comportementale qui a pour objectif d’améliorer la compréhension des comportements constitutifs de la pâte observés lors d’essais de pressage préliminaires. Cette étude est basée sur des essais de pressage de pâte de carbone chaude produite dans un moule rigide et sur des essais de pressage d’agrégats secs à l’intérieur du même moule instrumenté d’un piézoélectrique permettant d’enregistrer les émissions acoustiques. Cette analyse a précédé la caractérisation des propriétés de la pâte afin de mieux interpréter son comportement mécanique étant donné la nature complexe de ce matériau carboné dont les propriétés mécaniques sont évolutives en fonction de la masse volumique. Un premier montage expérimental a été spécifiquement développé afin de caractériser le module de Young et le coefficient de Poisson de la pâte. Ce même montage a également servi dans la caractérisation de la viscosité (comportement temporel) de la pâte. Il n’existe aucun essai adapté pour caractériser ces propriétés pour ce type de matériau chauffé à 150°C. Un moule à paroi déformable instrumenté de jauges de déformation a été utilisé pour réaliser les essais. Un second montage a été développé pour caractériser les coefficients de friction statique et cinétique de la pâte aussi chauffée à 150°C. Le modèle a été exploité afin de caractériser les propriétés mécaniques de la pâte par identification inverse et pour simuler la mise en forme d’anodes de laboratoire. Les propriétés mécaniques de la pâte obtenues par la caractérisation expérimentale ont été comparées à celles obtenues par la méthode d’identification inverse. Les cartographies tirées des simulations ont également été comparées aux cartographies des anodes pressées en laboratoire. La tomodensitométrie a été utilisée pour produire ces dernières cartographies de densité. Les résultats des simulations confirment qu’il y a un potentiel majeur à l’utilisation de la modélisation numérique comme outil d’optimisation du procédé de mise en forme de la pâte de carbone. La modélisation numérique permet d’évaluer l’influence de chacun des paramètres de mise en forme sans interrompre la production et/ou d’implanter des changements coûteux dans la ligne de production. Cet outil permet donc d’explorer des avenues telles la modulation des paramètres fréquentiels, la modification de la distribution initiale de la pâte dans le moule, la possibilité de mouler l’anode inversée (upside down), etc. afin d’optimiser le processus de mise en forme et d’augmenter la qualité des anodes.

Design, modelling, simulation and integration of cyber physical systems: methods and applications

The main drivers for the development and evolution of Cyber Physical Systems (CPS) are the reduction of development costs and time along with the enhancement of the designed products. The aim of this survey paper is to provide an overview of different types of system and the associated transition process from mechatronics to CPS and cloud-based (IoT) systems. It will further consider the requirement that methodologies for CPS-design should be part of a multi-disciplinary development process within which designers should focus not only on the separate physical and computational components, but also on their integration and interaction. Challenges related to CPS-design are therefore considered in the paper from the perspectives of the physical processes, computation and integration respectively. Illustrative case studies are selected from different system levels starting with the description of the overlaying concept of Cyber Physical Production Systems (CPPSs). The analysis and evaluation of the specific properties of a sub-system using a condition monitoring system, important for the maintenance purposes, is then given for a wind turbine.

Physics-Based Modeling of Power System Components for the Evaluation of Low-Frequency Radiated Electromagnetic Fields

The low-frequency electromagnetic compatibility (EMC) is an increasingly important aspect in the design of practical systems to ensure the functional safety and reliability of complex products. The opportunities for using numerical techniques to predict and analyze system’s EMC are therefore of considerable interest in many industries. As the first phase of study, a proper model, including all the details of the component, was required. Therefore, the advances in EMC modeling were studied with classifying analytical and numerical models. The selected model was finite element (FE) modeling, coupled with the distributed network method, to generate the model of the converter’s components and obtain the frequency behavioral model of the converter. The method has the ability to reveal the behavior of parasitic elements and higher resonances, which have critical impacts in studying EMI problems. For the EMC and signature studies of the machine drives, the equivalent source modeling was studied. Considering the details of the multi-machine environment, including actual models, some innovation in equivalent source modeling was performed to decrease the simulation time dramatically. Several models were designed in this study and the voltage current cube model and wire model have the best result. The GA-based PSO method is used as the optimization process. Superposition and suppression of the fields in coupling the components were also studied and verified. The simulation time of the equivalent model is 80-100 times lower than the detailed model. All tests were verified experimentally. As the application of EMC and signature study, the fault diagnosis and condition monitoring of an induction motor drive was developed using radiated fields. In addition to experimental tests, the 3DFE analysis was coupled with circuit-based software to implement the incipient fault cases. The identification was implemented using ANN for seventy various faulty cases. The simulation results were verified experimentally. Finally, the identification of the types of power components were implemented. The results show that it is possible to identify the type of components, as well as the faulty components, by comparing the amplitudes of their stray field harmonics. The identification using the stray fields is nondestructive and can be used for the setups that cannot go offline and be dismantled