Cost optimal maintenance in systems with imperfect maintenance

Otto-von Guericke-Universität Magdeburg, Fakultät für Mathematik, Dissertation, 2016

Automated generic integration of flight logbook data into aircraft maintenance systems

The automated transfer of flight logbook information from aircrafts into aircraft maintenance systems leads to reduced ground and maintenance time and is thus desirable from an economical point of view. Until recently, flight logbooks have not been managed electronically in aircrafts or at least the data transfer from aircraft to ground maintenance system has been executed manually. Latest aircraft types such as the Airbus A380 or the Boeing 787 do support an electronic logbook and thus make an automated transfer possible. A generic flight logbook transfer system must deal with different data formats on the input side – due to different aircraft makes and models – as well as different, distributed aircraft maintenance systems for different airlines as aircraft operators. This article contributes the concept and top level distributed system architecture of such a generic system for automated flight log data transfer. It has been developed within a joint industry and applied research project. The architecture has already been successfully evaluated in a prototypical implementation.

Analyse des Ermüdungsverhaltens von Beton anhand der Dehnungsentwicklung

Die Weiterentwicklungen in der Betontechnologie führten in den letzten Jahrzehnten zu Hochleistungsbetonen mit immer höheren Festigkeiten. Der Ermüdungsnachweis wurde jedoch kaum weiterentwickelt und beinhaltet immer noch sehr grobe Herangehensweisen bei der Berücksichtigung des Materialwiderstands von Beton. Für eine grundlegende Weiterentwicklung dieses Nachweises fehlt noch das notwendige Wissen zu den Mechanismen der Betonermüdung. Das Ziel dieser Arbeit war es daher, grundlegende Erkenntnisse zum Ermüdungsverhalten hochfester Betone bei unterschiedlichen zyklischen Beanspruchungen zu ermitteln und hierdurch zu einem besseren Verständnis der Mechanismen der Betonermüdung beizutragen. In der vorliegenden Arbeit wurde das Ermüdungsverhalten eines hochfesten Betons bei Druckschwellbeanspruchung anhand der Dehnungs- und Steifigkeitsentwicklungen untersucht. Betrachtet wurden dabei die Einflüsse der bezogenen Oberspannung, der Belastungsfrequenz und der Wellenform. Zusätzlich wurden, ausgehend von in der Literatur dokumentierten Ansätzen, Versuche bei monoton steigender Beanspruchung und Dauerstandbeanspruchung vergleichend durchgeführt. Die Dehnungs- und Steifigkeitsentwicklungen werden durch die untersuchten Belastungsparameter der Ermüdungsbeanspruchung eindeutig beeinflusst. Charakteristische Zusammenhänge zwischen der Beeinflussung einzelner Kenngrößen der Dehnungs- und Steifigkeitsentwicklung und der Beeinflussung der Bruchlastwechselzahlen wurden aufgezeigt. Anhand der Dehnungen und Steifigkeiten an den Phasenübergängen konnten Hinweise auf beanspru-chungsartabhängige Gefügezustände abgeleitet werden. Die vergleichende Auswertung des Dehnungsverhaltens bei monoton steigender Beanspruchung, Ermüdungsbeanspruchung und Dauerstandbeanspruchung zeigte, dass das Ermüdungsverhalten von Beton nicht adäquat in Anlehnung an andere Beanspruchungsarten beschrieben werden kann. Die Untersuchungsergebnisse wurden in eine Modellvorstellung übertragen, die zur Beurteilung der baustofflichen Phänomene bei zyklischen Beanspruchungen geeignet ist. Dabei wurde die Hypothese aufgestellt, dass sich unterschiedlich ausgeprägte Kleinst-Gefügeveränderungen beanspruchungsabhängig einstellen, die die Entstehung und Ausbreitung von Mikrorissen beeinflussen. Die detaillierte Untersuchung der Dehnungs- und Steifigkeitsentwicklungen führte zu neuen und tiefergehenden Erkenntnissen und sollte ergänzt durch die Betrachtungen von Gefügezuständen zukünftig weiterverfolgt werden.

Non-contact test set-up for aeroelasticity in a rotating turbomachine combining a novel acoustic excitation system with tip-timing

Due to trends in aero-design, aeroelasticity becomes increasingly important in modern turbomachines. Design requirements of turbomachines lead to the development of high aspect ratio blades and blade integral disc designs (blisks), which are especially prone to complex modes of vibration. Therefore, experimental investigations yielding high quality data are required for improving the understanding of aeroelastic effects in turbomachines. One possibility to achieve high quality data is to excite and measure blade vibrations in turbomachines. The major requirement for blade excitation and blade vibration measurements is to minimize interference with the aeroelastic effects to be investigated. Thus in this paper, a non-contact-and thus low interference-experimental set-up for exciting and measuring blade vibrations is proposed and shown to work. A novel acoustic system excites rotor blade vibrations, which are measured with an optical tip-timing system. By performing measurements in an axial compressor, the potential of the acoustic excitation method for investigating aeroelastic effects is explored. The basic principle of this method is described and proven through the analysis of blade responses at different acoustic excitation frequencies and at different rotational speeds. To verify the accuracy of the tip-timing system, amplitudes measured by tip-timing are compared with strain gage measurements. They are found to agree well. Two approaches to vary the nodal diameter (ND) of the excited vibration mode by controlling the acoustic excitation are presented. By combining the different excitable acoustic modes with a phase-lag control, each ND of the investigated 30 blade rotor can be excited individually. This feature of the present acoustic excitation system is of great benefit to aeroelastic investigations and represents one of the main advantages over other excitation methods proposed in the past. In future studies, the acoustic excitation method will be used to investigate aeroelastic effects in high-speed turbomachines in detail. The results of these investigations are to be used to improve the aeroelastic design of modern turbomachines.

Effect of Geometric Uncertainties on the Aerodynamic Characteristic of Offshore Wind Turbine Blades

Offshore wind turbines operate in a complex unsteady flow environment which causes unsteady aerodynamic loads. The unsteady flow environment is characterized by a high degree of uncertainty. In addition, geometry variations and material imperfections also cause uncertainties in the design process. Probabilistic design methods consider these uncertainties in order to reach acceptable reliability and safety levels for offshore wind turbines. Variations of the rotor blade geometry influence the aerodynamic loads which also affect the reliability of other wind turbine components. Therefore, the present paper is dealing with geometric uncertainties of the rotor blades. These can arise from manufacturing tolerances and operational wear of the blades. First, the effect of geometry variations of wind turbine airfoils on the lift and drag coefficients are investigated using a Latin hypercube sampling. Then, the resulting effects on the performance and the blade loads of an offshore wind turbine are analyzed. The variations of the airfoil geometry lead to a significant scatter of the lift and drag coefficients which also affects the damage-equivalent flapwise bending moments. In contrast to that, the effects on the power and the annual energy production are almost negligible with regard to the assumptions made.

Wind turbine rotor blade monitoring using digital image correlation: a comparison to aeroelastic simulations of a multi-megawatt wind turbine

Optical full-field measurement methods such as Digital Image Correlation (DIC) provide a new opportunity for measuring deformations and vibrations with high spatial and temporal resolution. However, application to full-scale wind turbines is not trivial. Elaborate preparation of the experiment is vital and sophisticated post processing of the DIC results essential. In the present study, a rotor blade of a 3.2 MW wind turbine is equipped with a random black-and-white dot pattern at four different radial positions. Two cameras are located in front of the wind turbine and the response of the rotor blade is monitored using DIC for different turbine operations. In addition, a Light Detection and Ranging (LiDAR) system is used in order to measure the wind conditions. Wind fields are created based on the LiDAR measurements and used to perform aeroelastic simulations of the wind turbine by means of advanced multibody codes. The results from the optical DIC system appear plausible when checked against common and expected results. In addition, the comparison of relative out-of-plane blade deflections shows good agreement between DIC results and aeroelastic simulations.

Aerodynamic behavior of an airfoil with morphing trailing edge for wind turbine applications

The length of wind turbine rotor blades has been increased during the last decades. Higher stresses arise especially at the blade root because of the longer lever arm. One way to reduce unsteady blade-root stresses caused by turbulence, gusts, or wind shear is to actively control the lift in the blade tip region. One promising method involves airfoils with morphing trailing edges to control the lift and consequently the loads acting on the blade. In the present study, the steady and unsteady behavior of an airfoil with a morphing trailing edge is investigated. Two-dimensional Reynolds-Averaged Navier-Stokes (RANS) simulations are performed for a typical thin wind turbine airfoil with a morphing trailing edge. Steady-state simulations are used to design optimal geometry, size, and deflection angles of the morphing trailing edge. The resulting steady aerodynamic coefficients are then analyzed at different angles of attack in order to determine the effectiveness of the morphing trailing edge. In order to investigate the unsteady aerodynamic behavior of the optimal morphing trailing edge, time-resolved RANS-simulations are performed using a deformable grid. In order to analyze the phase shift between the variable trailing edge deflection and the dynamic lift coefficient, the trailing edge is deflected at four different reduced frequencies for each different angle of attack. As expected, a phase shift between the deflection and the lift occurs. While deflecting the trailing edge at angles of attack near stall, additionally an overshoot above and beyond the steady lift coefficient is observed and evaluated.

Evaluation and FMEA of Fabrication Techniques for Metallic Grating Couplers on Polymer Substrates with Low Glass Transition Temperatures

The main task is to analyze the state of the art of grating couplers production and low-cost polymer substrates. Then to provide a recommendation of a new or adapted process for the production of metallic gratings on polymer sheets, based on a Failure Mode and Effect Analysis (FMEA). In order to achieve that, this thesis is divided into four chapters. After the first introductory chapter, the second section provides details about the state-of-the-art in optical technology platforms with focus on polymers and their main features for the aimed application, such as flexibility, low cost and roll to roll compatibility. It defines then the diffraction gratings and their specifications and closes with the explanation of adhesion mechanisms of inorganic materials on polymer substrates. The third chapter discusses processing of grating couplers. It introduces the basic fabrication methods and details a selection of current fabrication schemes found in literature with an assessment of their potential use for the desired application. The last chapter is a FMEA analysis of the retained fabrication process, called Flip and Fuse, in order to check its capability to realize the grating structure.

Influence of Cobalt on the Properties of Load-Sensitive Magnesium Alloys

In this study, magnesium is alloyed with varying amounts of the ferromagnetic alloying element cobalt in order to obtain lightweight load-sensitive materials with sensory properties which allow an online-monitoring of mechanical forces applied to components made from Mg-Co alloys. An optimized casting process with the use of extruded Mg-Co powder rods is utilized which enables the production of magnetic magnesium alloys with a reproducible Co concentration. The efficiency of the casting process is confirmed by SEM analyses. Microstructures and Co-rich precipitations of various Mg-Co alloys are investigated by means of EDS and XRD analyses. The Mg-Co alloys' mechanical strengths are determined by tensile tests. Magnetic properties of the Mg-Co sensor alloys depending on the cobalt content and the acting mechanical load are measured utilizing the harmonic analysis of eddy-current signals. Within the scope of this work, the influence of the element cobalt on magnesium is investigated in detail and an optimal cobalt concentration is defined based on the performed examinations.

Numerical simulation of strain-adaptive bone remodelling in the ankle joint

Background: The use of artificial endoprostheses has become a routine procedure for knee and hip joints while ankle arthritis has traditionally been treated by means of arthrodesis. Due to its advantages, the implantation of endoprostheses is constantly increasing. While finite element analyses (FEA) of strain-adaptive bone remodelling have been carried out for the hip joint in previous studies, to our knowledge there are no investigations that have considered remodelling processes of the ankle joint. In order to evaluate and optimise new generation implants of the ankle joint, as well as to gain additional knowledge regarding the biomechanics, strain-adaptive bone remodelling has been calculated separately for the tibia and the talus after providing them with an implant. Methods: FE models of the bone-implant assembly for both the tibia and the talus have been developed. Bone characteristics such as the density distribution have been applied corresponding to CT scans. A force of 5,200 N, which corresponds to the compression force during normal walking of a person with a weight of 100 kg according to Stauffer et al., has been used in the simulation. The bone adaptation law, previously developed by our research team, has been used for the calculation of the remodelling processes. Results: A total bone mass loss of 2% in the tibia and 13% in the talus was calculated. The greater decline of density in the talus is due to its smaller size compared to the relatively large implant dimensions causing remodelling processes in the whole bone tissue. In the tibia, bone remodelling processes are only calculated in areas adjacent to the implant. Thus, a smaller bone mass loss than in the talus can be expected. There is a high agreement between the simulation results in the distal tibia and the literature regarding. Conclusions: In this study, strain-adaptive bone remodelling processes are simulated using the FE method. The results contribute to a better understanding of the biomechanical behaviour of the ankle joint and hence are useful for the optimisation of the implant geometry in the future.

Multi-body simulation of a canine hind limb: model development, experimental validation and calculation of ground reaction forces

Background: Among other causes the long-term result of hip prostheses in dogs is determined by aseptic loosening. A prevention of prosthesis complications can be achieved by an optimization of the tribological system which finally results in improved implant duration. In this context a computerized model for the calculation of hip joint loadings during different motions would be of benefit. In a first step in the development of such an inverse dynamic multi-body simulation (MBS-) model we here present the setup of a canine hind limb model applicable for the calculation of ground reaction forces. Methods: The anatomical geometries of the MBS-model have been established using computer tomography- (CT-) and magnetic resonance imaging- (MRI-) data. The CT-data were collected from the pelvis, femora, tibiae and pads of a mixed-breed adult dog. Geometric information about 22 muscles of the pelvic extremity of 4 mixed-breed adult dogs was determined using MRI. Kinematic and kinetic data obtained by motion analysis of a clinically healthy dog during a gait cycle (1 m/s) on an instrumented treadmill were used to drive the model in the multi-body simulation. Results and Discussion: As a result the vertical ground reaction forces (z-direction) calculated by the MBS-system show a maximum deviation of 1.75%BW for the left and 4.65%BW for the right hind limb from the treadmill measurements. The calculated peak ground reaction forces in z- and y-direction were found to be comparable to the treadmill measurements, whereas the curve characteristics of the forces in y-direction were not in complete alignment. Conclusion: In conclusion, it could be demonstrated that the developed MBS-model is suitable for simulating ground reaction forces of dogs during walking. In forthcoming investigations the model will be developed further for the calculation of forces and moments acting on the hip joint during different movements, which can be of help in context with the in silico development and testing of hip prostheses.

Numerical investigations on the strain-adaptive bone remodelling in the periprosthetic femur: Influence of the boundary conditions

Background: There are several numerical investigations on bone remodelling after total hip arthroplasty (THA) on the basis of the finite element analysis (FEA). For such computations certain boundary conditions have to be defined. The authors chose a maximum of three static load situations, usually taken from the gait cycle because this is the most frequent dynamic activity of a patient after THA. Materials and methods: The numerical study presented here investigates whether it is useful to consider only one static load situation of the gait cycle in the FE calculation of the bone remodelling. For this purpose, 5 different loading cases were examined in order to determine their influence on the change in the physiological load distribution within the femur and on the resulting strain-adaptive bone remodelling. First, four different static loading cases at 25%, 45%, 65% and 85% of the gait cycle, respectively, and then the whole gait cycle in a loading regime were examined in order to regard all the different loadings of the cycle in the simulation. Results: The computed evolution of the apparent bone density (ABD) and the calculated mass losses in the periprosthetic femur show that the simulation results are highly dependent on the chosen boundary conditions. Conclusion: These numerical investigations prove that a static load situation is insufficient for representing the whole gait cycle. This causes severe deviations in the FE calculation of the bone remodelling. However, accompanying clinical examinations are necessary to calibrate the bone adaptation law and thus to validate the FE calculations.

Manufacturing conditioned roughness and wear of biomedical oxide ceramics for all-ceramic knee implants

Background: Ceramic materials are used in a growing proportion of hip joint prostheses due to their wear resistance and biocompatibility properties. However, ceramics have not been applied successfully in total knee joint endoprostheses to date. One reason for this is that with strict surface quality requirements, there are significant challenges with regard to machining. High-toughness bioceramics can only be machined by grinding and polishing processes. The aim of this study was to develop an automated process chain for the manufacturing of an all-ceramic knee implant. Methods: A five-axis machining process was developed for all-ceramic implant components. These components were used in an investigation of the influence of surface conformity on wear behavior under simplified knee joint motion. Results: The implant components showed considerably reduced wear compared to conventional material combinations. Contact area resulting from a variety of component surface shapes, with a variety of levels of surface conformity, greatly influenced wear rate. Conclusions: It is possible to realize an all-ceramic knee endoprosthesis device, with a precise and affordable manufacturing process. The shape accuracy of the component surfaces, as specified by the design and achieved during the manufacturing process, has a substantial influence on the wear behavior of the prosthesis. This result, if corroborated by results with a greater sample size, is likely to influence the design parameters of such devices.

Areal rainfall estimation using moving cars - computer experiments including hydrological modeling

The need for high temporal and spatial resolution precipitation data for hydrological analyses has been discussed in several studies. Although rain gauges provide valuable information, a very dense rain gauge network is costly. As a result, several new ideas have been emerged to help estimating areal rainfall with higher temporal and spatial resolution. Rabiei et al. (2013) observed that moving cars, called RainCars (RCs), can potentially be a new source of data for measuring rainfall amounts. The optical sensors used in that study are designed for operating the windscreen wipers and showed promising results for rainfall measurement purposes. Their measurement accuracy has been quantified in laboratory experiments. Considering explicitly those errors, the main objective of this study is to investigate the benefit of using RCs for estimating areal rainfall. For that, computer experiments are carried out, where radar rainfall is considered as the reference and the other sources of data, i.e. RCs and rain gauges, are extracted from radar data. Comparing the quality of areal rainfall estimation by RCs with rain gauges and reference data helps to investigate the benefit of the RCs. The value of this additional source of data is not only assessed for areal rainfall estimation performance, but also for use in hydrological modeling. The results show that the RCs considering measurement errors derived from laboratory experiments provide useful additional information for areal rainfall estimation as well as for hydrological modeling. Even assuming higher uncertainties for RCs as obtained from the laboratory up to a certain level is observed practical.

Electronic Packaging of Paper-Based Anisotropic Magnetoresistive Sensors

This report investigates adaptations of electronic packaging methods used to create stacks of these sensors. Four methods were developed and tested to determine the best option in terms of mechanical stability and electrical conductivity of the system. For the first method, a stack is created by way of through paper vias (TPVs), a hole that is cut in the pads of the sensors and then filled with electrically conductive adhesive through the openings on the two sensors to be joined. The second method is called mechanical caulking and connects sensors through pads which have been lined with copper tape backed with conductive adhesive. The connection is created with a small copper rivet which is flattened in place by compressive force. The third method is the stitching method which is inspired by sewing of fabric. A pattern of thin copper wire is stitched on the pad of a sensor that is lined with copper tape backed with conductive adhesive. The wire is then stitched through a second sensor that is treated similarly with copper tape and the stack receives the same pattern through the two layers as was applied to the first sensor alone. The final method is the collapsed daisy chain which is the linear connection of sensors to their neighboring sensors via copper tape backed with conductive adhesive. The row of sensors is then collapsed in an alternating orientation into a single stack.