Trukkitraktorin rungon suunnittelu ja laskenta

Tässä työssä suunniteltiin lappeenrantalaisen Astex Oy:n tilauksesta liikkuvan työkoneen runkorakenne. Työ tehtiin Lappeenrannan teknillisen yliopiston teräsrakenteiden laboratoriossa. Suunniteltava rakenne kuului linkkuohjattuun, noin 5000 kg painoiseen trukkitraktoriin. Lähtökohtana rakenteen suunnittelulle olivat tilaajan asettamat rakenteen geometriaan ja suorituskykyyn liittyvät reunaehdot ja rajoitteet. Uuden rakenteen suunnittelussa hyödynnettiin myös tilaajatahon kehittelemää vastaavan tyyppistä prototyyppirakennetta. Rakenteen suunnitteluprosessi koostui neljästä eri vaiheesta. Suunniteltavan rakenteen lähtökohtana olleelle prototyyppirakenteelle suoritettiin koneen käytönaikaisia venymäliuskamittauksia rakenteen kuormitushistorian selvittämiseksi. Mittauksista saatujen tulosten perusteella määritettiin kuormitukset uudelle suunniteltavalle rakenteelle. Määritettyjä kuormituksia hyödyntäen ideoitiin, suunniteltiin ja mallinnettiin uusi tilaajan vaatimuksia vastaava rakenne. Uudelle rakenteelle suoritettiin lujuusanalyysit FE-analyysiä hyödyntäen. Uuden rakenteen suunnittelussa kiinnitettiin huomiota rakenteen hyvään valmistettavuuteen ja suunniteltiin rakenneratkaisut tilaajataholle mahdollisimman optimaalisiksi. Suunnittelu- ja mallinnustyö tehtiin Solidworks 2014 ohjelmistolla. Rakenteen lujuustekniset tarkastelut sisälsivät rakennedetaljien analyyttistä mitoitusta ja laskentaa. FE-laskennalla selvitettiin rakenteen ääri- ja väsymiskestävyys. Laskenta sisälsi koko rakenteen globaaleja tarkasteluja, sekä eri kriittisten rakennedetaljien yksityiskohtaisempia analyysejä. FE-laskennan pääpaino oli rakenteen väsymisanalyyseissä, jotka toteutettiin Hot-Spot- ja särönkasvumenetelmillä. Rakenteen FE-analyysien suorittamisessa käytettiin Femap, NxNastran ja Abaqus-ohjelmistoja.

Distortion and internal warping torsion of a double symmetric hollow section

This thesis is made in cooperation with Laboratory of Steel Structures and the steel company SSAB. Maximization of the benefits of high-strength steel usually requires the usage of thin wall thicknesses. This means the failures related to buckling, distortion and warping stand out. One must be aware of these phenomena to design thin-walled structures stressed with forces such as torsional loading. It is also important to take into account small stress ranges when evaluating the accurate fatigue strength of structures. The objective of this thesis is to clarify the theory of the uniform and non-uniform torsion. This paper focuses on warping due to the non-uniform torsion in double symmetric box girder and structural hollow section. The arisen stress states are explained and researched using the finite element method. Another research target is the distortion in double symmetric box girder due to torsion, and the restraining effect of transverse diaphragms at the load end. Multiple transverse diaphragms are used to study more efficient restraining against warping and distortion than a common one end plate structure.

Inductance Calculation of Tooth-Coil Permanent-Magnet Synchronous Machines

Analytical calculation methods for all the major components of the synchronous inductance of tooth-coil permanentmagnet synchronous machines are reevaluated in this paper. The inductance estimation is different in the tooth-coil machine compared with the one in the traditional rotating field winding machine. The accuracy of the analytical torque calculation highly depends on the estimated synchronous inductance. Despite powerful finite element method (FEM) tools, an accurate and fast analytical method is required at an early design stage to find an initialmachine design structure with the desired performance. The results of the analytical inductance calculation are verified and assessed in terms of accuracy with the FEM simulation results and with the prototype measurement results.

Pyörivien koneiden ruuviliitosten mitoitus ja mitoitusohjelman laadinta standardien mukaisesti

Työn tarkoituksena oli löytää pyörivien koneiden ruuviliitosten mitoittamiseen parhaiten soveltuva ja kansainvälisesti tunnettu laskentamenetelmä. Tavoitteena oli laatia luotettava mitoitusohjelma, jota käyttämällä suunnittelijoiden työ nopeutuu ja tulokset ovat yhtenäisiä. Työssä vertaillaan pääasiassa standardien EN 1993-1-8 ja VDI 2230 mukaisia ruuviliitosten mitoitusmenetelmiä. Vertailun perusteella standardin VDI 2230 mukainen systemaattinen laskentamenetelmä soveltuu sähkökoneiden vääntöä välittävien ruuviliitosten mitoittamiseen analyyttisistä menetelmistä parhaiten. Laadittu mitoitusohjelma mitoittaa yksittäisen ruuviliitoksen standardin VDI 2230 mukaisesti, antaen tulokseksi lujuustarkasteluraportin. Lujuustarkasteluraportista käy ilmi projektin tiedot, mitoituksen lähtötiedot, lujuustarkastelut, esikiristysmomentti ja kierteen toiminnallisen osan vähimmäispituus. Kehitetty mitoitusohjelma antaa johdonmukaisia tuloksia, mutta ruuvin nimellisulkohalkaisijan automaattinen valinta ei aina mitoita ruuvia riittävän suureksi, jolloin ruuvin nimellisulkohalkaisija on määritettävä manuaalisesti. Ohjelman käyttäminen on suoraviivaista ja nopeaa kun mitoitetaan pyörähdyssymmetrisiä laippaliitoksia, joihin vaikuttaa ainoastaan vääntömomentti. Jos liitokseen vaikuttaa ruuvien pituusakselien suuntainen voima, on liitoksen pelkistäminen yksittäisestä ruuvista koostuvaksi liitokseksi vaikeampaa ja pelkistämiseen saatetaan tarvita elementti-menetelmää.

Cost Reduction of Permanent Magnet Synchronous Machines

Electrical machine drives are the most electrical energy-consuming systems worldwide. The largest proportion of drives is found in industrial applications. There are, however many other applications that are also based on the use of electrical machines, because they have a relatively high efficiency, a low noise level, and do not produce local pollution. Electrical machines can be classified into several categories. One of the most commonly used electrical machine types (especially in the industry) is induction motors, also known as asynchronous machines. They have a mature production process and a robust rotor construction. However, in the world pursuing higher energy efficiency with reasonable investments not every application receives the advantage of using this type of motor drives. The main drawback of induction motors is the fact that they need slipcaused and thus loss-generating current in the rotor, and additional stator current for magnetic field production along with the torque-producing current. This can reduce the electric motor drive efficiency, especially in low-speed, low-power applications. Often, when high torque density is required together with low losses, it is desirable to apply permanent magnet technology, because in this case there is no need to use current to produce the basic excitation of the machine. This promotes the effectiveness of copper use in the stator, and further, there is no rotor current in these machines. Again, if permanent magnets with a high remanent flux density are used, the air gap flux density can be higher than in conventional induction motors. These advantages have raised the popularity of PMSMs in some challenging applications, such as hybrid electric vehicles (HEV), wind turbines, and home appliances. Usually, a correctly designed PMSM has a higher efficiency and consequently lower losses than its induction machine counterparts. Therefore, the use of these electrical machines reduces the energy consumption of the whole system to some extent, which can provide good motivation to apply permanent magnet technology to electrical machines. However, the cost of high performance rare earth permanent magnets in these machines may not be affordable in many industrial applications, because the tight competition between the manufacturers dictates the rules of low-cost and highly robust solutions, where asynchronous machines seem to be more feasible at the moment. Two main electromagnetic components of an electrical machine are the stator and the rotor. In the case of a conventional radial flux PMSM, the stator contains magnetic circuit lamination and stator winding, and the rotor consists of rotor steel (laminated or solid) and permanent magnets. The lamination itself does not significantly influence the total cost of the machine, even though it can considerably increase the construction complexity, as it requires a special assembly arrangement. However, thin metal sheet processing methods are very effective and economically feasible. Therefore, the cost of the machine is mainly affected by the stator winding and the permanent magnets. The work proposed in this doctoral dissertation comprises a description and analysis of two approaches of PMSM cost reduction: one on the rotor side and the other on the stator side. The first approach on the rotor side includes the use of low-cost and abundant ferrite magnets together with a tooth-coil winding topology and an outer rotor construction. The second approach on the stator side exploits the use of a modular stator structure instead of a monolithic one. PMSMs with the proposed structures were thoroughly analysed by finite element method based tools (FEM). It was found out that by implementing the described principles, some favourable characteristics of the machine (mainly concerning the machine size) will inevitable be compromised. However, the main target of the proposed approaches is not to compete with conventional rare earth PMSMs, but to reduce the price at which they can be implemented in industrial applications, keeping their dimensions at the same level or lower than those of a typical electrical machine used in the industry at the moment. The measurement results of the prototypes show that the main performance characteristics of these machines are at an acceptable level. It is shown that with certain specific actions it is possible to achieve a desirable efficiency level of the machine with the proposed cost reduction methods.

Sekaelementit absoluuttisten solmukoordinaattien menetelmässä

Tässä lisensiaatintyössä käsitellään sekaelementtien sovellusmahdollisuuksia absoluuttisten solmukoordinaattien menetelmässä. Absoluuttisten solmukoordinaattien menetelmä on uudentyyppinen lähestymistapa elementtimenetelmän elementtien koordinaattien määrittämiseksi ja sen yhtenä tavoitteena on tehostaa suuria siirtymiä tai kiertymiä sisältävien elementtien laskentatehokkuutta. Tässä työssä absoluuttisten solmukoordinaattien menetelmä esitellään pääpiirteittäin sekä annetaan esimerkkejä muutamista tyypillisimmistä elementeistä lausuttuna edellä mainittujen koordinaattien perusteella. Sekaelementeiksi kutsutaan elementtityyppejä, missä tuntemattomien muuttujien joukkoja on aina enemmän kuin yksi. Sekaelementit erottavat redusoitumattomista elementeistä siirtymäkentän sisältyminen muuttujaryhmään ja hybridielementeistä muuttujien identtiset ulottuvuudet. Sekaelementtejä käytetään esimerkiksi kokoonpuristumattomien materiaalien rakenneanalyyseissä, alentamaan elementiltä vaadittavia jatkuvuusehtoja tai mallintamaan ilmiöitä, missä fysikaaliset ominaisuudet ovat jostain syystä voimakkaasti toisistaan riippuvaisia. Tämän lisensiaatintyön kirjoittamiseksi on tehty tutkimusta sekaelementtien mahdollisuuksista toimia absoluuttisten solmukoordinaattien menetelmässä. Tutkimuksen tuloksena on saatu aikaan kaksi tässä työssä esiteltävää, varsin rajatun toimintakyvyn omaavaa sekaelementtityyppiä, joiden siirtymäkentät on määritelty globaalien koordinaattien suhteen sisältäen myös orientaatiotermit. Tutkimusaihe vaatii kuitenkin vielä paljon lisätyötä, ennen kuin sekaelementtityyppejä voidaan kauttaaltaan soveltaa absoluuttisten solmukoordinaattien menetelmällä toteutetuissa rakenneanalyyseissä.

Effect of loading type on the fatigue strength of symmetric and asymmetric welded joints made of ultra high strength steel

In this study, finite element analyses and experimental tests are carried out in order to investigate the effect of loading type and symmetry on the fatigue strength of three different non-load carrying welded joints. The current codes and recommendations do not give explicit instructions how to consider degree of bending in loading and the effect of symmetry in the fatigue assessment of welded joints. The fatigue assessment is done by using effective notch stress method and linear elastic fracture mechanics. Transverse attachment and cover plate joints are analyzed by using 2D plane strain element models in FEMAP/NxNastran and Franc2D software and longitudinal gusset case is analyzed by using solid element models in Abaqus and Abaqus/XFEM software. By means of the evaluated effective notch stress range and stress intensity factor range, the nominal fatigue strength is assessed. Experimental tests consist of the fatigue tests of transverse attachment joints with total amount of 12 specimens. In the tests, the effect of both loading type and symmetry on the fatigue strength is studied. Finite element analyses showed that the fatigue strength of asymmetric joint is higher in tensile loading and the fatigue strength of symmetric joint is higher in bending loading in terms of nominal and hot spot stress methods. Linear elastic fracture mechanics indicated that bending reduces stress intensity factors when the crack size is relatively large since the normal stress decreases at the crack tip due to the stress gradient. Under tensile loading, experimental tests corresponded with finite element analyzes. Still, the fatigue tested joints subjected to bending showed the bending increased the fatigue strength of non-load carrying welded joints and the fatigue test results did not fully agree with the fatigue assessment. According to the results, it can be concluded that in tensile loading, the symmetry of joint distinctly affects on the fatigue strength. The fatigue life assessment of bending loaded joints is challenging since it depends on whether the crack initiation or propagation is predominant.

On the anharmonic, multi-phonon, Debye-Waller contributions to the phonon-limited resistivity of metals : applications to Na and K

The anharmonic, multi-phonon (MP), and Oebye-Waller factor (OW) contributions to the phonon limited resistivity (;0) of metals derived by Shukla and Muller (1979) by the doubletime temperature dependent Green function method have been numerically evaluated for Na and K in the high temperature limit. The anharmonic contributions arise from the cubic and quartic shift of phonons (CS, QS), and phonon width (W) and the interference term (1). The QS, MP and OW contributions to I' are also derived by the matrix element method and the results are in agreement with those of Shukla and Muller (1979). In the high temperature limit, the contributions to;O from each of the above mentioned terms are of the type BT2 For numerical calculations suitable expressions are derived for the anharmonic contributions to ~ in terms of the third and fourth rank tensors obtained by the Ewald procedure. The numerical calculation of the contributions to;O from the OW, MP term and the QS have been done exactly and from the CS, Wand I terms only approximately in the partial and total Einstein approximations (PEA, TEA), using a first principle approach (Shukla and Taylor (1976)). The results obtained indicate that there is a strong pairwise cancellation between the: OW and MP terms, the QS and CS and the Wand I terms. The sum total of these contributions to;O for Na and K amounts to 4 to 11% and 2 to 7%, respectively, in the PEA while in the TEA they amount to 3 to 7% and 1 to 4%, respectively, in the temperature range.

Mechanical simulation of the endovascular repair of abdominal aortic aneurysms

Ce travail de thèse porte sur la simulation du déploiement des prothèses vasculaires de type stent-graft (SG) lors de la réparation endovasculaire (EVAR) des anévrismes de l’aorte abdominale (AAA). Cette étude se présente en trois parties: (i) tests mécaniques en flexion et compression de SG couramment utilisés (corps et jambage de marque Cook) ainsi que la simulation numérique desdits tests, (ii) développement d’un modèle numérique d’anévrisme, (iii) stratégie de simulation du déploiement des SG. La méthode numérique employée est celle des éléments finis. Dans un premier temps, une vérification du modèle éléments finis (MEF) des SG est realisée par comparaison des différents cas de charge avec leur pendant expérimental. Ensuite, le MEF vasculaire (AAA) est lui aussi vérifié lors d’une comparaison des niveaux de contraintes maximales principales dans la paroi avec des valeurs de la littérature. Enfin, le déploiement est abordé tout en intégrant les cathéters. Les tests mécaniques menés sur les SG ont été simulés avec une différence maximale de 5,93%, tout en tenant compte de la pré-charge des stents. Le MEF de la structure vasculaire a montré des contraintes maximales principales éloignées de 4,41% par rapport à un modèle similaire précédemment publié. Quant à la simulation du déploiement, un jeu complet de SG a pu être déployé avec un bon contrôle de la position relative et globale, dans un AAA spécifique pré-déformé, sans toutefois inclure de thrombus intra-luminal (TIL). La paroi du AAA a été modélisée avec une loi de comportement isotropique hyperélastique. Étant donné que la différence maximale tolérée en milieu clinique entre réalité et simulation est de 5%, notre approche semble acceptable et pourrait donner suite à de futurs développements. Cela dit, le petit nombre de SG testés justifie pleinement une vaste campagne de tests mécaniques et simulations supplémentaires à des fins de validation.

A Variational Calculation of TE and TM Cutoff Wavenumbers in Circular Eccentric Guides by Conformal Mapping

The cutoff wavenumbers of higher order modes in circular eccentric guides are computed with the variational analysis combined with a conformal mapping. A conformal mapping is applied to the variational formulation, and the variational equation is solved by the finite-element method. Numerical results for TE and TM cutoff wavenumbers are presented for different distances between the centers and ratio of the radii. Comparisons with numerical results found in the literature validate the presented method

Development and Analysis of a Novel Isosceles Trapezoidal Dielectric Resonator Antenna For Wireless Communication

This thesis describes the development and analysis of an Isosceles Trapezoidal Dielectric Resonator Antenna (ITDRA) by realizing different DR orientations with suitable feed configurations enabling it to be used as multiband, dual band dual polarized and wideband applications. The motivation for this work has been inspired by the need for compact, high efficient, low cost antenna suitable for multi band application, dual band dual polarized operation and broadband operation with the possibility of using with MICs, and to ensure less expensive, more efficient and quality wireless communication systems. To satisfy these challenging demands a novel shaped Dielectric Resonator (DR) is fabricated and investigated for the possibility of above required properties by trying out different orientations of the DR on a simple microstrip feed and with slotted ground plane as well. The thesis initially discusses and evaluates recent and past developments taken place within the microwave industry on this topic through a concise review of literature. Then the theoretical aspects of DRA and different feeding techniques are described. Following this, fabrication and characterization of DRA is explained. To achieve the desired requirements as above both simulations and experimental measurements were undertaken. A 3-D finite element method (FEM) electromagnetic simulation tool, HFSSTM by Agilent, is used to determine the optimum geometry of the dielectric resonator. It was found to be useful in producing approximate results although it had some limitations. A numerical analysis technique, finite difference time domain (FDTD) is used for validating the results of wide band design at the end. MATLAB is used for modeling the ITDR and implementing FDTD analysis. In conclusion this work offers a new, efficient and relatively simple alternative for antennas to be used for multiple requirements in the wireless communication system.

Investigations on Structural response of Water Backed Perforated plates

The study envisaged herein contains the numerical investigations on Perforated Plate (PP) as well as numerical and experimental investigations on Perforated Plate with Lining (PPL) which has a variety of applications in underwater engineering especially related to defence applications. Finite element method has been adopted as the tool for analysis of PP and PPL. The commercial software ANSYS has been used for static and free vibration response evaluation, whereas ANSYS LS-DYNA has been used for shock analysis. SHELL63, SHELL93, SOLID45, SOLSH190, BEAM188 and FLUID30 finite elements available in the ANSYS library as well as SHELL193 and SOLID194 available in the ANSYS LS-DYNA library have been made use of. Unit cell of the PP and PPL which is a miniature of the original plate with 16 perforations have been used. Based upon the convergence characteristics, the utility of SHELL63 element for the analysis of PP and PPL, and the required mesh density are brought out. The effect of perforation, geometry and orientation of perforation, boundary conditions and lining plate are investigated for various configurations. Stress concentration and deflection factor are also studied. Based on these investigations, stadium geometry perforation with horizontal orientation is recommended for further analysis.Linear and nonlinear static analysis of PP and PPL subjected to unit normal pressure has been carried out besides the free vibration analysis. Shock analysis has also been carried out on these structural components. The analytical model measures 0.9m x 0.9m with stiffener of 0.3m interval. The influence of finite element, boundary conditions, and lining plate on linear static response has been estimated and presented. Comparison of behavior of PP and PPL in the nonlinear strain regime has been made using geometric nonlinear analysis. Free vibration analysis of the PP and PPL has been carried out ‘in vacuum’ condition and in water backed condition, and the influence of water backed condition and effect of perforation on natural frequency have been investigated.Based upon the studies on the vibration characteristics of NPP, PP and PPL in water backed condition and ‘in vacuum’ condition, the reduction in the natural frequency of the plate in immersed condition has been rightly brought out. The necessity to introduce the effect of water medium in the analysis of water backed underwater structure has been highlighted.Shock analysis of PP and PPL for three explosives viz., PEK, TNT and C4 has been carried out and deflection and stresses on plate as well as free field pressure have been estimated using ANSYS LS-DYNA. The effect of perforations and the effect of lining plate have been predicted. Experimental investigations of the measurement of free field pressure using PPL have been conducted in a shock tank. Free field pressure has been measured and has been validated with finite element analysis results. Besides, an experiment has been carried out on PPL, for the comparison of the static deflection predicted by finite element analysis.The distribution of the free field pressure and the estimation of differential pressure from experimentation and the provision for treating the differential pressure as the resistance, as a part of the design load for PPL, has been brought out.

Finite Element Analysis of Warship Structures

Warships are generally sleek, slender with V shaped sections and block coefficient below 0.5, compared to fuller forms and higher values for commercial ships. They normally operate in the higher Froude number regime, and the hydrodynamic design is primarily aimed at achieving higher speeds with the minimum power. Therefore the structural design and analysis methods are different from those for commercial ships. Certain design guidelines have been given in documents like Naval Engineering Standards and one of the new developments in this regard is the introduction of classification society rules for the design of warships.The marine environment imposes subjective and objective uncertainties on ship structure. The uncertainties in loads, material properties etc.,. make reliable predictions of ship structural response a difficult task. Strength, stiffness and durability criteria for warship structures can be established by investigations on elastic analysis, ultimate strength analysis and reliability analysis. For analysis of complicated warship structures, special means and valid approximations are required.Preliminary structural design of a frigate size ship has been carried out . A finite element model of the hold model, representative of the complexities in the geometric configuration has been created using the finite element software NISA. Two other models representing the geometry to a limited extent also have been created —- one with two transverse frames and the attached plating alongwith the longitudinal members and the other representing the plating and longitudinal stiffeners between two transverse frames. Linear static analysis of the three models have been carried out and each one with three different boundary conditions. The structural responses have been checked for deflections and stresses against the permissible values. The structure has been found adequate in all the cases. The stresses and deflections predicted by the frame model are comparable with those of the hold model. But no such comparison has been realized for the interstiffener plating model with the other two models.Progressive collapse analyses of the models have been conducted for the three boundary conditions, considering geometric nonlinearity and then combined geometric and material nonlinearity for the hold and the frame models. von Mises — lllyushin yield criteria with elastic-perfectly plastic stress-strain curve has been chosen. ln each case, P-Delta curves have been generated and the ultimate load causing failure (ultimate load factor) has been identified as a multiple of the design load specified by NES.Reliability analysis of the hull module under combined geometric and material nonlinearities have been conducted. The Young's Modulus and the shell thickness have been chosen as the variables. Randomly generated values have been used in the analysis. First Order Second Moment has been used to predict the reliability index and thereafter, the probability of failure. The values have been compared against standard values published in literature.

Performance Assessment of Sandwich Structures with Debonds and Dents

A sandwich construction is a special form of the laminated composite consisting of light weight core, sandwiched between two stiff thin face sheets. Due to high stiffness to weight ratio, sandwich construction is widely adopted in aerospace industries. As a process dependent bonded structure, the most severe defects associated with sandwich construction are debond (skin core bond failure) and dent (locally deformed skin associated with core crushing). Reasons for debond may be attributed to initial manufacturing flaws or in service loads and dent can be caused by tool drops or impacts by foreign objects. This paper presents an evaluation on the performance of honeycomb sandwich cantilever beam with the presence of debond or dent, using layered finite element models. Dent is idealized by accounting core crushing in the core thickness along with the eccentricity of the skin. Debond is idealized using multilaminate modeling at debond location with contact element between the laminates. Vibration and buckling behavior of metallic honeycomb sandwich beam with and without damage are carried out. Buckling load factor, natural frequency, mode shape and modal strain energy are evaluated using finite element package ANSYS 13.0. Study shows that debond affect the performance of the structure more severely than dent. Reduction in the fundamental frequencies due to the presence of dent or debond is not significant for the case considered. But the debond reduces the buckling load factor significantly. Dent of size 8-20% of core thickness shows 13% reduction in buckling load capacity of the sandwich column. But debond of the same size reduced the buckling load capacity by about 90%. This underscores the importance of detecting these damages in the initiation level itself to avoid catastrophic failures. Influence of the damages on fundamental frequencies, mode shape and modal strain energy are examined. Effectiveness of these parameters as a damage detection tool for sandwich structure is also assessed

Relativistic LCAO with Minimax Principle and New Balanced Basis Sets

Relativistic density functional theory is widely applied in molecular calculations with heavy atoms, where relativistic and correlation effects are on the same footing. Variational stability of the Dirac Hamiltonian is a very important field of research from the beginning of relativistic molecular calculations on, among efforts for accuracy, efficiency, and density functional formulation, etc. Approximations of one- or two-component methods and searching for suitable basis sets are two major means for good projection power against the negative continuum. The minimax two-component spinor linear combination of atomic orbitals (LCAO) is applied in the present work for both light and super-heavy one-electron systems, providing good approximations in the whole energy spectrum, being close to the benchmark minimax finite element method (FEM) values and without spurious and contaminated states, in contrast to the presence of these artifacts in the traditional four-component spinor LCAO. The variational stability assures that minimax LCAO is bounded from below. New balanced basis sets, kinetic and potential defect balanced (TVDB), following the minimax idea, are applied with the Dirac Hamiltonian. Its performance in the same super-heavy one-electron quasi-molecules shows also very good projection capability against variational collapse, as the minimax LCAO is taken as the best projection to compare with. The TVDB method has twice as many basis coefficients as four-component spinor LCAO, which becomes now linear and overcomes the disadvantage of great time-consumption in the minimax method. The calculation with both the TVDB method and the traditional LCAO method for the dimers with elements in group 11 of the periodic table investigates their difference. New bigger basis sets are constructed than in previous research, achieving high accuracy within the functionals involved. Their difference in total energy is much smaller than the basis incompleteness error, showing that the traditional four-spinor LCAO keeps enough projection power from the numerical atomic orbitals and is suitable in research on relativistic quantum chemistry. In scattering investigations for the same comparison purpose, the failure of the traditional LCAO method of providing a stable spectrum with increasing size of basis sets is contrasted to the TVDB method, which contains no spurious states already without pre-orthogonalization of basis sets. Keeping the same conditions including the accuracy of matrix elements shows that the variational instability prevails over the linear dependence of the basis sets. The success of the TVDB method manifests its capability not only in relativistic quantum chemistry but also for scattering and under the influence of strong external electronic and magnetic fields. The good accuracy in total energy with large basis sets and the good projection property encourage wider research on different molecules, with better functionals, and on small effects.