SIMPACK Wind and Drivetrain Conference

Transcription

Agenda
Modeling Elements
Shafts
Bearings and Mounts
Transmission Elements
Gear Pair
Flexible Bodies
Rotorblades
Aerodynamics
Analysis Methods
Resonance Analysis
Transient Analysis
Order Analysis
Stress and Durability
Scripting / Batch
Simulink Interfaces
Conclusions
SIMPACK AG, S. Mulski 2010-06-17
Page 2
Shafts
Joint “To Marker”
Body Reference Frame (BRF)
• Body data transferred to “To Marker” of Joint
• Recommended: BRF on axis (easier handling of
flexible bodies)
BRF
BRF, Joint “To Marker” on axis
Recommended
BRF, Joint “To Marker”
Not Recommended
Page 3
Bearings and Mounts
Primitive Cylinder 02
• For rotating shafts: Segment colour since v. 8900
• For bearings: Inner diameter with v. 8904
Page 4
Bearings and Mounts
Different Force Elements
• Linear and non-linear stiffness and damping
• 6x6 matrices
• User Routines
• Integrated specialized software (Romax)
• Complete contact model (not commonly done)
Page 5
Bearings and Mounts
BEARINX- SIMPACK
• Schaeffler Technologies GmbH & Co. KG
Page 6
Bearings and Mounts
Romax Bearing
• Standard element since v. 8902
• Look up catalogue (20.000 standard elements SKF, FAG, Koyo, Torrington)
• Possible to enter outer diameter, bore and width
• Romax calculates contact for each simulation
step, as opposed to using look-up tables
• Simple linear damping model
Page 7
Bearings and Mounts
Force Elements 41, 42 and 43
• Evaluation of alignment for calculating moments due to cardanic stiffnesses
Page 8
Bearings and Mounts
• Results depend upon the order of rotation angles
1st alpha
2nd beta
3rd gamma
Page 9
Bearings and Mounts
Before v. 8903 two possible modeling techniques:
1. Always define “From” and “To” markers of force element with z-axis aligned along rotation axis
2. Use extra body for bearing housing with extra joint and constraint
GBX_Housing

FE_43
BR

d
Shaft
Page 10
Bearings and Mounts
With v. 8903:
• Choice of “From” and “To” markers of force element is arbitrary
• Simplified modeling
• Rotation axis defined within force element
GBX_Housing
FE_43

Shaft
Page 11
Bearings and Mounts
Force Element 70, Elasto Hydro Dynamic (EHD) Bearings
With v. 8902
• Calculation of the oil pressure distribution taking flexible
deformation of shaft and shell into account
• Embedded Tower software
“TRUE” EHD analysis (deformed bearing geometry
considered during online EHD calculation)
Page 12
Bearings and Mounts
With v. 8902
• Increasing complexity requires increased computation time
Page 13
Bearings and Mounts
1. Impedance Chart Method
- Interpolation in dimensionless chart
- Cylindrical bearing geometry
- Constant gap in axial direction (no tilting)
- No surface roughness contact
2. Online FEM Method
- Solution of Reynolds Equation in every time step
- Arbitrary bearing geometry (Grooves, Oil supply)
- Variable gap in axial direction (Tilting)
- With surface roughness contact
3. EHD Method
- Features as Online FEM Method
- In addition local bearing deformation
- With surface roughness contact
Online FEM Method
EHD Method
x
y
z
Model Complexity
Local Elast.
Global Elasticity
Methods
Calculation Speed
With v. 8902
Impedanzce Method
• Increasing complexity requires increased computation time
Page 14
Bearings and Mounts
Force Element 42, Dynamic Bushing Hydromount
• Implemented with v. 8902
• Suspension bushings, hydromounts, crankshaft viscodampers
• Rotational and translational frequency and amplitude dependent elements
rubber bushing
hydromount
viscodamper
Page 15
Bearings and Mounts
Force Element 42, Dynamic Bushing Hydromount
• Easy switching of element detail using parameterization
Page 16
Bearings and Mounts
Force Elements 42, Dynamic Bushing Hydromount
• Parameter fitting in preprocessing
Page 17
Extensive library of gear elements
• Various levels of detail for optimum solver speed and accuracy
1-D torsional vibration model
Torque converter
Detailed gearpair
applied moments
applied moments
support arm forces
applied forces
support arm forces
bearing forces
bending moments
teeth meshing forces/moments
teeth meshing excitations
Page 18
Extensive element library
• Gearboxes (FE 014, 052, 055, 056, 057, 067, 225)
• Transmission joints (FE 053, 054, 058, 059)
• Belt Drives (FE 240)
Page 19
Torque Convertors
•
FE 014 “Gearbox Torque to Torque”
Application: Elastic transmission for a “black-box” gearbox
Features: Transmission ratio, linear/non-linear
stiffness/damping, non-uniaxial axes, flexible shafts
•
FE 057 “Planetary Gear”
Application: Automotive & wind turbine drivetrains
Features (see FE 014, plus): Extra sun/planet/ring bodies,
parallel axes only
Page 20
Gear Pair
What do Formula 1 Racing and Wind Turbines have in common?
Detailed SIMPACK Gearwheels developed for F1 (2004)
Page 21
Gear Pair
SIMPACK Gear Pair
• Internal and external gears
• Involute spur and helical gears
• Profile shift
• Profile and flank modification
• Single and multiple tooth contact
• Non-parallel axes with load distribution
• Dynamic changing backlash and friction
• Dynamic separation of gear wheel distance
Page 22
Gear Pair
SIMPACK Gear Pair
• Excitation from tooth meshing
Courtesy of Prof. Schlecht, TU Dresden
Page 23
Gear Pair
SIMPACK Gear Pair Primitive – New v. 8904
1. Bevel gear rim thickness
2. Tooth profile modification
Page 24
Gear Pair
SIMPACK Gear Pair Primitive – New v. 8904
1. Bevel gear rim thickness
Rim thickness
Before v8904
With v8904
Page 25
Gear Pair
SIMPACK Gear Pair Primitive –
New v. 8904
2. Tooth profile modification
Left Flank = off
Right Flank = on
Left Flank = on
Right Flank = on
Page 26
Gear Pair
Distance
Tip Modification
Amount
┴
Exponent
yellow=1, orange=2, red=3
Root Modification
Distance
Amount *
┴
Exponent
*Perpendicular to the root circle (dedendum); modification only calculated up to base circle.
Page 27
Gear Pair
Distance
Circular Modification
(Pressure) Slope Modification
Amount
┴
Distance
sr   angle  r  distance 
Angle
Page 28
Gear Pair
Left/Right Side Modification
Distance
Amount
┴
┴
┴
Exponent
Lead Crowning
Amount
┴
┴
┴
Page 29
Gear Pair
Lead Angular Modification
Bias (Twist)
Angle
Angle
Page 30
Gear Pair
Modification by Array
Page 31
Gear Pair
SIMPACK Gear Pair Force Element 225 – New 8904
Page 32
Gear Pair
Gear Pair Slicing
• Necessary for non-parallel axes and flank modifications
• Previously done by time consuming modeling
• Slicing now possible using single input parameter in force
element
to
from
Courtesy of Erik Pfleger, Siemens AG
Page 33
Gear Pair
Data Check – Output File for Each Gear Pair in Model
Page 34
Gear Pair
Basic Output Values
• On/Off using parameterisation
Page 35
Gear Pair
Advanced Output Values
• On/Off and type selection using
parameterization
t
z
Page 36
Gear Pair
parameterization
y
z
x
Page 37
Gear Pair
parameterization
Number of
slices = 1
n tooth +1
n tooth 0
n tooth -1
Page 38
Gear Pair
parameterization
Number of
slices = 21
LIVE DEMO
Etc.
Page 39
Flexible Tower
Modelling of Flexible Tower
• SIMBEAM
• Parameterized SIMBEAM model
• Rotorblade generator
• Import from FE
Page 40
Flexible Tower
Modeling of Flexible Tower
SIMBEAM parameterized
• Known diameters and wall thicknesses
• Easy-to-model variants
Z +0,00001
Page 41
Flexible Tower
SIMBEAM Rotorblade Generator
• Known cross-section stiffnesses
• Easy to model variants
Page 42
Flexible Tower
Import from FE Model
• Detailed FE structure
• Stress and durability analysis
Page 43
Spec: 16717,
Flexible
Bodies
Support for beam element with twist-bend coupling
SIMBEAM Elements - New v. 8903
• Independent mass and elastic properties
• Arbitrary center of shear location
• Center of mass and elastic center location
• EULER-BERNOULLI and TIMOSCHENKO beam
formulation
• Non double-symmetric profiles
• Profiles with eccentric loads (w.r.t. element reference
frame)
• Non-homogenious cross-sections
Page 44
Flexible Bodies
SIMBEAM Rotorblade Generator
• Re-ordering of columns
• Flags for defining location of aerodynamic
markers
• Flags for defining orientation of stiffness and
inertia properties
• Flags for defining reference system for the shear,
c.g., and elastic axes (pitch axis or element
Reference System)
• Options for choosing which markers to generate)
• New naming convention for bodies and markers
of generated rotorblade body
• Improvements in SIMBEAM and FEMBS
Basic
Advanced
• Easy-to-model variants
• Detailed FE model not required
LIVE Demo
Page 45
Flexible Bodies
SIMBEAM Rotorblade Generator – Validation
• Eigenfrequencies identical (NASTRAN)
• Excellent comparison results obtainable
Important Points to Consider for Comparisons
• Many different interpolation methods (SIMPACK Rotorblade
Generator and FE codes)
• SIMBEAM elements always along neutral axis
• For twist/bend coupling a small border for “Zero Elements”
required in FEMBS (e.g. 10.e-10)
• A large number of modes should be considered for stability
calculations
Neutral
axis
SIMBEAM and FE
Some FE Codes
Page 46
Flexible Bodies
FE Model Example
• FE model preparation
• Connection node location
• Measurement nodes location
Courtesy NREL, GRC project
Page 47
Aerodynamics
Wind Turbine Aerodynamics
• AeroDyn (NREL)
• Bladed (Master thesis)
• Flex5 (Company specific)
• ECN models (BEM, AWSM)
• CFD (Flower)
• Etc.
AWSM
Page 48
Aerodynamics
MZR
FZR
SIMPACK – AeroDyn (NREL)
MXR
MYR
FXR
ZR
FYR
YR
XR
• With 8904 – standard interface
• Compilation of code no longer necessary
• AeroDyn .dll for SIMPACK available on NREL
website
• Supported by SIMPACK AG
XR in direction of the rotor axis
ZR radially, orientated to rotor blade 1
and perpendicular to XR
YR perpendicular to XR,
so that XR, YR, ZR rotate clockwise
Page 49
Analyses
Eigenvalue Results in PostProcessor (v. 8903)
• Eigenvalue amplitude
• Phase
• Kinetic energy
• Drag and drop of multiple channels
Eva file
Page 50
Excitation
Composition of Time Excitation Using Specific Order
Components, via Fourier Series (v. 8902)
• Analytical excitation
• Order, amplitude and phase can be derived from measured excitation
k1 =1
A1
phi1
k2 =2
A2
phi2
+
k3 =3
A3
phi3
+
Page 51
Analyses
Eigenvalue Analysis
• Parameter variation
• Batch commands
Page 52
Analyses
velocity
Run-Up FFT
• Multiple quasi-static solver runs
• Plotting FFT of each result
time
amplitude
frequency
velocity
Page 53
Analyses
velocity
Order Analysis
• One single run-up
time
amplitude
frequency
velocity
Page 54
Analyses
Order Analysis
amplitude
• One single run-up
time
amplitude
velocity
order
Page 55
Analyses
NVH: Engine Caused Driveline Oscillations
• Model of the entire truck including engine and driveline
• Flexible bodies
• Roller testrig
•Optimization of driveline behavior
Page 56
Analyses
NVH: Engine Caused Driveline Oscillations
• Analysis of individual orders
• Determination of responsible order, (e.g cause of drone)
• Determining main path of excitation
• Plotting of all orders, 100% plot
• Optimization of driveline behavior
Force
z
Sum
2nd
1st
rpm
Page 57
Analyses
Aliasing
• Frequency sweep
1
y(t)  A  sin (Ω0  k  t)  t
2
Ω 0  2.  f 0
f 0  20 [ Hz]
t max  1 [s]
f max  200 [ Hz]
k  180 [1 / s 2 ]
F r e q u e n c y
S
w
e
[ s ]
e e p
1 . 1 0
0 . 5 5
Frequency Sweep
0 . 0 0
- 0 . 5 5
- 1 . 1 0
0 . 0
0 . 2
0 . 4
0 . 6
t im
0 . 8
1 . 0
Page 58
Analyses
Aliasing
S a m p lin g r a te 1 0 0 [ H z ]
1 .1 0
0 .5 5
0 .0 0
- 0 .5 5
- 1 .1 0
0 .0
0 .2
0 .4
0 .6
0 .8
1 .0
0 .6
0 .8
1 .0
0 .6
0 .8
1 .0
0 .6
0 .8
1 .0
t im e [ s ]
1 .1 0
0 .5 5
0 .0 0
- 0 .5 5
- 1 .1 0
0 .0
0 .2
0 .4
t im e [ s ]
1 .1 0
0 .5 5
0 .0 0
- 0 .5 5
- 1 .1 0
0 .0
0 .2
0 .4
t im e [ s ]
S a m p lin g r a te 5 0 0 0 [H z ]
1 .1 0
0 .5 5
0 .0 0
- 0 .5 5
- 1 .1 0
0 .0
0 .2
0 .4
t im e [ s ]
Page 59
Analyses
Stress Analysis
• Superposition of modal stresses
• Applied forces
Courtesy of Komai
Page 60
Analyses
Stress and Durability Analysis
(Integrated within SIMPACK)
(SIMPACK export to FEMFAT)
Page 61
SIMPACK Scripting
Qt Script for Applications (QSA)
• QSA is an easy-to-learn, cross-platform,
interpreted scripting language
Typical Scripting Usage
• Creating batch tasks
• Automatic report generation
• Writing macros
• Customize GUI
Command area
Echo area
Learning Scripting
• Use the macro recorder for easily generate your scripts
• Example scripts available in the SIMPACK Documentation
• Scripting Tutorial available for 8904
Page 62
SIMPACK Scripting
Examples for Scripting
• Create a GUI for selecting a model and starting the solver
• Create a script for applying filter chains (PostProc)
• Create a simple ASCII exporter (batch mode)
Page 63
SIMPACK Batch Commands
Why Batch Jobs?
• Batch = Shell or script driven execution of programs or program modules
Advantages
• Easy variant calculations
• Job execution, independent from any GUI
(remote login without X-application)
• Execution of several time extensive jobs
“over night”
• Defining a complete analysis scenario
(PreProc-Solver-PostProc) by calling only
one script
• Results are standardized
Page 64
SIMPACK Batch Commands
Where?
• Execute the batch in the command shell MSYS (delivered with SIMPACK)
Supported Functionalities
Example file: MyBatch.ksh
• Time integration
• Driven equilibrium
• Inverse kinematics
• Test call
• Linear system analysis
• Rotorblade
• SIMAT
• VTL
# ---------------------------------------------------------------------------# --- Simulation: Shell-Commands
# ---------------------------------------------------------------------------mkdir ./Eig/
rm ./Eig/*.eva
# ---------------------------------------------------------------------------# --- Model: 06_linear_resonance_analysis.sys
# ---------------------------------------------------------------------------model=06_linear_resonance_analysis
#
#
#
#
------------------------------------------------------------------------------ Simulation: Eigenvalue
---------------------------------------------------------------------------10 = time of integration [s] at which the eigenvalues should be calculated
simpack integ $model
simpack linear_eig 10 none $model
mv
mv
;
"./${model}.output/${model}.ev.sbr" "${wkdir}/Eig/${model}__10.ev.sbr"
"./${model}.output/${model}.eva"
"${wkdir}/Eig/${model}__10.eva"
Page 65
Overview of the Interfaces to MATLAB and Simulink
SIMAT - Linear Model Export
SIMAT - Co-simulation
Page 66
Overview of the Interfaces to MATLAB and Simulink
MatSIM
Code Export
Page 67
Using “MatSIM” for the Multi-Domain Simulations
Overview of the “MatSIM” Interface
MATLAB/Simulink Model
MatSIM creates a
new SIMPACK Control
Element
Real Time
Workshop
Coupled Simulation in SIMPACK
Page 68
Using “MatSIM” for the Multi-Domain Simulations
Simulation of an Asynchronous Motor and a Generator Short-Circuit
SIMPACK
MATLAB/Simulink II
(MatSIM-element)
MATLAB/Simulink I
(MatSIM-element)
M t 
U Zwischenkreis
converter
(as time excitation)
iR t 
u R t 
u S t 
uT t 
Asynchronous
motor
iS t 
iT t 
short-circuit
functions
Coupled simulation in SIMPACK.
SIMPACK
Simulation of variants of the Simulink model directly in SIMPACK

parameter
(from measurements)
Page 69
Conclusion
New with SIMPACK 8904:
• Profile and flank modification
• Automatic slicing
• Visualisation of force arrows
• Improved SIMBEAM and Rotorblade Generator for
flutter calculations
• And many other improved functionalities
Easier and faster modeling with improved
accuracy!
Page 70

SIMPACK Wind and Drivetrain Conference

Transcription

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