MAGIC MACHINE-GROUND INTERACTION CONSORTIUM

Transcription

1 MAGIC MACHINE-GROUND INTERACTION CONSORTIUM Modeling, Simulation, and Validation of Tracked Vehicles Dr. Holger Haut, Simertis GmbH, Germany 9. December 2014

2 Overview Introduction The Simertis GmbH Application Area of MBS Tracked Vehicle Peculiarity Modeling Analyzing Verification Tests Application Conclusion

3 Introduction Simertis GmbH

4 History of the Simertis GmbH RWTH AACHEN University One of the biggest Technical University in Germany Department of Excavation and Mining Group (BGMR) Focused on mining and mineral processing Initial Step for MBS from TEREX Mining (2002) New method of analyzing crawler kinematics Carried out first Crawler Project with TEREX Mining (2003) Plug-In Crawler Engineering partner for the industry (2004) Further developing of method and plug-ins Crawler engineering for different companies (since 2005) Development of DIGertis (2006) Foundation of the Simertis GmbH (2006)

5 Portfolio of the Simertis GmbH Engineering/Consulting Workflows Methods Integration Projects Software Development In-house Solutions for Consulting License for Products/Plugin Engineering Consulting Partnership & Cooperation University of Wisconsin Madison University of Aachen (several departments) Other university and research institution Fluidon MSC.Software Partnership & Cooperation Software Development

6 Research & Development Projects High R&D part at each projects Internal R&D Projects Long-term R&D Government funded Internal R&D Govermentfunded NRW BMWi EU

7 Example of Methods Lattice-Boom Crane

8 Discreted MBS-Model Lattice-Boom Crane Lattice boom 106 elements Geometries CAD-import Building in MBS system Linking 6x6 stiffness field External calculation

9 Software Development Simulation of a Hydraulic Excavator Attachment Digging forces Digging & loading material with the bucket Workingspace of the attachment Breakout force Crowd force BOOM Cylinder STICK Cylinder BUCKET TILT Cylinder BREAKOUT FORCE CROWD FORCE

10 Analysis Attachment of a Hydraulic Excavator Calculation of the digging forces DIN Breakout force Crowd force Dynamic Stability Tipping of the Excavator ISO DIN Hydraulic lift capacity Analyzing area Workingspace Settings Boundary conditions Cylinder pressure

11 Software DIGertis

12 Software DIGertis Analyzing Working Space

13 Software DIGertis Analyzing Working Space (Breakout Force)

14 Software DIGertis Analyzing Working Space (Breakout Force)

15 Tracked Vehicle

16 Motivation A new Application Area Motivation Weight & operation conditions High mechanical stresses Flexibility & mobility Long working live Solution MBS & plug-in crawler

17 Classical Applications for Multibodysimulation (MBS) Customers Rail industry Aviation Automotive

18 Workflow for MBS-Modelling

19 Efficient Workflow for MBS-Modelling 3D CAD Parasolid SolidWorks Creating Parts MBS- Software MSC.ADAMS Module CHAIN Positioning the Parts Properties of the Parts Definition of the Kinematics Contacts and Functions Post Processing Specification Optimization of the geometry Contact analysis Complex, various geometries Use of 3D-CAD Data Different kinematics Flexible modelling Timesaving modelling Low costs for module development Embedded in a standard MBSsystem

20 Workflow for MBS-Modelling

21 Track Systems Challenges System chain High number of parts High number of chain links High degree of freedom Parts are linked to a system Leads to a high cross-linked system Each individual parameter effects the full system E.g. tension force effects the kinematic System has non bounded areas Chain slack System can swing Swinging chain Kinematic defined more or less by form closure Free kinematic Manifold different systems Challenge for simulation and analyzes

22 Mining Machine Track Systems Conclusion Complex and manifold systems Generally statements should be viewed with skepticism Don t read tea leaves Analyze, analyze and analyze more

23 Simulation and Analyzing Support for Product Development Components Shoe Top Roller Tumbler Idler Bottom Roller Position Applied Simulation Projects by Simertis Kinematik System Shoe Tumbler DPRS SPRS Doozer Idler Bottom Roller Top Roller Undercarriage Product Definiton Overload Geometry Influence Operating Mode Preload Tension System Chain Pitch Rim Diameter Geometry Change Wear Tear

24 Example of a Crawler Analysis TEREX Mining Power transmission Tumbler to shoes Distribution of the forces Rim and sprocket Focus on geometry Tumbler and shoes Behavior at wear conditions Higher or lower stress Stable or unstable kinematics Verification by different designs of the crawler and video analysis

25 Example of a Crawler Analysis TEREX Mining Qualitative comparison of different track systems e.g. Double path roller system (DPRS) Single path roller system (SPRS) DPRS SPRS

26 Example Force Distribution Rim & Sprocket Forward Drive - Complete Forces at Sprocket and Rim 100% Crawler Track A Crawler Track B Distribution of Forces 80% 60% 40% 20% 0% New Wear 2% New Wear 2% Sprocket Rim

27 Example of a Crawler Analysis Analysis Stress of the parts: e.g. rollers Dynamics, influence of the shoes forces, bearing loads Contact Analysis: e.g. Sprocket Contact forces, dynamics Characteristics

28 Example of a Crawler Analysis Kinematic: Sprocket/Chain Track in Backward drive 3% wear

29 Example of a Crawler Analysis Kinematic: Sprocket/Chain Track out DPRS Backward drive Track out SPRS Backward drive

30 Example of a Crawler Analysis Kinematic: Sprocket/Chain Track in Forward drive 0% wear

31 Example of a Crawler Analysis Kinematic: Sprocket/Chain Minimum & maximum distance of the point of contact

32 Example of a Crawler Analysis RWE POWER

33 Pin of the Shoe with Slackness

34 Co-Simulation MBS & Hydraulic Simulation Simulation models Hydraulics (e.g. DSHplus) MBS (MSC.ADAMS) Control Circuit diagram Calculation Hydraulic & MBS Solver Parallel, online Dynamics Hydraulic Control, response, flexibility MBS Inertia, flexibility

35 Co-Simulation MBS & Hydraulic Simulation

36 Different Applications

37 Chain Drive Chain Analysis Dynamic Tensioning system

38 Belt Belt drive Analysis Dynamic Tensioning system

39 Bulk Solid Discs Conveyor Analysis Discs Sprocket

40 Verification

41 Verification Customers problems are our verification Knowledge Cross-linked systems Extensive & sophisticated models Simertis

42 Simulation &.

43 . Physical Tests

44 R&D New Test Set i-mass Integrated Machine Sensor System Goal Autarkic Universal Wireless-Sensor-System for Online-Condition-Monitoring Partner RWTH Aachen, IMR IMST GmbH Thiele GmbH & Co. KG Simertis GmbH Eickhoff Bergbautechnik GmbH Eickhoff Antriebstechnik GmbH Bergbautechnik GmbH Antriebstechnik GmbH Budget 4.5 Mio EUR Duration 3 years

45 R&D New Test Set Universal SoC-sensor Stat of the art: multi-chip module (MCM) i-mass developement: SoC Sensor- Architektur i-mass Applications Chain for lifting Chain for mining Mining machinery Windturbine gear

46 R&D New Test Set Armored Face Conveyor (AFC)

47 R&D New Test Set Armored Face Conveyor (AFC)

48 AFC System Behavior

49 Test Data / Simulation Motivation Test data from physical tests Chain bucket elevator AUMUND Fördertechnik GmbH Customer Dyckerhoff fab Lengerich Capacity 350 t/h, bei 1,54 m/s Height 53,75 m Dead end with test data [Bilder exemplarisch]

50 Test Data / Simulation Chain Bucket Elevator

51 Chain Bucket Elevator Simulation and Analyzes Propelled Wheel Forces Contact forces at the propelled wheel Track-in, track-out (meshing)

52 Conclusion Tracked vehicle still challenging System itself Simulation, modeling Analyzing Actual simulation techniques are many times not the bottleneck Do the work which can actual done Knowledge in simulation Design development

53 Conclusion Take next step Co-simulation with hydraulic simulation Machine-ground interaction Generally statements should be viewed with skepticism Don t read tea leaves Analyze, analyze and do more analyzes

54 Invitation to Aachen Germany

55 Invitation Virtual Reality (VR)

56 Thank you!