SIMPACK Wind and Drivetrain Conference

Transcription

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2 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 Page 2

3 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

4 Bearings and Mounts Primitive Cylinder 02 For rotating shafts: Segment colour since v For bearings: Inner diameter with v Page 4

5 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

6 Bearings and Mounts BEARINX- SIMPACK Schaeffler Technologies GmbH & Co. KG Page 6

7 Bearings and Mounts Romax Bearing Standard element since v Look up catalogue ( 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

8 Bearings and Mounts Force Elements 41, 42 and 43 Evaluation of alignment for calculating moments due to cardanic stiffnesses Page 8

9 Bearings and Mounts Force Elements 41, 42 and 43 Results depend upon the order of rotation angles 1 st alpha 2 nd beta 3 rd gamma Page 9

10 Bearings and Mounts Force Elements 41, 42 and 43 Before v 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 BR FE_43 d Shaft Page 10

11 Bearings and Mounts Force Elements 41, 42 and 43 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

12 Bearings and Mounts Force Element 70, Elasto Hydro Dynamic (EHD) Bearings With v 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

13 Bearings and Mounts Force Element 70, Elasto Hydro Dynamic (EHD) Bearings With v Increasing complexity requires increased computation time Page 13

14 Bearings and Mounts Force Element 70, Elasto Hydro Dynamic (EHD) Bearings 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 Impedanzce Method Increasing complexity requires increased computation time Page 14

15 Bearings and Mounts Force Element 42, Dynamic Bushing Hydromount Implemented with v Suspension bushings, hydromounts, crankshaft viscodampers Rotational and translational frequency and amplitude dependent elements rubber bushing hydromount viscodamper Page 15

16 Bearings and Mounts Force Element 42, Dynamic Bushing Hydromount Easy switching of element detail using parameterization Page 16

17 Bearings and Mounts Force Elements 42, Dynamic Bushing Hydromount Parameter fitting in preprocessing Page 17

18 Transmission Elements 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

19 Transmission Elements 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

20 Transmission Elements 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

21 Gear Pair What do Formula 1 Racing and Wind Turbines have in common? Detailed SIMPACK Gearwheels developed for F1 (2004) Page 21

22 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

23 Gear Pair SIMPACK Gear Pair Excitation from tooth meshing Courtesy of Prof. Schlecht, TU Dresden Page 23

24 Gear Pair SIMPACK Gear Pair Primitive New v Bevel gear rim thickness 2. Tooth profile modification Page 24

25 Gear Pair SIMPACK Gear Pair Primitive New v Bevel gear rim thickness Rim thickness Before v8904 With v8904 Page 25

26 Gear Pair SIMPACK Gear Pair Primitive New v Tooth profile modification Left Flank = off Right Flank = on Left Flank = on Right Flank = on Page 26

27 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

28 Gear Pair Distance Circular Modification (Pressure) Slope Modification Amount Distance s r angle r distance Angle Page 28

29 Gear Pair Left/Right Side Modification Distance Amount Exponent Lead Crowning Amount Page 29

30 Gear Pair Lead Angular Modification Bias (Twist) Angle Angle Page 30

31 Gear Pair Modification by Array Page 31

32 Gear Pair SIMPACK Gear Pair Force Element 225 New 8904 Page 32

33 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

34 Gear Pair Data Check Output File for Each Gear Pair in Model Page 34

35 Gear Pair Basic Output Values On/Off using parameterisation Page 35

36 Gear Pair Advanced Output Values On/Off and type selection using parameterization t z Page 36

37 Gear Pair Advanced Output Values On/Off and type selection using parameterization y z x Page 37

38 Gear Pair Advanced Output Values On/Off and type selection using parameterization Number of slices = 1 n tooth +1 n tooth 0 n tooth -1 Page 38

39 Gear Pair Advanced Output Values On/Off and type selection using parameterization Number of slices = 21 LIVE DEMO Etc. Page 39

40 Flexible Tower Modelling of Flexible Tower SIMBEAM Parameterized SIMBEAM model Rotorblade generator Import from FE Page 40

41 Flexible Tower Modeling of Flexible Tower SIMBEAM parameterized Known diameters and wall thicknesses Easy-to-model variants Z +0,00001 Page 41

42 Flexible Tower Modeling of Flexible Tower SIMBEAM Rotorblade Generator Known cross-section stiffnesses Easy to model variants Page 42

43 Flexible Tower Modeling of Flexible Tower Import from FE Model Detailed FE structure Stress and durability analysis Page 43

44 Spec: 16717, Flexible Bodies Support for beam element with twist-bend coupling SIMBEAM Elements - New v 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

45 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

46 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

47 Flexible Bodies FE Model Example FE model preparation Connection node location Measurement nodes location Courtesy NREL, GRC project Page 47

48 Aerodynamics Wind Turbine Aerodynamics AeroDyn (NREL) Bladed (Master thesis) Flex5 (Company specific) ECN models (BEM, AWSM) CFD (Flower) Etc. AWSM Page 48

49 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

50 Analyses Eigenvalue Results in PostProcessor (v. 8903) Eigenvalue amplitude Phase Kinetic energy Drag and drop of multiple channels Eva file Page 50

51 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

52 Analyses Eigenvalue Analysis Parameter variation Batch commands Page 52

53 Analyses velocity Run-Up FFT Multiple quasi-static solver runs Plotting FFT of each result time amplitude frequency velocity Page 53

54 Analyses velocity Order Analysis One single run-up Plotting FFT of each result time amplitude frequency velocity Page 54

55 Analyses Order Analysis amplitude One single run-up Plotting FFT of each result time amplitude velocity order Page 55

56 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

57 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

58 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 Frequency Sweep t im Page 58

59 Analyses Aliasing S a m p lin g r a te [ H z ] t im e [ s ] S a m p lin g r a te [ H z ] t im e [ s ] S a m p lin g r a te [ H z ] t im e [ s ] S a m p lin g r a te [H z ] t im e [ s ] Page 59

60 Analyses Stress Analysis Superposition of modal stresses Applied forces Courtesy of Komai Page 60

61 Analyses Stress and Durability Analysis (Integrated within SIMPACK) (SIMPACK export to FEMFAT) Page 61

62 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

63 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

64 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

65 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 = 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

66 Overview of the Interfaces to MATLAB and Simulink SIMAT - Linear Model Export SIMAT - Co-simulation Page 66

67 Overview of the Interfaces to MATLAB and Simulink MatSIM Code Export Page 67

68 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

69 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

70 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