Abstract: Sedimentation of magnetorheological (MR) fluid affects its working. MR fluid is a smart fluid that has unique qualities such as quick responsiveness and easy controllability. It is used in the MR damper, MR brake, and MR clutch. In this work effect of sedimentation on torque transmission in the shear mode operated MR clutch is investigated. A test rig is developed to test the impact of sedimentation on torque transmission in the MR clutch. Torque transmission capability of MR clutch has been measured under two conditions to confirm the result of sedimentation. The first experiment is done just after filling and the other after one week. It has been observed that transmission torque is decreased after sedimentation. Hence sedimentation affects the working of the MR clutch.
Abstract: Hardware in Loop (HIL) testing is done to test and validate a particular product especially in building technology. When it comes to building technology, it is more important to test the products for their efficiency. The test rig in the HIL simulator may contribute to some uncertainties on measured efficiency. The uncertainties include physical uncertainties and scenario-based uncertainties. In this paper, a simple uncertainty analysis framework for an HIL setup is shown considering only the physical uncertainties. The entire modeling of the HIL setup is done in Dymola. The uncertain sources are considered based on available knowledge of the components and also on expert knowledge. For the propagation of uncertainty, Monte Carlo Simulation is used since it is the most reliable and easy to use. In this article it is shown how an HIL setup can be modeled and how uncertainty propagation can be performed on it. Such an approach is not common in building energy analysis.
Abstract: The heat pipe is a thermal device which allows efficient transport of thermal energy. The experimental work of this research was split into two phases; phase 1 is the development of the facilities, material and test rig preparation. Phase 2 is the actual experiments and measurements of the thermal control mockup inside the modified vacuum chamber (MVC). Due to limited funds, the development on the thermal control subsystem was delayed and the experimental facilities such as suitable thermal vacuum chamber with space standard specifications were not available from the beginning of the research and had to be procured over a period of time. In all, these delays extended the project by one and a half year. Thermal control subsystem needs a special facility and equipment to be tested. The available vacuum chamber is not suitable for the thermal tests. Consequently, the modification of the chamber was a must. A vacuum chamber has been modified to be used as a Thermal Vaccum Chamber (TVC). A MVC is a vacuum chamber modified by using a stainless mirror box with perfect reflectability and the infrared lamp connected with the voltage regulator to vary the lamp intensity as it will be illustrated through the paper.
Abstract: This paper presents the experimental study of vibration generated by friction materials of an automotive disc brake system using brake test rig. Effects of silica sand particles which are available on the road surface as an environmental condition with a size varied from 150 μm to 600 μm are evaluated. Also, the vibration of the brake disc is examined against the friction material in humidity environment conditions under variable rotational speed. The experimental results showed that the silica sand particles have significant contribution on the value of vibration amplitude which enhances with increasing the size of silica sand particles at different speed conditions. Also, it is noticed that the friction material is sensitive to humidity and the vibration magnitude increases under wet testing conditions. Moreover, it can be reported that with increasing the applied pressure and rotational speed of the braking system, the vibration amplitudes decrease for all cases.
Abstract: Structural frequency response testing is accurate in identifying the dynamic characteristic of a machinery structure. In practical perspective, conventional structural frequency response testing such as experimental modal analysis with impulse technique (also known as “impulse testing”) has limitation especially on its long acquisition time. The high acquisition time is mainly due to the redundancy procedure where the engineer has to repeatedly perform the test in 3 directions, namely the axial-, horizontal- and vertical-axis, in order to comprehensively define the dynamic behavior of a 3D structure. This is unfavorable to numerous industries where the downtime cost is high. This study proposes to reduce the testing time by using oblique impact. Theoretically, a single oblique impact can induce significant vibration responses and vibration modes in all the 3 directions. Hence, the acquisition time with the implementation of the oblique impulse technique can be reduced by a factor of three (i.e. for a 3D dynamic system). This study initiates an experimental investigation of impulse testing with oblique excitation. A motor-driven test rig has been used for the testing purpose. Its dynamic characteristic has been identified using the impulse testing with the conventional normal impact and the proposed oblique impact respectively. The results show that the proposed oblique impulse testing is able to obtain all the desired natural frequencies in all 3 directions and thus providing a feasible solution for a fast and time effective way of conducting the impulse testing.
Abstract: Supersonic nozzles are commonly used to purify natural gas in gas processing technology. As an innovated technology, it is employed to overcome the deficit of the traditional method, related to gas dynamics, thermodynamics and fluid dynamics theory. An indoor test rig is built to study the dehumidification process of moisture fluid. Humid air was chosen for the study. The working fluid was circulating in an open loop, which had provision for filtering, metering, and humidifying. A stainless steel supersonic separator is constructed together with the C-D nozzle system. The result shows that dehumidification enhances as NPR increases. This is due to the high intensity in the turbulence caused by the shock formation in the divergent section. Such disturbance strengthens the centrifugal force, pushing more particles toward the near-wall region. In return return, the pressure recovery factor, defined as the ratio of the outlet static pressure of the fluid to its inlet value, decreases with NPR.
Abstract: Linear actuators are deployed in a wide range of applications. This paper presents the modeling and system identification of a variable excited linear direct drive (LDD). The LDD is designed based on linear hybrid stepper technology exhibiting the characteristic tooth structure of mover and stator. A three-phase topology provides the thrust force caused by alternating strengthening and weakening of the flux of the legs. To achieve best possible synchronous operation, the phases are commutated sinusoidal. Despite the fact that these LDDs provide high dynamics and drive forces, noise emission limits their operation in calm workspaces. To overcome this drawback an additional excitation of the magnetic circuit is introduced to LDD using additional enabling coils instead of permanent magnets. The new degree of freedom can be used to reduce force variations and related noise by varying the excitation flux that is usually generated by permanent magnets. Hence, an identified simulation model is necessary to analyze the effects of this modification. Especially the force variations must be modeled well in order to reduce them sufficiently. The model can be divided into three parts: the current dynamics, the mechanics and the force functions. These subsystems are described with differential equations or nonlinear analytic functions, respectively. Ordinary nonlinear differential equations are derived and transformed into state space representation. Experiments have been carried out on a test rig to identify the system parameters of the complete model. Static and dynamic simulation based optimizations are utilized for identification. The results are verified in time and frequency domain. Finally, the identified model provides a basis for later design of control strategies to reduce existing force variations.
Abstract: In this paper, an experimental and theoretical study on the bogie pseudo-hunting motion of a reduced-scale model railway vehicle, running on double-curved rails, is presented. Since the actual bogie hunting motion, occurring for real railway vehicles running on straight rails at high travelling speeds, cannot be obtained in laboratory conditions, due to the speed and wavelength limitations, a pseudo- hunting motion was induced by employing double-curved rails. Firstly, the test rig and the experimental procedure are described. Then, a geometrical model of the double-curved rails is presented. Based on such model, the variation of the carriage rotation angle relative to the bogies and the working conditions of the yaw damper are clarified. Vibration spectra recorded during vehicle travelling, on straight and double-curved rails, are presented and interpreted based on a simple vibration model of the railway vehicle. Ride comfort of the vehicle is evaluated according to the ISO 2631 standard, and also by using some particular frequency weightings, which account for the discomfort perceived during the reading and writing activities. Results obtained in this work are useful for the adequate design of the yaw dampers, which are used to attenuate the lateral vibration of the train car bodies.
Abstract: Thermal power technology such as the TEG (Thermo-Electric Generator) arouses significant attention worldwide for waste heat recovery. Despite the potential benefits of marine application due to the permanent heat sink from sea water, no significant studies on this application were to be found. In this study, a test rig has been designed and built to test the performance of the TEG on engine operating points. The TEG device is built from commercially available materials for the sake of possible economical application. Two types of commercial TEM (thermo electric module) have been studied separately on the test rig. The engine data were extracted from a commercial Diesel engine since it shares the same principle in terms of engine efficiency and exhaust with the marine Diesel engine. An open circuit water cooling system is used to replicate the sea water cold source. The characterization tests showed that the silicium-germanium alloys TEM proved a remarkable reliability on all engine operating points, with no significant deterioration of performance even under sever variation in the hot source conditions. The performance of the bismuth-telluride alloys was 100% better than the first type of TEM but it showed a deterioration in power generation when the air temperature exceeds 300 °C. The temperature distribution on the heat exchange surfaces revealed no useful combination of these two types of TEM with this tube length, since the surface temperature difference between both ends is no more than 10 °C. This study exposed the perspective of use of TEG technology for marine engine exhaust heat recovery. Although the results suggested non-sufficient power generation from the low cost commercial TEM used, it provides valuable information about TEG device optimization, including the design of heat exchanger and the types of thermo-electric materials.
Abstract: Understanding the nature of wheel and rail wear in the railway field is of fundamental importance to the safe and cost effective operation of the railways. Twin disc wear testing is used extensively for studying wear of wheel and rail materials. The University of Huddersfield twin disc rig was used in this paper to examine the effect of surface conditions on wheel and rail wear measurement under a range of wheel/rail contact conditions, with and without contaminants. This work focuses on an investigation of the effect of dry, wet, and lubricated conditions and the effect of contaminants such as sand on wheel and rail wear. The wheel and rail wear measurements were carried out by using a replica material and an optical profilometer that allows measurement of wear in difficult location with high accuracy. The results have demonstrated the rate at which both water and oil reduce wheel and rail wear. Scratches and other damage were seen on the wheel and rail surfaces after the addition of sand and consequently both wheel and rail wear damage rates increased under these conditions. This work introduced the replica material and an optical instrument as effective tools to study the effect of surface conditions on wheel and rail wear.
Abstract: This paper describes the design process of a 200 MHz Ground Penetrating Radar (GPR) and a battery powered concrete vertical concrete surface climbing mobile robot. The key design feature is a miniaturized 200 MHz dipole antenna using additional radiating arms and procedure records a reduction of 40% in length compared to a conventional antenna. The antenna set is mounted in front of the robot using a servo mechanism for folding and unfolding purposes. The robot’s adhesion mechanism to climb the reinforced concrete wall is based on neodymium permanent magnets arranged in a unique combination to concentrate and maximize the magnetic flux to provide sufficient adhesion force for GPR installation. The experiments demonstrated the robot’s capability of climbing reinforced concrete wall carrying the attached prototype GPR system and perform floor-to-wall transition and vice versa. The developed GPR’s performance is validated by its capability of detecting and localizing an aluminium sheet and a reinforcement bar (rebar) of 12 mm diameter buried under a test rig built of wood to mimic the concrete structure environment. The present robotic GPR system proves the concept of feasibility of undertaking inspection procedure on large concrete structures in hazardous environments that may not be accessible to human inspectors.
Abstract: The operational life of rotating machines has to be extended using a predictive condition maintenance tool. Among various condition monitoring techniques, vibration analysis is most widely used technique in industry. Signals are extracted for evaluating the condition of machine; further diagnostics is carried out with detected signals to extend the life of machine. With help of detected signals, further interpretations are done to predict the occurrence of defects. To study the problem of defects, a test rig with various possibilities of defects is constructed and experiments are performed considering the unbalanced condition. Further, this paper presents an approach for fault diagnosis of unbalance condition using Elman neural network and frequency-domain vibration analysis. Amplitudes with variation in acceleration are fed to Elman neural network to classify fault or no-fault condition. The Elman network is trained, validated and tested with experimental readings. Results illustrate the effectiveness of Elman network in rotor-bearing system.
Abstract: A novel Active Flap System (AFS) has been developed
at DTU Wind Energy, as a result of a 3-year R&D project following
almost 10 years of innovative research in this field. The full scale AFS
comprises an active deformable trailing edge has been tested at the
unique rotating test facility at the Risø Campus of DTU Wind Energy
in Denmark. The design and instrumentation of the wing section and
the AFS are described. The general description and objectives of the
rotating test rig at the Risø campus of DTU are presented, along
with an overview of sensors on the setup and the test cases. The
post-processing of data is discussed and results of steady, flap step
and azimuth control flap cases are presented.
Abstract: This paper represents an experimental study of LPG
diffusion flame at elevated preheated air temperatures. The flame is
stabilized in a vertical water-cooled combustor by using air swirler. An
experimental test rig was designed to investigate the different
operating conditions. The burner head is designed so that the LPG fuel
issued centrally and surrounded by the swirling air issues from an air
swirler. There are three air swirlers having the same dimensions but
having different blade angles to give different swirl numbers of 0.5,
0.87 and 1.5. The combustion air was heated electrically before
entering the combustor up to a temperature about 500 K. Five air to
fuel mass ratios of 15, 20, 30, 40 and 50 were also studied. The effect
of preheated air temperature, swirl number and air to fuel mass ratios
on the temperature maps, visible flame length, high temperature region
(size) and exhaust species concentrations are studied. Some results
show that as the preheated air temperature increases, the volume of
high temperature region also increased but the flame length decreased.
Increasing the preheated air temperature, EINOx, EICO2 and EIO2
increased, while EICO decreased. Increasing the preheated air
temperature from 300 to 500 K, for all air swirl numbers used, the
highest increase in EINOx, EICO2 and EIO2 are 141, 4 and 65%,
respectively.
Abstract: Dynamics of a rotor supported by air bearings is
strongly depends on the pressure distribution between the rotor and
the bearing. In this study, internal pressure in air bearings is
numerical and experimental analyzed for different radial clearances.
Firstly the pressure distribution between rotor and bearing is modeled
using Reynold's equation and this model is solved numerically. The
rotor-bearing system is also modeled in four degree of freedom and it
is simulated for different radial clearances. Then, in order to validate
numerical results, a test rig is designed and the rotor bearing system
is run under the same operational conditions. Pressure signals of left
and right bearings are recorded. Internal pressure variations are
compared for numerical and experimental results for different radial
clearances.
Abstract: Diffusion stills have been effective in water
desalination. The present work represents a model of the distillation
process by using vertical single-effect diffusion stills. A semianalytical
model has been developed to model the process. A
software computer code using Engineering Equation Solver EES
software has been developed to solve the equations of the developed
model. An experimental setup has been constructed, and used for the
validation of the model. The model is also validated against former
literature results. The results obtained from the present experimental
test rig, and the data from the literature, have been compared with the
results of the code to find its best range of validity. In addition, a
parametric analysis of the system has been developed using the
model to determine the effect of operating conditions on the system's
performance. The dominant parameters that affect the productivity of
the still are the hot plate temperature that ranges from (55- 90°C) and
feed flow rate in range of (0.00694-0.0211 kg/m2-s).
Abstract: The substantial similarity of fatigue mechanism in a
new test rig for rolling contact fatigue (RCF) has been investigated. A
new reduced-scale test rig is designed to perform controlled RCF
tests in wheel-rail materials. The fatigue mechanism of the rig is
evaluated in this study using a combined finite element-fatigue
prediction approach. The influences of loading conditions on fatigue
crack initiation have been studied. Furthermore, the effects of some
artificial defects (squat-shape) on fatigue lives are examined. To
simulate the vehicle-track interaction by means of the test rig, a threedimensional
finite element (FE) model is built up. The nonlinear
material behaviour of the rail steel is modelled in the contact
interface. The results of FE simulations are combined with the critical
plane concept to determine the material points with the greatest
possibility of fatigue failure. Based on the stress-strain responses, by
employing of previously postulated criteria for fatigue crack initiation
(plastic shakedown and ratchetting), fatigue life analysis is carried
out. The results are reported for various loading conditions and
different defect sizes. Afterward, the cyclic mechanism of the test rig
is evaluated from the operational viewpoint. The results of fatigue
life predictions are compared with the expected number of cycles of
the test rig by its cyclic nature. Finally, the estimative duration of the
experiments until fatigue crack initiation is roughly determined.
Abstract: A new small–scale test rig developed for rolling
contact fatigue (RCF) investigations in wheel–rail material. This
paper presents the scaling strategy of the rig based on dimensional
analysis and mechanical modelling. The new experimental rig is
indeed a spinning frame structure with multiple wheel components
over a fixed rail-track ring, capable of simulating continuous wheelrail
contact in a laboratory scale. This paper describes the
dimensional design of the rig, to derive its overall scaling strategy
and to determine the key elements’ specifications. Finite element
(FE) modelling is used to simulate the mechanical behavior of the rig
with two sample scale factors of 1/5 and 1/7. The results of FE
models are compared with the actual railway system to observe the
effectiveness of the chosen scales. The mechanical properties of the
components and variables of the system are finally determined
through the design process.
Abstract: Nonstandard tests are necessary for analyses and
verification of new developed structural and technological solutions
with application of composite materials. One of the most critical
primary structural parts of a typical aerospace structure is T-joint.
This structural element is loaded mainly in shear, bending, peel and
tension. The paper is focused on the shear loading simulations. The
aim of the work is to obtain a representative uniform distribution of
shear loads along T-joint during the mechanical testing. A new
design of T-joint test procedure, numerical simulation and
optimization of representative boundary conditions are presented.
The different conditions and inaccuracies both in simulations and
experiments are discussed. The influence of different parameters on
stress and strain distributions is demonstrated on T-joint made of
CFRP (carbon fibre reinforced plastic). A special test rig designed by
VZLU (Aerospace Research and Test Establishment) for T-shear test
procedure is presented.
Abstract: The study deals with the challenges in developing a
test rig to test the performance of water lubricated journal bearing.
The test rig is designed to simulate the working conditions of the
bearing in order to understand their performance before they are put
in operation. The bearing that is studied is the commercially available
water lubricated bearing which has a rubber liner bonded with a rigid
metal shell. The lubricant enters the bearing axially through a
pressurized inlet tank and exits to an outlet tank which is at
sufficiently low pressure. The load on the bearing is applied through
the dead weight system which acts both in upward and downward
direction so that net load acts on the bearing. The issues in feeding
the lubricant into the bearing from the inlet side and preventing the
leakage of the lubricant is discussed. The application of the load on
the test bearing while maintaining the bearing afloat is also discussed.