virtual technique in forecasting states of exploited machines

PROCEEDINGS OF THE INSTITUTE OF VEHICLES
4(95)/2013
Tomasz Kałaczyński1, Marcin Łukasiewicz2, Tomasz Kasprowicz3, Michał Liss4
VIRTUAL TECHNIQUE IN FORECASTING STATES
OF EXPLOITED MACHINES
1. Introduction
In modern times, man improves manufacturing processes mainly focus their attention
on minimizing the time it takes to complete the process. One of the possible and most
common methods of shortening the time to accelerate some of the processes. These subprocesses related to human factors, environment and engineering. Dynamic development
and technological advancement results in today's machines, they are much more efficient,
and also more than ever susceptible to damage. That is why a growing role in the design
and maintenance of machines play a modern engineering applications that enable
simulation of the machine during its design and predict the places most at risk of failure
and the possible impact of these failures on the operation of the machine. These
applications are providing, monitoring conditions become part of the machinery
diagnostic systems.
2. Modern applications that support the design and prediction of machine
One of the applications of engineering design support as well as forecasting and
predicting future states of machines is an application LMS Virtual.Lab. It allows you to
mix together the most important aspects of simulations and tests on actual models This
application offers a unique hybrid approach to machine simulation input from real
objects are merged of simulated virtual objects. This approach makes it more accurate
simulations become and thus provide for precise location of the faults and their effect on
the behavior of the structure. Modern approach to process design and operational
applications such as offered by LMS Virtual.Lab survived shown in Fig. 1. This
approach allows even during the design stage of research to make models of machines
without having to build prototypes. Is also associated with the minimization of the
environmental magnetic interactions which today is an equally important issue as the
maintenance of fitness equipment.
This application offers a unique hybrid approach to machine simulation input from
real objects are combined with simulated virtual objects.
This application was split into modules, each corresponding to a different type of
analysis performed:
1
Tomasz Kałaczyński, Ph.D, Eng., PhD, assistant in Department of Vehicle and Diagnostics,
Bydgoszcz University of Technology and Life Science.
Marcin Łukasiewicz, Ph.D, Eng., PhD, assistant in Department of Vehicle and Diagnostics,
Bydgoszcz University of Technology and Life Science.
3
Tomasz Kasprowicz, BSc, technician stuff in Department of Vehicle and Diagnostics, Bydgoszcz University
of Technology and Life Science.
4
Michał Liss, M.Sc, Eng., technician in Department of Vehicle and Diagnostics, Bydgoszcz University
of Technology and Life Science
2
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MOTION-simulation of the real behavior of the objects and the ability to
modify them without having to build a prototype and testing.
CORRELATION comparison and validation of compliance with the reality of
the model based on the results of measurements
STRUCTURES-facilitates and accelerates collaboration with specialized
software shortening the design process
NOISE & VIBRATION-product provides complete information on the
interference and noise caused by operation of the device
ACOUSTICS-Achieving the desired sound effect in the design stage without
having to build a prototype
Durability-design optimization for stress fatigue
OPTIMIZATION-Improvement of the model and to improve the construction
parameters
Fig. 1. Graphical representation of the process of design and operational
3. Research Facility
The object of the study was to design the framework of the 'Buggy'. Aim of the study
is shown in Figure 2.
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Fig. 2. Object of research.
The aim of the study was to verify the implementation of virtual techniques
in operational research, to determine the predictability of the real object of study based
on a virtual model.
4. Mileage tests and measurements.
For the test was designed frame construction LMS Virtual.Lab application. Fig. 3
simulations have been carried out at the same time have determined the location of future
failures and the conditions under which the structure will be damaged.
Fig. 3. The design framework LMS Virtual.Lab
Design elements were normalized (Fig. 4) In order to provide the best possible
results.
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Fig. 4. Standardized components.
The next stage of the research was to build a vehicle frame structure (Fig. 5) and
subjecting it to a different force for enforcement to verify sites and power failures where
the structure is damaged.
Fig. 5. Construction of frame.
In the block diagram (Fig. 6) Was presented the research proces
Project
Building
Construction
Simulation
research
LMS.Virtual.
Lab
Fig. 6. Block diagram of the test.
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Research of
the real
object
The final stage of the study was a comparative analysis of actual results with the
results of virtual simulation.
5. The result of research
The results in the form of graphical representations of the confluence of forces
shown in the figures below.
In the first stage of the research model has been charged with forcing forces
enforcing the corresponding force during normal operation (Fig. 7, Fig. 8).
Fig. 7. Stress design load strength of the LMS Virtual.Lab 3kN
Fig. 8. Stress and deformation of the load-bearing elements LMS Virtual.Lab
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The next stage of simulation was to determine the strength at which damage first
appear in the structure (Fig. 9, Fig. 10).
Fig. 9. The first deformation of the structure at a force of 12kN
Fig. 10. Stress and deformation of the load-bearing elements LMS Virtual.Lab
The final stage of the simulation study was to predict the progress of structural
damage (Fig. 11, Fig. 12).
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Fig. 11. Simulation of structural damage progression
Fig. 12. Estimated damage to the element of the course.
6. Analysis of results.
The simulations revealed that the weakest part of the structure are the front shock
mount. Confirmation of the simulation is reflected in the actual model that has been
damaged in exactly the same places and in the same manner as the virtual model. The
first failure occurred at a force of about 12kN (Fig. 13, Fig. 14).
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Fig. 13. The first damage on the strength of 12kN LMS Virtual.Lab.
Fig. 14. Damage to model the real strength of approximately 12kN.
The next stage of the research was to predict the course of progress of damage
(Fig. 15, Fig.16). For this purpose, the construction was subjected to loads exceeding
12kN. Damage to the actual model is shown in Figure 17 and 18.
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Fig. 15. Progress damage model LMS Virtual.Lab
Fig. 16. Progress damage model LMS Virtual.Lab.
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Fig. 17. Damage to the actual model
Fig. 18. Damage to the actual model
7. Conclusions
Traditional testing laboratories need to have be equipped with suitable recording
signals. Research using virtual technology allows the assessment of changes in the
operation of machinery.
Using the latest engineering applications such as: LMS Virtual.Lab., CATIA, and so
gain above all, saving time spent on research prototypes. It becomes possible to predict
the location of the state changes, to prevent them and if they were able to predict their
development.
Using modern simulation programs can get the same information as in the case
studies of real praying, while reducing the resources and time, and at the same time we
are able to minimize the impact on the environment during the test which nowadays is
becoming an important issue due to the strict rules environment.
This paper is a part of investigative project WND-POIG.01.03.01-00-212/09
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References:
Kałaczyński T., Łukasiewicz M., Żółtowski B.: The study of dynamic state
industrial machines. Zeszyty Naukowe Instytutu Pojazdów Politechniki
Warszawskiej, 3(89)/2012, Warszawa 2012r
[2]
Kałaczyński T., Żółtowski M.: Techniki wirtualne w badaniach stanu, zagrożeń
bezpieczeństwa i środowiska eksploatowanych maszyn. Wydawnictwo Argonex,
44 strony, Bydgoszcz 2011r.
[3]
Łukasiewicz M., Kałaczyński T., Żółtowski B.: Zastosowanie programów
komputerowych wspomagających projektowanie silników spalinowych w
odniesieniu do minimalizacji skutków oddziaływania na środowisko, "Logistyka"
nr 6/2012 (grudniowe wydanie), ISSN 1231-4578.
[4]
Żółtowski B., Łukasiewicz M., Kałaczyński T.: "Techniki informatyczne w
badaniach
stanu
maszyn",
Wydawnictwa
Uczelniane
Uniwersytetu
Technologiczno - Przyrodniczego w Bydgoszczy, Bydgoszcz 2012r
[1]
Abstract
In modern times, a man improves manufacturing processes mainly focus their
attention on minimizing the time it takes to complete the process. One of the possible and
most common methods of reduction the time to accelerate some of the processes.
One of the engineering design applications support as well as forecasting and
predicting future states of machines is an application LMS Virtual.Lab.
It allows you to mix the most important aspects of simulations and tests on real
models
Keywords: simulation, the real model, diagnostic
TECHNIKI WIRTUALNE W PROGNOZOWANIU STANU
EKPLOATOWANEJ MASZYNY
Streszczenie
W współczesnych czasach człowiek ulepsza procesy wytwarzania skupiając swoją
uwagę głównie na minimalizacji czasu potrzebnego na wykonanie danego procesu.
Jedną z możliwych i najpowszechniejszych metod skracanie tego czasu jest
przyspieszenie niektórych pod procesów. Podprocesy te odnoszą się do czynników
ludzkich, otoczenia oraz maszyn.
Jedną z aplikacji inżynierskich wspomagających projektowanie jak i również
prognozowanie i przewidywanie przyszłych stanów maszyn jest aplikacja LMS
Virtual.Lab.
Pozwala ona na połączenie najważniejszych aspektów symulacji i testów na
rzeczywistych modelach
Słowa kluczowe: symulacja, model rzeczywisty, diagnozowanie
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