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Fakultät Maschinenwesen, Institut für Maschinenelemente und Maschinenkonstruktion, Lehrstuhl Maschinenelemente

Possibilities to Use Multi-Body System Simulation Results to Design Components of Large Drivetrains

SIMPACK User Meeting 2014

Prof. Dr.-Ing. Berthold Schlecht | Dr.-Ing. Thomas Rosenlöcher

Augsburg, 9. October 2014


Technische Universität DresdenChair of Machine Elements

• Technische Universität Dresden Chair of Machine Elements

• Field of research: drive technology, especially gear technology and components

09.10.2014 2Possibilities to Use Multi-Body System Simulation Results to Design Components of Large Drivetrains


Technische Universität DresdenChair of Machine Elements

• Dynamic analysis of electro-mechanical drive systems• Improvement and verification of simulation techniques• Investigations in the time and frequency domain using the MBS and FEM• Analyses of drive train systems and drive train concepts• Verification of simulation models by measurement results


2001 2002 2003 2004 2005

approx. 0.7 MW approx. 1.5 MW approx. 2.0 MW

Prof. Dr.-Ing. Berthold Schlecht | Dr.-Ing. Thomas Rosenlöcher09.10.2014 4Possibilities to Use Multi-Body System Simulation Results to Design Components of Large Drivetrains

Dynamic analysis of electro-mechanical drive systems

roller mill train drive ladle cranes

thruster bucket wheel excavatormechanical watches


• Overhead crane with 4 welded box girder• Span width 22 m, service weight: 770 t


Analysis of a 400 t ladle crane drive train



Parameter Determination

(mass, mass moment of inertia)

SSS

ZZYYXX

zyxm

III

,,

,,

Flexibility of shafts(discretisation, beam approaches,

finite-element models)

Bearings Couplings

source: www.tschan.de

Rope drum, traverse

Gearing(GEAR PAIR, user routines)

Gear boxes and supporting structure


• Frequency domain, natural frequency at 0.4 Hz




• Frequency domain, natural frequency at 63.7 Hz




• Influence of the level of detail of the simulation model to the torsional natural frequencies



variant

V6 V5 V4 V3 V2 V1

level of detail of the model

modelled as modal reduced

FE-model

supporting structure X

main gearbox X X

drum gearbox X X

gearbox, 6 degrees of freedom X X

degrees of freedom

of drivetrain compon-

ents

equatorial rotat. axes X X X

radial displacement X X X X

axial displacement X X X X X

polar axis of rotation X X X X X X

calculated natural frequencies

1st torsional natural frequency [Hz] 26.3 29.3 30.4 30.6 30.7 30.7

2nd torsional natural frequency [Hz] 31.1 30.5 33.5 38.0 48.3 48.5

3rd torsional natural frequency [Hz] 31.9 33.5 37.0 45.1 50.9 51.9

4th torsional natural frequency [Hz] 48.6 52.0 62.6 86.0 143.1 163.3


• Load cases to be analysed

• Braking concept• Redundant system, consists of

operational brakes on the motor sided shafts and emergency stop brakes on the rope drums



Reason for the emergency stop

Emergency stop

Breakage of a shaft

Direction of motion

Upwards Downwards

Load TraverseTraverse and filled ladle



Load case: emergency stop Load case: shaft breakage(drum sided)

Effect of the level of model detailing on the gearing forces in the gear boxes

emergency stop shaft breakage




• 3-point supported drivetrain, rotor diameter 90 m, 3-staged planetary-helical gear stage gear box


Analysis of a 3 MW windturbine





variant

V8 V7 V6 V5 V4 V3 V2 V1


modelled as modal

reduced finite-

element-model

main frame X

gearbox housing X

main shaft X X

planet carrier X X X

gearbox housing, 6 degrees of freedom X X X X

degrees of freedom of

the drivetrain components

equatorial rotation axes X X X X X

radial displacement X X X X X X

axial displacement X X X X X X X

polar axis of rotation X X X X X X X X

flexible rotor blades X X X X X X X X


1st torsional natural frequency [Hz] 1.5 1.5 1.7 1.7 2.2 2.2 2.2 2.2

2nd torsional natural frequency [Hz] 2.9 2.9 3.0 3.1 4.1 4.1 4.1 4.1

3rd torsional natural frequency [Hz] 6.2 6.2 6.3 6.3 8.0 8.0 8.1 8.1

4th torsional natural frequency [Hz] 13.2 13.2 13.3 13.3 16.2 16.2 16.5 16.5



• Degrees of freedom of the gearbox housing



variant

V8 V7 V6 V5 V4 V3 V2 V1


modelled as modal

reduced finite-

element-model

main frame X

gearbox housing X

main shaft X X

















• Elasticity of the main shaft



variant

V8 V7 V6 V5 V4 V3 V2 V1


modelled as modal

reduced finite-

element-model

main frame X

gearbox housing X

main shaft X X

















• Elasticity of the planet carrier and the supportingstructure



variant

V8 V7 V6 V5 V4 V3 V2 V1


modelled as modal

reduced finite-

element-model

main frame X

gearbox housing X

main shaft X X
















• Determination: natural frequencies, excitations -> Campbell-diagram












• Detailed analysis of the excitation behaviour• Slow run up of the wind turbine, calculation of the frequency spectrum• Rotatory acceleration of the sun shaft, stage 2



gear mesh frequency, stage 3, 1st order

gear mesh frequency, stage 2, 1st order

gear mesh frequency, stage 2, 2nd order

gear mesh frequency, stage 2, 3rd order






• Analysis of the acting forces in the gear stages, distribution of the gearing forces over the width of the gearing





• Gear stage 1, contact between sun and one planet• Presentation of the gearing forces for one revolution of the planet carrier



Weight of the rotor neglected

Analysis for nominal load

Weight of hub and rotor blades considered


forc

e [m

]

forc

e [m

]



• Gear stage 1, contact between sun and one planet• Presentation of the gearing forces for one revolution of the planet carrier






Additional modelling of the wind loads

forc

e [m

]

forc

e [m

]


• Simulation model must represent all relevant system properties with sufficient accuracy

• Modelling approach has to adapt to the design of the drivetrain

• Knowledge of the correct system boundaries often requires a very detailed simulation model

• Although torsional vibration models suffice for many analyses, the larger modelling effort required for detailed 3D MBS simulation is often necessary


Conclusion


Technische Universität Dresden

Department of Mechanical Engineering

Institute of Machine Elements and Machine Design

Chair of Machine Elements

Münchner Platz 3D-01062 Dresden

www.tu-dresden.de/me

Thank You for Your Attention


Possibilities to Use Multi-Body System Simulation Results ... … · Possibilities to Use Multi-Body System Simulation Results to Design ... Possibilities to Use Multi-Body System

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