620 Ingenieurwissenschaften und zugeordnete Tätigkeiten
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The lattice Boltzmann method (LBM) stands apart from conventional macroscopic approaches due to its low numerical dissipation and reduced computational cost, attributed to a simple streaming and local collision step. While this property makes the method particularly attractive for applications such as direct noise computation, it also renders the method highly susceptible to instabilities. A vast body of literature exists on stability-enhancing techniques, which can be categorized into selective filtering, regularized LBM, and multi-relaxation time (MRT) models. Although each technique bolsters stability by adding numerical dissipation, they act on different modes. Consequently, there is not a universal scheme optimally suited for a wide range of different flows. The reason for this lies in the static nature of these methods; they cannot adapt to local or global flow features. Still, adaptive filtering using a shear sensor constitutes an exception to this. For this reason, we developed a novel collision operator that uses space- and time-variant collision rates associated with the bulk viscosity. These rates are optimized by a physically informed neural net. In this study, the training data consists of a time series of different instances of a 2D barotropic vortex solution, obtained from a high-order Navier–Stokes solver that embodies desirable numerical features. For this specific text case our results demonstrate that the relaxation times adapt to the local flow and show a dependence on the velocity field. Furthermore, the novel collision operator demonstrates a better stability-to-precision ratio and outperforms conventional techniques that use an empirical constant for the bulk viscosity.
The transport of carbon dioxide through pipelines is one of the important components of Carbon dioxide Capture and Storage (CCS) systems that are currently being developed. If high flow rates are desired a transportation in the liquid or supercritical phase is to be preferred. For technical reasons, the transport must stay in that phase, without transitioning to the gaseous state. In this paper, a numerical simulation of the stationary process of carbon dioxide transport with impurities and phase transitions is considered. We use the Homogeneous Equilibrium Model (HEM) and the GERG-2008 thermodynamic equation of state to describe the transport parameters. The algorithms used allow to solve scenarios of carbon dioxide transport in the liquid or supercritical phase, with the detection of approaching the phase transition region. Convergence of the solution algorithms is analyzed in connection with fast and abrupt changes of the equation of state and the enthalpy function in the region of phase transitions.
A Fourier scatterometry setup is evaluated to recover the key parameters of optical phase gratings. Based on these parameters, systematic errors in the printing process of two-photon polymerization (TPP) gray-scale lithography three-dimensional printers can be compensated, namely tilt and curvature deviations. The proposed setup is significantly cheaper than a confocal microscope, which is usually used to determine calibration parameters for compensation of the TPP printing process. The grating parameters recovered this way are compared to those obtained with a confocal microscope. A clear correlation between confocal and scatterometric measurements is first shown for structures containing either tilt or curvature. The correlation is also shown for structures containing a mixture of tilt and curvature errors (squared Pearson coefficient r2 = 0.92). This compensation method is demonstrated on a TPP printer: a diffractive optical element printed with correction parameters obtained from Fourier scatterometry shows a significant reduction in noise as compared to the uncompensated system. This verifies the successful reduction of tilt and curvature errors. Further improvements of the method are proposed, which may enable the measurements to become more precise than confocal measurements in the future, since scatterometry is not affected by the diffraction limit.
This paper presents a novel approach to address noise, vibration, and harshness (NVH) issues in electrically assisted bicycles (e-bikes) caused by the drive unit. By investigating and optimising the structural dynamics during early product development, NVH can decisively be improved and valuable resources can be saved, emphasising its significance for enhancing riding performance. The paper offers a comprehensive analysis of the e-bike drive unit’s mechanical interactions among relevant components, culminating—to the best of our knowledge—in the development of the first high-fidelity model of an entire e-bike drive unit. The proposed model uses the principles of elastic multi body dynamics (eMBD) to elucidate the structural dynamics in dynamic-transient calculations. Comparing power spectra between measured and simulated motion variables validates the chosen model assumptions. The measurements of physical samples utilise accelerometers, contactless laser Doppler vibrometry (LDV) and various test arrangements, which are replicated in simulations and provide accessibility to measure vibrations onto rotating shafts and stationary structures. In summary, this integrated system-level approach can serve as a viable starting point for comprehending and managing the NVH behaviour of e-bikes.
Heutzutage werden alternative Mobilitätslösungen immer wichtiger. Dabei haben eBikes ihr Potential längst unter Beweis gestellt. Der zugehörige Markt ist über die letzten 10 Jahre enorm gewachsen und gleichermaßen auch die Erwartungen an das Produkt, wie bspw. eine Fahrt ohne störende Vibrationen und Geräusche zu haben. Der Motorfreilauf leistet dabei einen maßgeblichen Einfluss auf das dynamische Verhalten. In diesem Beitrag soll daher eine methodische Vorgehensweise vorgestellt werden, um mittels Versuch und Simulation den Einfluss des Motorfeilaufs auf das dynamische Verhalten der eBike Antriebseinheit zu bestimmen.
Stably stratified Taylor–Green vortex simulations are performed by lattice Boltzmann methods (LBM) and compared to other recent works using Navier–Stokes solvers. The density variation is modeled with a separate distribution function in addition to the particle distribution function modeling the flow physics. Different stencils, forcing schemes, and collision models are tested and assessed. The overall agreement of the lattice Boltzmann solutions with reference solutions from other works is very good, even when no explicit subgrid model is used, but the quality depends on the LBM setup. Although the LBM forcing scheme is not decisive for the quality of the solution, the choice of the collision model and of the stencil are crucial for adequate solutions in underresolved conditions. The LBM simulations confirm the suppression of vertical flow motion for decreasing initial Froude numbers. To gain further insight into buoyancy effects, energy decay, dissipation rates, and flux coefficients are evaluated using the LBM model for various Froude numbers.
Trends of environmental awareness, combined with a focus on personal fitness and health, motivate many people to switch from cars and public transport to micromobility solutions, namely bicycles, electric bicycles, cargo bikes, or scooters. To accommodate urban planning for these changes, cities and communities need to know how many micromobility vehicles are on the road. In a previous work, we proposed a concept for a compact, mobile, and energy-efficient system to classify and count micromobility vehicles utilizing uncooled long-wave infrared (LWIR) image sensors and a neuromorphic co-processor. In this work, we elaborate on this concept by focusing on the feature extraction process with the goal to increase the classification accuracy. We demonstrate that even with a reduced feature list compared with our early concept, we manage to increase the detection precision to more than 90%. This is achieved by reducing the images of 160 × 120 pixels to only 12 × 18 pixels and combining them with contour moments to a feature vector of only 247 bytes.
Der vorliegende Beitrag befaßt sich mit Automatisierungsmöglichkeiten in Textilbetrieben für konventionelle als auch für nichtkonventionelle Spinnverfahren. Aus der Vielzahl derzeit existenter Produktionsschritte werden die standardisierbaren Automatisierungskombinationen zwischen den eingesetzten Textilmaschinen von Karden bis zu Spinnautomaten herausgearbeitet. Hierfür werden die heute in der Praxis befindlichen Transportmittel aufgezeigt und, vom Materialfluß ausgehend, die Zuordnungsmöglichkeiten der Maschinen in den Produktionsschritten und deren Automatisierungsbausteine definiert. Durch eine ganzheitliche Betrachtungsweise werden je nach Automatisierungsziel die verschiedenen Lösungsansätze diskutiert und als Bausteine gegenübergestellt. Hierdurch werden neue mechatronische Automatisierungslösungen vorgestellt, die eine Integration von Produktionsschritten oder die Automatisierung zwischen den einzelnen Produktionsschritten ermöglicht.
Yams of the most widely differing nature are produced in textile mills. The production stages necessary for this are carried out with the aid of textile machines. Between these individual textile machines - from cards to spinning machines - sliver cans serve as a rule as transport containers, in which the sensitive sliver material is temporarily stored, and presented to the next production stage.
Mathematische Modellbildung zur Befahrbarkeitssimulation einer mobilen Tiefsee-Arbeitsmaschine
(1988)
Die Forderung nach dem systematischen Gewinnen von Tiefsee-Erzen, wie beispielsweise Manganknollen, mit selbstfahrenden Arbeitsmaschinen führt auf das schwierige Problem der Befahrbarkeit (Traffikabilität) des Tiefseebodens. Im vorliegenden Beitrag wird ein mathematisches Modell zur Befahrbarkeitssimulation einer ferngesteuerten Sammelmaschine vorgestellt. Am Beispiel eines, als Konstruktionsentwurf spezifizierten, aktiven Manganknollenkollektors im großtechnischen Maßstab werden die Modellannahmen und Voraussetzungen für den zugrundeliegenden Tiefseeboden, das Fahrwerk und die betrachteten Betriebszustände und Lastsituationen beschrieben. Mit Hilfe eines koordinatentransformierten Kräftesystems werden die Wechselbeziehungen zwischen Tiefseeboden und einem Vierraupen-Fahrwerk in einem Algorithmus zusammengefaßt. Als Anwendungsbeispiele werden mittels EDV-Programmierung interessierende Betriebszustände und Lastsituationen simuliert. Abschließend werden weitere Modellvarianten aufgezeigt.
The utilization of simulation procedures is gaining increasing attention in the product development of extrusion blow molded parts. However, some simulation steps, like the simulation of shrinkage and warpage, are still associated with uncertainties. The reason for this is on the one hand a lack of standardized interfaces for the transfer of simulation data between different simulation tools, and on the other hand the complex time-, temperature- and process-dependent material behavior of the used semi crystalline polymers. Using a new vendor neutral interface standard for the data transfer, the shrinkage analysis of a simple blow molded part is investigated and compared to experimental data. A linear viscoelastic material model in combination with an orthotropic process- and temperature-dependent thermal expansion coefficient is used for the shrinkage prediction. A good agreement is observed. Finally, critical parameters in the simulation models that strongly influence the shrinkage analysis are identified by a sensitivity study.
Jet engines of airplanes are designed such that in some components damage occurs and accumulates in service without being critical up to a certain level of damage. Since maintenance, repair, and component exchange are very cost-intensive, it is necessary to predict efficiently the component lifetime with high accuracy. A former developed lifetime model, based on interpolated results of aerodynamic and structural mechanics simulations, uses material parameters estimated from literature values of standard creep experiments. For improved accuracy, an experimental procedure is developed for the characterization of the short-time creep behavior, which is relevant for the operation of turbine blades of jet engines. To consider microstructural influences resulting from the manufacturing of thin-walled single crystal turbine blades, small-scale specimens from used turbine blades are extracted and tested in short- and medium-time creep experiments. Based on experimental results and literature values, a creep model, which describes the fracture behavior for a wide range of creep loads, is calibrated and is now used for the lifetime prediction of turbine blades under real loading conditions.
In this paper, a gas-to-power (GtoP) system for power outages is digitally modeled and experimentally developed. The design includes a solid-state hydrogen storage system composed of TiFeMn as a hydride forming alloy (6.7 kg of alloy in five tanks) and an air-cooled fuel cell (maximum power: 1.6 kW). The hydrogen storage system is charged under room temperature and 40 bar of hydrogen pressure, reaching about 110 g of hydrogen capacity. In an emergency use case of the system, hydrogen is supplied to the fuel cell, and the waste heat coming from the exhaust air of the fuel cell is used for the endothermic dehydrogenation reaction of the metal hydride. This GtoP system demonstrates fast, stable, and reliable responses, providing from 149 W to 596 W under different constant as well as dynamic conditions. A comprehensive and novel simulation approach based on a network model is also applied. The developed model is validated under static and dynamic power load scenarios, demonstrating excellent agreement with the experimental results.
Animal models are often needed in cancer research but some research questions may be answered with other models, e.g., 3D replicas of patient-specific data, as these mirror the anatomy in more detail. We, therefore, developed a simple eight-step process to fabricate a 3D replica from computer tomography (CT) data using solely open access software and described the method in detail. For evaluation, we performed experiments regarding endoscopic tumor treatment with magnetic nanoparticles by magnetic hyperthermia and local drug release. For this, the magnetic nanoparticles need to be accumulated at the tumor site via a magnetic field trap. Using the developed eight-step process, we printed a replica of a locally advanced pancreatic cancer and used it to find the best position for the magnetic field trap. In addition, we described a method to hold these magnetic field traps stably in place. The results are highly important for the development of endoscopic tumor treatment with magnetic nanoparticles as the handling and the stable positioning of the magnetic field trap at the stomach wall in close proximity to the pancreatic tumor could be defined and practiced. Finally, the detailed description of the workflow and use of open access software allows for a wide range of possible uses.
Der Einsatz von Remote-Laboren in ingenieurwissenschaftlichen Studiengängen ermöglicht Studierenden an einigen Hochschulen die ortsunabhängige Nutzung von Laboren, Maschinen und Robotern. Remote-Labore eignen sich in besonderer Weise dafür, den digitalisierungsbedingten Anforderungen und dem Qualifikationsbedarf aus Wirtschaft und Industrie zu begegnen. Die Onlinebedienung von Laboren bietet viele Ansatzpunkte für den Erwerb digitaler Kompetenzen, wie beispielsweise das Sammeln und Analysieren von Big Data, das Entwickeln geeigneter Schnittstellen für den Onlinezugriff oder den korrekten Einsatz zur Verfügung stehender softwarebasierter Messtechnik. Auch während der Coronapandemie im Sommersemester 2020, als der reguläre Zugang zu Laboren aufgrund der Kontaktbeschränkungen nicht erlaubt war, ermöglichten Remote-Labore den Studierenden praktische Erfahrungen. Jedoch stellen nicht nur die didaktischen, sondern auch die technischen und organisatorischen Aspekte ingenieurwissenschaftliche Studiengänge bei der Umsetzung von Remote-Laboren vor anspruchsvolle Aufgaben. Der nachfolgende Beitrag greift diese Aspekte auf und beschreibt anhand ausgewählter Beispiele, wie die Umsetzung und Integration von Remote-Laboren in Studium und Lehre gelingen kann, aber auch welche Herausforderungen nach wie vor bestehen.
The solvent exchange as one of the most important steps during the manufacturing process of organic aerogels was investigated. This step is crucial as a preparatory step for the supercritical drying, since the pore solvent must be soluble in supercritical carbon dioxide to enable solvent extraction. The development and subsequent optimization of a suitable system with a peristaltic pump for automatic solvent exchange proved to be a suitable approach. In addition, the influence of zeolites on the acceleration of the process was found to be beneficial. To investigate the process, the water content in acetone was determined at different times using Karl Fischer titration. The shrinkage, densities, as well as the surface areas of the aerogels were analyzed. Based on these, the influence of various process parameters on the final structure of the obtained aerogels was investigated and evaluated. Modeling on diffusion in porous materials completes this study.
In this contribution, we perform computer simulations to expedite the development of hydrogen storages based on metal hydride. These simulations enable in-depth analysis of the processes within the systems which otherwise could not be achieved. That is, because the determination of crucial process properties require measurement instruments in the setup which are currently not available. Therefore, we investigate the reliability of reaction values that are determined by a design of experiments.
Specifically, we first explain our model setup in detail. We define the mathematical terms to obtain insights into the thermal processes and reaction kinetics. We then compare the simulated results to measurements of a 5-gram sample consisting of iron-titanium-manganese (FeTiMn) to obtain the values with the highest agreement with the experimental data. In addition, we improve the model by replacing the commonly used Van’t-Hoff equation by a mathematical expression of the pressure-composition-isotherms (PCI) to calculate the equilibrium pressure.
Finally, the parameters’ accuracy is checked in yet another with an existing metal hydride system. The simulated results demonstrate high concordance with experimental data, which advocate the usage of approximated kinetic reaction properties by a design of experiments for further design studies. Furthermore, we are able to determine process parameters like the entropy and enthalpy.
The simultaneous operation of multiple different semiconducting metal oxide (MOX) gas sensors is demanding for the readout circuitry. The challenge results from the strongly varying signal intensities of the various sensor types to the target gas. While some sensors change their resistance only slightly, other types can react with a resistive change over a range of several decades. Therefore, a suitable readout circuit has to be able to capture all these resistive variations, requiring it to have a very large dynamic range. This work presents a compact embedded system that provides a full, high range input interface (readout and heater management) for MOX sensor operation. The system is modular and consists of a central mainboard that holds up to eight sensor-modules, each capable of supporting up to two MOX sensors, therefore supporting a total maximum of 16 different sensors. Its wide input range is archived using the resistance-to-time measurement method. The system is solely built with commercial off-the-shelf components and tested over a range spanning from 100Ω to 5 GΩ (9.7 decades) with an average measurement error of 0.27% and a maximum error of 2.11%. The heater management uses a well-tested power-circuit and supports multiple modes of operation, hence enabling the system to be used in highly automated measurement applications. The experimental part of this work presents the results of an exemplary screening of 16 sensors, which was performed to evaluate the system’s performance.
Failure prognostic builds up on constant data acquisition and processing and fault diagnosis and is an essential part of predictive maintenance of smart manufacturing systems enabling condition based maintenance, optimised use of plant equipment, improved uptime and yield and to prevent safety problems. Given known control inputs into a plant and real sensor outputs or simulated measurements, the model-based part of the proposed hybrid method provides numerical values of unknown parameter degradation functions at sampling time points by the evaluation of equations that have been derived offline from a bicausal diagnostic bond graph. These numerical values are computed concurrently to the constant monitoring of a system and are stored in a buffer of fixed length. The data-driven part of the method provides a sequence of remaining useful life estimates by repeated projection of the parameter degradation into the future based on the use of values in a sliding time window. Existing software can be used to determine the best fitting function and can account for its random parameters. The continuous parameter estimation and their projection into the future can be performed in parallel for multiple isolated simultaneous parametric faults on a multicore, multiprocessor computer.
The proposed hybrid bond graph model-based, data-driven method is verified by an offline simulation case study of a typical power electronic circuit. It can be used to implement embedded systems that enable cooperating machines in smart manufacturing to perform prognostic themselves.
AErOmAt Abschlussbericht
(2020)
Das Projekt AErOmAt hatte zum Ziel, neue Methoden zu entwickeln, um einen erheblichen Teil aerodynamischer Simulationen bei rechenaufwändigen Optimierungsdomänen einzusparen. Die Hochschule Bonn-Rhein-Sieg (H-BRS) hat auf diesem Weg einen gesellschaftlich relevanten und gleichzeitig wirtschaftlich verwertbaren Beitrag zur Energieeffizienzforschung geleistet. Das Projekt führte außerdem zu einer schnelleren Integration der neuberufenen Antragsteller in die vorhandenen Forschungsstrukturen.
This paper proposes an approach to an ANN-based temperature controller design for a plastic injection moulding system. This design approach is applied to the development of a controller based on a combination of a classical ANN and integrator. The controller provides a fast temperature response and zero steady-state error for three typical heaters (bar, nozzle, and cartridge) for a plastic moulding system. The simulation results in Matlab Simulink software and in comparison to an industrial PID regulator have shown the advantages of the controller, such as significantly less overshoot and faster transient (compared to PID with autotuning) for all examined heaters. In order to verify the proposed approach, the designed ANN controller was implemented and tested using an experimental setup based on an STM32 board.
Bond graph software can simulate bond graph models without the user needing to manually derive equations. This offers the power to model larger and more complex systems than in the past. Multibond graphs (those with vector bonds) offer a compact model which further eases handling multibody systems. Although multibond graphs can be simulated successfully, the use of vector bonds can present difficulties. In addition, most qualitative, bond graph–based exploitation relies on the use of scalar bonds. This article discusses the main methods for simulating bond graphs of multibody systems, using a graphical software platform. The transformation between models with vector and scalar bonds is presented. The methods are then compared with respect to both time and accuracy, through simulation of two benchmark models. This article is a tutorial on the existing methods for simulating three-dimensional rigid and holonomic multibody systems using bond graphs and discusses the difficulties encountered. It then proposes and adapts methods for simulating this type of system directly from its bond graph within a software package. The value of this study is in giving practical guidance to modellers, so that they can implement the adapted method in software.
TREE Jahresbericht 2017
(2018)
Knapp fünf Jahre nach Gründung als Fachbereichsinstitut und zwei Jahre nach Verankerung als zentrale wissenschaftliche Einrichtung der Hochschule präsentieren wir - nicht ganz ohne Stolz - den ersten Jahresbericht des Instituts TREE. Er soll in seiner Breite als auch in seiner Tiefe die Stärken unserer gemeinschaftlichen Anstrengungen im Forschungsfeld der nachhaltigen Technologien aufzeigen: interdisziplinär, forschungsstark, nachwuchsfördernd und gesellschaftszugewandt. TREE ist weiterhin ein im Aufbruch begriffenes Institut, aber gerade das Jahr 2017 zeigt auch, dass wir uns schon in der Wissenschaftslandkarte einen Namen machen konnten: nach NaWETec konnte mit dem Themenkomplex "Effiziente Transportalternativen" ein zweiter Forschungsschwerpunkt drittmittelgefördert etabliert werden. Erste Promotionen im Rahmen des TREE konnten erfolgreich abgeschlossen und interessante Nachwuchswissenschaftler für "FHKarrierewege" gewonnen werden.
Analytical redundancy relations are fundamental in model-based fault detection and isolation. Their numerical evaluation yields a residual that may serve as a fault indicator. Considering switching linear time-invariant system models that use ideal switches, it is shown that analytical redundancy relations can be systematically deduced from a diagnostic bond graph with fixed causalities that hold for all modes of operation. Moreover, as to a faultless system, the presented bond graph–based approach enables to deduce a unique implicit state equation with coefficients that are functions of the discrete switch states. Devices or phenomena with fast state transitions, for example, electronic diodes and transistors, clutches, or hard mechanical stops are often represented by ideal switches which give rise to variable causalities. However, in the presented approach, fixed causalities are assigned only once to a diagnostic bond graph. That is, causal strokes at switch ports in the diagnostic bond graph reflect only the switch-state configuration in a specific system mode. The actual discrete switch states are implicitly taken into account by the discrete values of the switch moduli. The presented approach starts from a diagnostic bond graph with fixed causalities and from a partitioning of the bond graph junction structure and systematically deduces a set of equations that determines the wanted residuals. Elimination steps result in analytical redundancy relations in which the states of the storage elements and the outputs of the ideal switches are unknowns. For the later two unknowns, the approach produces an implicit differential algebraic equations system. For illustration of the general matrix-based approach, an electromechanical system and two small electronic circuits are considered. Their equations are directly derived from a diagnostic bond graph by following causal paths and are reformulated so that they conform with the matrix equations obtained by the formal approach based on a partitioning of the bond graph junction structure. For one of the three mode-switching examples, a fault scenario has been simulated.
In diesem Paper wird das abbildende Millimeterwellen-Radarsystem SAMMI® (Stand Alone MilliMeter wave Imager) des Fraunhofer-Institutes für Hochfrequenzphysik und Radartechnik FHR vorgestellt. SAMMI ist ein CW System welches bei einer Messfrequenz von 78 GHz die Proben in Transmission vermisst. Durch ein Endlosband wird ein kontinuierlicher Materialstrom sichergestellt, wobei ein DIN A4 Blatt innerhalb von 20 s durchleuchtet wird. SAMMI besitzt die Größe eines durchschnittlichen Laserdruckers wodurch es leicht zu transportieren und in wenigen Minuten einsatzbereit ist. Die mittels SAMMI erfassten Messdaten, können bereits während der Datenerfassung mit verschiedenen bereits vorinstallierten Verfahren aufbereitet und analysiert werden. Zu den integrierten Algorithmen in SAMMI® gehören unter anderen Verfahren zum 2D-Phase Unwrapping-, Cluster- und Rekonstruktions-Algorithmen zur Berechnung der Materialparameter. Die offene Softwareschnittstelle erlaubt auch die Implementierung eigener Verfahren auf der mitgelieferten Computer-Hardware. Mit den integrierten Algorithmen bietet SAMMI® eine Vielzahl an Möglichkeiten um z.B. Verunreinigungen in Materialien zu detektieren oder Schwankungen im Fertigungsprozess frühzeitig zu identifizieren. Desweiteren ist SAMMI® eine optimale Ausbildungsplattform in den Bereichen der industriellen Bildverarbeitung mittels Hochfrequenzsensoren. Insbesondere können Verfahren für unterschiedliche Anwendungen getestet bzw. für Anwendungen weiterentwickelt werden. Es werden konkrete Beispiele aus dem Bereich der Qualitätssicherung erläutert und Möglichkeiten des Gerätes und der Millimeterwellen-Technologie für die zerstörungsfreie Prüfung in Detail beschrieben.