A simulation-based probabilistic design method for arctic sea transport systems

When designing an arctic cargo ship, it is necessary to consider multiple stochastic factors. This paper evaluates the merits of a simulation-based probabilistic design method specifically developed to deal with this challenge. The outcome of the paper indicates that the incorporation of simulations and probabilistic design parameters into the design process enables more informed design decisions. For instance, it enables the assessment of the stochastic transport capacity of an arctic ship, as well as of its long-term ice exposure that can be used to determine an appropriate level of ice-strengthening. The outcome of the paper also indicates that significant gains in transport system cost-efficiency can be obtained by extending the boundaries of the design task beyond the individual vessel. In the case of industrial shipping, this allows for instance the consideration of port-based cargo storage facilities allowing for temporary shortages in transport capacity and thus a reduction in the required fleet size / ship capacity.     

Rule-based control of a semi-active suspension for minimal sprung mass acceleration: design and measurement

In this paper, a rule-based controller is developed for the control of a semi-active suspension to achieve minimal vertical acceleration. The rules are derived from the results obtained with a model predictive controller. It is shown that a rule-based controller can be derived that mimics the results of the model predictive controller and minimises vertical acceleration. Besides this, measurements on a test vehicle show that the developed rule-based controller achieves a real-world reduction of the vertical acceleration, which is in agreement with the simulations.     

Influence of wheel and rail profile shape on the initiation of rolling contact fatigue cracks at high axle loads

The influence of wheel and rail profile shape features on the initiation of rolling contact fatigue (RCF) cracks is evaluated based on the results of multi-body vehicle dynamics simulations. The damage index and surface fatigue index are used as two damage parameters to assess the influence of the different features. The damage parameters showed good agreement to one another and to in-field observations. The wheel and rail profile shape features showed a correlation to the predicted RCF damage. The RCF damage proved to be most sensitive to the position of hollow wear and thus bogie tracking. RCF initiation and crack growth can be reduced by eliminating unwanted shape features through maintenance and design and by improving bogie tracking.     

On the implementation of an auxiliary pantograph for speed increase on existing lines

The contact between pantograph and catenary at high speeds suffers from high dynamic contact force variation due to stiffness variations and wave propagation. To increase operational speed on an existing catenary system, especially for soft catenary systems, technical upgrading is usually necessary. Therefore, it is desirable to explore a more practical and cost-saving method to increase the operational speed. Based on a 3D pantograph–catenary finite element model, a parametric study on two-pantograph operation with short spacing distances at high speeds shows that, although the performance of the leading pantograph gets deteriorated, the trailing pantograph feels an improvement if pantographs are spaced at a proper distance. Then, two main positive effects, which can cause the improvement, are addressed. Based on a discussion on wear mechanisms, this paper suggests to use the leading pantograph as an auxiliary pantograph, which does not conduct any electric current, to minimise additional wear caused by the leading pantograph. To help implementation and achieve further improvement under this working condition, this paper investigates cases with optimised uplift force on the leading pantograph and with system parameter deviations. The results show that the two positive effects still remain even with some system parameter deviations. About 30% of speed increase should be possibly achieved still sustaining a good dynamic performance with help of the optimised uplift force.     

Clamping performance of fastener in windshield wiper assembly using theoretical and experimental methods

Improper clamping of wiper arms can cause problems in the operation of the wiper. An excessive clamping force can cause damage to the wiper arm head. On the other hand, an insufficient clamping force can cause self-loosening of the nut. Given the lack of direct research on the clamping force of the fastener in wiper assembly, this study verifies the existing clamping performance of the fastener in windshield wiper assembly by theoretical and experimental methods. The theoretical calculation results show that all the clamping performance are satisfied under the general snow load condition. However, under the critical load condition, maximum assembly preload and safety margin against slipping are in disagreement with the standard values. This problem is solved by increasing the strength grade of the bolt. The experimental results show a reducing tendency of the clamping force during the snow durability test. However, this reducing clamping force during the 60,000 test cycles is acceptable. In the case of nut reusing more than two times possibly cause a problem of its loosening because of insufficient clamping force. Therefore, it is recommended that the nut should not be reused more than two times.     

Robust inspection technique for detection of flatness defects of oil pans

This paper discusses two different methods for the detection of flatness defects present on the mounting surfaces of oil pans using laser-scanned point clouds. The first method involves registration, which is a widely used method in the field of 3D data inspection: scanned point clouds are registered with CAD data and the iterative closest point (ICP) algorithm is used for further comparison. The second method is our proposed method, a simple yet effective method for measuring the flatness of an oil pan mounting surface. The process is based on the construction of a reference plane on the scanned surface. The oil pan mounting surface is scanned by a 3D laser scanner, obtaining point cloud data that is then further processed to reduce noise. Using this processed data, a reference plane parallel to the direction of the mounting surface is defined at the mean position of the mounting surface. The direction of the reference plane is determined by the normal vector of the mounting surface. Construction of the reference plane is carried out by the singular value decomposition (SVD) technique. The deviation of the surface from the reference plane is measured by calculating the error distance between the points of the surface to the reference plane using the least-squares method.     

Design process to minimize roof surface defects using a flexural function and Finite Element analysis

The appearance and exterior precision of passenger cars aesthetics has become an important factor in the automotive industry. During vehicle assembly, the curvature of the roof can change slightly and create cosmetic defects that affect the exterior appearance. The critical factor causing curvature change on the roof is the thermally driven expansion of an elastomer-based mastic sealer which is applied between the exterior roof panel and support rail during the frame assembly process. Therefore the expansion of the mastic sealer was modeled to predict the curvature change in the roof panel. In order to evaluate the causes and predict the curvature change quantitatively, a Finite Element (FE) simulation of the oven heating and mastic curing was performed. Validation of the simulation model was performed by comparing the local deformation and amount of the curvature change on the roof obtained from the actual process. In order to minimize the curvature change, the Taguchi method was used in conjunction with the FE model where a total of eight factors were chosen to perform a sensitivity analysis. In order to exclude the deformation due to residual stress resulting from the oven process, it was selected as a noise factor. Response was taken as the maximum curvature change calculated by a flexural function which was used to distinguish absolute curvature that is not affected by the horizontal or vertical movement of roof panel. A total of 18 cases were analyzed with length of each sealer, pitch of sealer, and rail location being identified as the most influential factors affecting the curvature change. Using the optimum values, the amount of curvature change in the roof panel was reduced by 12 percent.     

Pressure model based coordinated control of VGT and dual-loop EGR in a diesel engine air-path system

This paper describes a pressure-model-based coordinated control method of a variable geometry turbine (VGT) and dual-loop exhaust gas recirculation (EGR) in a diesel engine air-path system. Conventionally, air fraction or burnt gas fraction states are controlled for the control of dual-loop EGR systems, but fraction control is not practical since sensors for fractions are not available on production engines. In fact, there is still great controversy over how best to select control outputs for dual-loop EGR systems. In this paper, pressure and mass flow states are chosen as control outputs without fraction states considering the availability and reliability of sensors. A coordinated controller based on the simple control-oriented model is designed with practical aspects, which is applicable for simultaneous operations of high pressure (HP) EGR, low pressure (LP) EGR, and VGT. In addition, the controller adopts the method of input-output linearization using back-stepping to solve the chronic problems of conventional pressure-based controllers such as coupling effects between operations of HP EGR, and VGT. The control performance is verified by simulation based on the proven GT-POWER model of a heavy-duty 6000cc diesel engine air-path.