Prototype Test Rig Research Articles

Integrated Design and Optimization of a Direct Drive Axial Flux Permanent Magnet Generator for a Tidal Turbine

The C-GEN is a novel topology of direct drive air-core permanent magnet generator being developed at University of Edinburgh [1]. The topology has many benefits such as; absence of cogging torque, reduced mass and ease of manufacturing. A 20 kW prototype test rig and 15kW machine for a wind turbine has been manufactured and tested previously. Initial sizing studies for wind turbines indicate that the C-GEN concept will be up to 50% lighter than conventional iron cored PM direct drive generators [1]. In addition to the applications wind turbines, C-GEN technology can also be implemented for marine energy power take-off systems. To investigate that, a feasibility study is being undertaken in collaboration with two wave and two tidal energy companies. In this paper, design and optimization method of an axial flux permanent magnet generator for a tidal energy converter device has been investigated. An analytical optimization tool is designed that combines electromagnetic, structural and thermal aspects of the machine design. A genetic algorithm optimization method has been utilized based on the operation conditions of generator and pre-defined constraints on dimensions and material limitations. The output of the analytical design tool is compared with the electromagnetic FEA simulations. The results showed that proposed analytical calculation method is consistent with FEA results

Damage mechanisms of spline teeth of friction plates under non-uniform impact

The fatigue fracture failure of friction plates seriously affects the safety of high-power density transmission systems due to the non-uniform impact with the inner hub. However, the crack initiation inducement and underlying damage mechanisms are still confused so far, which has critical significance for improving the service life. To address this problem, the matrix metallographic structure of friction plates was observed by Scanning Electron Microscope (SEM), which excludes internal defects within the organization. Then, an impact dynamic model was established to investigate the collision laws between spline teeth and the inner hub. The effect of the inner hub’s speed fluctuations on the impact force and acceleration was analyzed, and an analytical relationship between tooth root stress, impact force, and gear parameters was established. A large module simulation prototype test rig was designed based on the proposed equivalent model to verify the impact dynamic model. Results show that the majority of collisions between spline teeth and the inner hub are “catch-up collisions”, which well explains the non-uniform impact phenomenon. The “frontal collisions” will only occur when the speed of the inner hub is lower than that of the friction plate. The higher cumulative frequency of tensile stress on the pull side of spline teeth roots by “catch-up collisions” reveals the underlying mechanism for the differential extent of cracks’ damage. The minimum bending stress of the teeth root is 125.5 MPa at a pressure angle of 32°, which shows a linear increase with tooth clearance. The fatigue fracture of friction plates has been effectively suppressed after structural optimization.

Ergonomic design and evaluation of gemstone polishing workstation

Objectives. Gemstone polishers suffer from musculoskeletal problems due to constrained working postures, substantially influenced by the poor design of conventional gemstone polishing workstations. The present study investigated the effects of three workstation adjustment parameters (illumination at workstation, polishing height, tool post position) on postural angle, muscle activity and perceived postural discomfort in order to develop recommendations for new gemstone polishing workstations. Methods. Twelve professional gemstone polishers performed the polishing task on a prototype test-rig in 27 different test conditions. Taguchi’s L27 orthogonal array was employed to estimate the optimum setting for gemstone polishing workstation design. Results. Study variables had a significant influence on postural angles. Polishing height substantially influenced muscle activity and perceived discomfort in the shoulder and lower back region. Tool post position was found to be the determinant factor for forearm muscle activity and perceived discomfort in the wrist/forearm region. Based on the findings, illumination of 1500 lux, polishing at 15 cm above the elbow height and a 20° tool position was recommended. Conclusions. Our findings present an alternative approach to using Taguchi’s design of experiment for workstation improvement, which has received very little attention in ergonomics studies. A confirmation test was conducted to validate the study recommendations.

Development of and Research on a Prototype Test Rig for Assessing the Quality of Electrical-Insulation Materials

Development of and Research on a Prototype Test Rig for Assessing the Quality of Electrical-Insulation Materials

Durability Analysis of the Prototype Test Rig for Main Rotors

This paper presents an analysis of the strength of a prototype test rig for testing rotors of unmanned aerial vehicles. Digital design software was used for the design work that covered the creation of a virtual model of the test rig and strength analysis of its key elements. The paper discusses the test rig solutions, applied to date, of the small main rotor research. From the assumed operational parameters and structural parameters of the rotor, the main forces acting on the designed structure were determined: lifting force, reaction torque and empty mass of the test rig. Suitable actuators of the control system enabling the regulation of the total pitch and periodic pitch of the rotor, within the full range of the angle of attack, were selected for the rotor under test. The FEM (Finite Element Method) strength analysis was carried out for the proposed support structure and the correctness of the design was verified.

Failure analysis of a high-speed induction machine driven by a SiC-inverter and operating on a common shaft with a high-speed generator

Due to ongoing research work, a prototype test rig for testing high speed motors/generators has been developed. Its design is quite unique as the two high speed machines share a single shaft with no support bearings between them. A very high maximum operating speed, up to 80,000 rpm, was required. Because of the need to minimise vibration during operation at very high rotational speeds, rolling bearings were used. To eliminate the influence of higher harmonics of supply voltage and current on the formation of torque oscillations on the shaft and excessive losses in the form of heat, a voltage source inverter with high switching silicon carbide (SiC) power transistors characterizing high precision of the output voltage generation with a fundamental harmonic frequency of several kilohertz has been used. During the first start-ups, it turned out that the system was not stable, and a failure occurred. The paper presents the consequences that may arise when a machine operating at a speed of about 70,000 rpm fails. The article contains pictures of a generator failure that occurred at a high rotational speed.

Development and research of a prototype test rig for assessing the quality of electrical insulation materials

Development and research of a prototype test rig for assessing the quality of electrical insulation materials

Hybrid Welding of Metal-Polymer Composites with a Non- Conducting Polymer Layer

Metal-polymer composites (MPCs) are becoming increasingly popular primarily because of their high strength-to-weight ratio. Metal-polymer composites consist of three layers, i.e. two external metallic sheets (linings) and the core made of plastic. The presence of the internal plastic layer makes MPCs impossible to join using conventional welding processes, which significantly limits their usability. One of the solutions to the problem involves the use of hybrid methods, e.g. ultrasonic method-aided resistance welding. The research work discussed in the article involved the development of a prototype test rig and a technology enabling the joining of the Litecor® composite with steel DP600. The joining process consisted of two stages. The first stage involved the removal of the non-conducting layer of polymer from the welding area and the making of an appropriate electric contact for resistance welding. The second stage was the classical resistance spot welding process. The development of the concept posed a challenge as it was necessary to develop an appropriate acoustic waveguide for high-power ultrasonic waves which, at the same time, could transfer loads in the form of electrode force as well as provide appropriate electric and thermal conductivity without compromising acoustic parameters during the welding process. The development of the test rig was followed by the performance of numerous tests aimed to identify the appropriate window of process parameters. Test joints were subjected to macrographic, strength, ultrasonic and topographic tests.

Investigation of the deposition behaviour and antibacterial effectivity of allicin aerosols and vapour using a lung model.

Allicin is a natural antibiotic produced by garlic as a defence against pathogens and pests. Due to the worldwide increase in antibiotic resistance, new antibiotics are desperately required. Allicin is such a candidate and is active against several multidrug-resistant (MDR) strains of human pathogens, including methicillin-resistant Staphylococcus aureus (MRSA). When administered orally, allicin is titrated out by glutathione in the cells and blood, and effective therapeutic concentrations are difficult to achieve at the site of an infection. However, in the case of lung infections, allicin can be delivered directly to pathogens via the pulmonary route. In this study, we designed and constructed an in vitro lung test rig, which allowed us to model accurately the exposure of lung air-passage surfaces to allicin and gentamicin, in order to examine the feasibility of combating lung infections by direct inhalation. A prototype test rig of lung bronchi with three bifurcations was constructed, which could be coated internally with a thin layer of bacteria-seeded agar medium. The deposition of antimicrobial aerosols on the modelled bronchial surfaces was followed in preliminary tests without the need for animal experiments. The differential sensitivity of the test bacteria to different antibiotics and the dose-dependency of inhibition was shown using the model. Furthermore, a synergistic effect of allicin vapour and ethanol in inhibiting bacterial growth was demonstrated. The modelling of the axial velocity air-flow distribution correlated with the regions indicating the inhibition of bacterial growth, demonstrating that the model has predictive value and can reduce the requirement for animal sacrifice in pre-clinical trials of novel antibiotics.

Development of a Prototype Test Rig for Leak Detection in Pipelines

Over the years, the conventional method most industries use in detecting pipeline leakages is called the pressure test. This method is too stressful and even takes longer time to locate the exact location of the leak. This work studies the unconventional way of detecting oil leakage with a view of designing a model control system to detect leak without human intervention, both on-the-job and off the job. In this work, a prototype test rig was designed and fabricated. Its components include pipes and piping components, air valve, adaptor, barometer, MxF Socket, non-return valve, pressure relief valve, and reducers. The rig was fabricated based on its 3D architecture using solid works application tool. The rig has four different flow line with pressure sensors and gauges mounted on each line. Pressure transducers on the rigs keeps monitoring the pressure inside the rig and immediately it detects a pressure drop below the threshold value, the micro controller based on the programmed code on it communicates with the SMS module which subsequently sends an SMS alert to the programmed phone number and gives the location of the leak as well as the actual pressure in that location. Thus, this study enhances quick leak detection, thus, gainfully helps to minimize losses during on the job operation in the case of spills and saves time in locating the exact point of leakage.

Development of Test Rig for Robotization of Mining Technological Processes – Oversized Rock Breaking Process Case

Production chain (PCh) in underground copper ore mine consists of several subprocesses. From our perspective implementation of so called ZEPA approach (Zero Entry Production Area) might be very interesting [16]. In practice, it leads to automation/robotization of subprocesses in production area. In this paper was investigated a specific part of PCh i.e. a place when cyclic transport by LHDs is replaced with continuous transport by conveying system. Such place is called dumping point. The objective of dumping points with screen is primary classification of the material (into coarse and fine material) and breaking oversized rocks with hydraulic hammer. Current challenges for the underground mining include e.g. safety improvement as well as production optimization related to bottlenecks, stoppages and operational efficiency of the machines. As a first step, remote control of the hydraulic hammer has been introduced, which not only transferred the operator to safe workplace, but also allowed for more comfortable work environment and control over multiple technical objects by a single person. Today literature analysis shows that current mining industry around the world is oriented to automation and robotization of mining processes and reveals technological readiness for 4th industrial revolution. The paper is focused on preliminary analysis of possibilities for the use of the robotic system to rock-breaking process. Prototype test rig has been proposed and experimental works have been carried out. Automatic algorithms for detection of oversized rocks, crushing them as well as sweeping and loosening of material have been formulated. Obviously many simplifications have been assumed. Some near future works have been proposed.

Development and experimental testing of a hybrid Stirling engine-adsorption chiller auxiliary power unit for heavy trucks

This paper identifies the key technical requirements for a heavy truck auxiliary power unit (APU) and explores a potential alternative technology for use in a next-generation APU which could eliminate key problems related to emissions, noise and maintenance experienced today by conventional diesel engine-vapour compression APUs. The potential performance of a novel hybrid Stirling engine-adsorption chiller concept is investigated and benchmarked against the incumbent technology using a reduced-order model based on experimental data.Experimental results from a Stirling-adsorption system (SAS) prototype test rig are also presented which highlight system integration dynamics and overall performance. The adsorption chiller achieved an average COP of 0.42±0.06 and 2.3±0.1kWt of cooling capacity at the baseline test condition. The prototype SAS test rig demonstrates that there appear to be no major technology barriers remaining that would prevent adoption of the SAS concept in a next-generation APU. Such a system could offer a reduction of exhaust emissions, greenhouse gases (GHG), ozone-depleting substances, noise, low maintenance and the potential for fuel flexibility and higher reliability. Preliminary modelling results indicate that the proposed system could offer superior overall electrical and cooling efficiencies compared to incumbent APUs and demonstrate a payback period of 4.6years.

Feasibility study of a hybrid wind turbine system – Integration with compressed air energy storage

Wind has been recognized as one of major realistic clean energy sources for power generation to meet the continuously increased energy demand and to achieve the carbon emission reduction targets. However, the utilisation of wind energy encounters an inevitable challenge resulting from the nature of wind intermittency. To address this, the paper presents the recent research work at Warwick on the feasibility study of a new hybrid system by integrating a wind turbine with compressed air energy storage. A mechanical transmission mechanism is designed and implemented for power integration within the hybrid system. A scroll expander is adopted to serve as an “air-machinery energy converter”, which can transmit additional driving power generalized from the stored compressed air to the turbine shaft for smoothing the wind power fluctuation. A mathematical model for the complete hybrid process is developed and the control strategy is investigated for corresponding cooperative operations. A prototype test rig for implementing the proposed mechanism is built for proof of the concept. From the simulated and experimental studies, the energy conversion efficiency analysis is conducted while the system experiences different operation conditions and modes. It is proved that the proposed hybrid wind turbine system is feasible technically.

Laser Intensity as a Basis for the Design of Passive Laser Safety Barriers – A Dangerous Approach

Abstract Modern laser beam sources provide radiation with high output power and brilliance. Additionally, innovative laser system technology enables the deflection of the laser into every direction. These developments depict new aspects in laser safety. On the one hand, there is no standard design approach for laser safety barriers and, on the other hand, no practical database of resulting protection times is available. A prototype test rig was built up, which allows the determinationof the protection time of different passive safety barriers. By experimental investigations, a process model for single steel sheets was established, which provides a relation between the applied process parameters and the protection time of the safety barrier. Within the conducted investigations, the laser power and the spot diameter were varied, whereas former investigations only considered the total laser intensity. The presented results show the influence of the varied parameters on the protection time and provide a first database, which will be extended within further investigations.

Incorporating dust lift-off into a CFD model of a blast furnace gravity dust-catcher

A gravity dust-catcher separates a mixture of dusts from the spent top gas flow of a blast furnace. These dusts are predominantly made up of limestone, iron ore and coke/coal. As a result of the turbulent gas flow patterns within a dust-catcher, modelling of the flow pattern can be very complex, attributed to the turbulent vortices that can be formed within the main body of the structure. Using data from an experimental prototype test rig, a simple model to capture the lift-off characteristics of particle lift-off from dust pile surfaces is created and incorporated into a computational fluid dynamics (CFD) model of the dust-catcher.The variation of particle separation performance over a typical blast furnace (BF) operational cycle is analysed. An attempt is made to explain the observed phenomena in terms of particle–fluid interaction. It is found that particle separation efficiency is largely unaffected by dust lift-off at low dust-catcher hopper fullness levels, but is significant at higher levels. It is found that the topography of the dust surface is important when predicting particle lift-off trends. It is concluded that this is due to the exposure experienced by a given particle when subjected to a surface velocity.

In-Situ Creep Testing Capability for the Advanced Test Reactor

An instrumented creep testing capability is being developed for specimens irradiated in pressurized water reactor coolant conditions at the Advanced Test Reactor (ATR). A test rig has been developed such that samples will be subjected to stresses up to 350 MPa at temperatures up to 370°C in pile. Initial Idaho National Laboratory (INL) efforts to develop this creep testing capability for the ATR are summarized. In addition to providing an overview of in-pile creep test capabilities available at other test reactors, this paper reports efforts by the INL to evaluate a prototype test rig in an autoclave at INL’s High Temperature Test Laboratory. Data from autoclave tests with Type 304 stainless steel and copper specimens are reported.

Linear variable differential transformer (LVDT)-based elongation measurements in Advanced Test Reactor high temperature irradiation testing

New materials are being considered for fuel, cladding and structures in next generation and existing nuclear reactors. These materials can undergo significant dimensional and physical changes during high temperature irradiations. Currently, such changes are determined by repeatedly irradiating a specimen for a specified period of time in the Advanced Test Reactor (ATR) and then removing it from the reactor for evaluation. The labor and time to remove, examine and return irradiated samples for each measurement make this approach very expensive. In addition, such techniques provide limited data and may disturb the phenomena of interest. To resolve these issues, an instrumented creep testing capability is being developed for specimens irradiated under pressurized water reactor coolant conditions in the ATR at the Idaho National Laboratory (INL). This paper reports the status of INL efforts to develop this testing capability. In addition to providing an overview of in-pile creep test capabilities available at other test reactors, this paper focuses on efforts to design and evaluate a prototype test rig in an autoclave at INL's High Temperature Test Laboratory.

Evaluation of fluid pressures applied to the building envelope during maintenance

Maintenance of the building envelope is required by the New Zealand Building Code. Although normal maintenance is not specifically defined, the code does limit the forces that might be applied to a building as defined in AS/NZS 1170:2002, Structural Design Actions. This article reports on research that quantifies and contextualizes the pressures that are applied to the building envelope during washing. The study includes evaluation of pressures exerted by the garden hose as well as small and medium-sized water blasters that are typically used by home-owners. A prototype test rig was designed and built to measure the forces applied by the water to flat surfaces, intersections and internal corners. Measurements were recorded at various distances from the test rig. Directly relating the recorded data to the water penetration limit state, the building envelope's design limit, identifies cleaning processes that are inappropriate and breach the NZ Building Act. The results identified that some commonly performed cleaning processes may subject a building's exterior to forces significantly greater than they are tested or designed to withstand. Significantly, the greatest forces a building's envelope (its elements and details) will experience throughout its life are those applied during the cleaning of the building.

가스 파이프라인 상의 압력 부식에 의한 흠집 검사를 위한 원격 와전류 탐상 기술

Magnetic flux leakage(MFL) 신호를 이용하여 비파괴 검사 신호를 획득하는데 주로 사용하는 감지기 또는 금속 덩어리를 의미하는 pig 이용 기술은 일반적으로 천연 가스 전송에 사용되는 강철 파이프라인 상의 대량 부식 흔적을 감지하는데 널리 이용 되어지고 있다. 이를 대체할 수 있는 비파괴 검사 기술의 양상에 대하여 소개 하자면, 지하에 매설된 가스 파이프라인의 바깥 면에 가로축을 따라 난, 부식에 의한 결함에 일반적으로 동반하는 '압력에 의한 부식 흠집(Stress Corrosion Crack : SCC)'을 탐지하는 기술이 있다. 본 논문은 가스 파이프라인 상의 가능성 있는 SCC 검출 장치로서 탐촉자의 원거리에 형성된 다상 회전 전자장 활용 기술에 대하여 논하고 있다. Pig 원형에 대한 묘사와 비파괴 신호 검사용 탐촉자에 대한 설명이 덧붙여져 있으며 결함 검지장치의 유한 요소 모델링과 연관한 부분에 관하여도 발전적으로 논하였다. 테스트 용 pig를 이용한 초기 실험 결과는 본 논문에서 보이고 있는 비파괴 검사 양식이 가스 파이프 라인의 가로축을 따라 발생한 결함에 매우 민감하게 반응하고 있음을 보이고 있다. Magnetic flux leakage (MFL) pigs are traditionally used for the detection of gross corrosion on steel pipelines used for the transmission of natural gas. Alternative nondestructive evaluation (NDE) modalities are required for the detection of stress corrosion cracking (SCC) which tends to exist in colonies oriented axially along the length of the pipeline. This paper describes the use of multiphase rotating magnetic fields in the remote region of the probe as a possible SCC detection mechanism. Details of a prototype pig and test rig are given and the challenges associated with the finite element modeling of the device are discussed. Initial experimental results show that this novel NDE modality is sensitive to axially oriented tight cracks.

Remote field eddy current testing for detection of stress corrosion cracks in gas transmission pipelines

Magnetic flux leakage (MFL) pigs are traditionally used for the detection of gross corrosion on steel pipelines used for the transmission of natural gas. Alternative nondestructive evaluation (NDE) modalities are required for the detection of stress corrosion cracking (SCC), which tends to exist in colonies oriented axially along the length of the pipeline. This paper describes the use of multi-phase rotating magnetic fields in the remote region of the probe as a possible SCC detection mechanism. Details of a prototype pig and test rig are given and the challenges associated with the finite element modeling of the device are discussed. Initial experimental results show that this novel NDE modality is sensitive to axially oriented tight cracks.