LMS Solutions Durability testing

Transcription

1 LMS Solutions Durability testing Chiel Verhoeven Solutions seminar Spain 1 Welcome and introduction 2 Durability testing 3 Structural testing 4 Acoustic testing 5 End 2 copyright LMS International

2 Durability: more than just breaking things Video fragment from BBC s Top Gear Challenge: Euro Egg CAP test Buy a cheap car Drive 30 Mph on MIRA proving ground Test comfort and durability using eggs They get charged for every piece of trim they loose 3 copyright LMS International LMS Durability engineering solutions Understanding Operational loads Target setting & Test Procedures Design Optimisation Virtual Product Validation Physical Product Optimisation & Validation Final Product Test Mobile data acquisition Data analysis Simulation Laboratory shaker trials Extensive field testing Scadas recorder Test.Xpress LMS TecWare Virtual.Lab LMS TecWare Scadas recorder Test.Xpress 4 copyright LMS International

3 LMS Durability engineering solutions Understanding Operational loads Target setting & Test Procedures Design Optimisation Virtual Product Validation Physical Product Optimisation & Validation Final Product Test Mobile data acquisition Data analysis Simulation Laboratory shaker trials Extensive field testing Where to use durability for? Predict when your product fails Learn how your customers use your product Validate your product in a shorter time 5 copyright LMS International Agenda Durability testing 1 Scadas hardware 2 Durability data acquisition 3 Durability processing 4 Demonstration 6 copyright LMS International

4 LMS SCADAS Mobile Technology Product portfolio N&V & Recorder Lab, In-field & unattended SCR platform Durability Lab, In-field & unattended SCD platform Tuned for advanced N&V applications Operable with the recorder functionality Tuned for durability applications IP54 dust and water protected frame LMS SCADAS Mobile Technology N&V Lab & In-field SCM platform Tuned for classical N&V applications Derivative for dedicated Vibration Control frames 7 copyright LMS International Overview LMS systems Scadas Mobile platform SCR01 SCR02 SCR05 SCR07 Internal battery No moving components Autonomous measuring CAN, GPS Master-slave SCR09 8 copyright LMS International

5 LMS SCADAS Mobile platform Overall functionality 4 to 72 channels Master slave configuration for distributed systems and channel expansion Up to khz sampling rate per channel 24-bit DSP technology 150dB spurious free dynamic range SCM09 SCM05 SCM02 SCM01 9 copyright LMS International LMS SCADAS Mobile platform Overall functionality Ruggedness Robust Advanced heat management no fan -10 to 55 o C ambient Dimensions W=345 H=74 D=300 High performance 14MSamples/second secured connection long cable length Flexibility wide range DC wide range AC battery with fuel gage >100 minutes autonomy Connectivity 4-72 channels and beyond master/slave V / ICP / MIC / Charge / Temperatures strain gauges digital audio GPS CAN Dimensions W=203 H=55 D= copyright LMS International

6 LMS SCADAS Recorder Platform Overall functionality Based on LMS SCADAS Mobile platform Autonomous recording on CompactFlash card SCR09 On-the-spot validation of measured data Wireless PDA smart control with Bluetooth communication On-board GPS and CAN SCR07 Parallel data streaming to internal memory & PC Easy-to-use recorder software for acquisition measurement setup, instant data validation and data export SCR05 SCR02 11 copyright LMS International SCR01 LMS SCADAS Durability Recorder Platform Overall functionality Incrementing on LMS SCADAS Recorder platform Top performer in tough conditions Water & dust protected Ingress protection code IP54 Shock & Vibration protection - MIL-STD 810F Strain, vibration and displacement measurements in one single measurement card SCD09 (IP32) SCD07 (IP54) 12 copyright LMS International

7 LMS Scadas mobile modules Accommodating a wide variety of NVH transducers V8E: Voltage and ICP VD8E: Voltage, ICP, differential inputs VM8E: Voltage, ICP and microphone VS8E: Voltage, ICP and digital audio VC8E: Voltage, ICP and charge VB8E: Voltage, ICP and bridge DB8: Voltage and bridge T8: Thermocouple RV4: Torsional vibration inputs Accelerometers: piezoelectric, ICP or capacitive Force and pressure sensors: piezoelectric or strain gauges Microphones and SI probes: conventional or ICP Strain gauges: conventional 120Ω/350Ω or semiconductor Tacho sensors: inductive, capacitive, CAN or optical Temperature sensors: type E, J, K, N, R, S and T thermocouple 13 copyright LMS International Solutions seminar Spain 1 Scadas hardware 2 Durability data acquisition 3 Durability processing 4 Demonstration 27 copyright LMS International

8 LMS Durability engineering solutions Understanding Operational loads Target setting & Test Procedures Design Optimisation Virtual Product Validation Mobile data acquisition Data analysis Simulation Scadas recorder Test.Xpress LMS TecWare Virtual.Lab Physical Product Optimisation & Validation Final Product Test Laboratory shaker trials Extensive field testing LMS TecWare Scadas recorder Test.Xpress 28 copyright LMS International Which sensors to use? Force Stress/Strain Acceleration Pressure Moment Displacement Temperature Others 29 copyright LMS International

9 Which sensors to use? Force WFTs Stress/Strain Acceleration Pressure Strain gages DC-accelerometers Pressure sensors Wheel forces Component forces Tension Compression Torque Local stresses Body accelerations Subsystems Brake pressure Air pressure - dampers Moment Displacement Temperature Others WFTs, Strain Gages, Torque Sensors Engine torque Drive shafts Laser, String pods Absolute displ. Relative displ. e.g. damper, bushings Thermocouple Laser Engine Gearbox GPS Global position CAN signals control unit quantities Angle sensors etc. 30 copyright LMS International LMS SCADAS Modules DB8 Eight channel Voltage / Bridge module (DB8) Cost-effective universal module for durability data acquisition Fully equipped bridge amplifier, sensor supply options and standard voltage input Connectivity DC accelerometers (MEMS, piezoresistive), Strain gauges, Force and pressure transducers Potentiometers Specifications High quality 7-pin LEMO connectors Input mode selectable per channel 1/1, ½ and ¼ bridge configuration Bridge supply up to 10VDC Bridge balancing 120Ω and 350Ω bridge completion Internal shunt calibration Support of differential and single-ended active sensors 31 copyright LMS International

10 LMS SCADAS Modules VB8-E Eight channel voltage/icp /Bridge module Most versatile Scadas module standard voltage/icp /TEDS and fully equipped bridge amplifier sensor supply options and standard voltage input Connectivity ICP accelerometers ICP microphones DC accelerometers (MEMS, piezoresistive), Strain gauges, Force and pressure transducers Potentiometers Specifications Sampling up to khz High quality 7-pin LEMO connectors Input mode selectable per channel 1/1, ½ and ¼ bridge configuration Bridge supply up to 10VDC Accurate bridge balancing through current injection 120Ω and 350Ω bridge completion Internal shunt calibration Differential and single-ended active sensors 32 copyright LMS International Maximum measurement power in one single box Analog channels Temperature Strain gauges (fullbridge, half-bridge, quarter-bridge) DC Accelerometers (bridge-type capacitive, piezo-resistive, MEMS-based) Potentiometers Signal conditioning of every channel is software selectable Load cells, pressure transducer Simplify your set-up, reduce cabling errors and guaranteed high-quality data 35 copyright LMS International

11 Maximum measurement power in one single box Built-in GPS and embedded CAN Built-in GPS receiver external CAN Low-speed and High-speed vehicle bus data Speed RPM Instant and accurate absolute time, position, speed Simplify your set-up, reduce cabling errors and guaranteed high-quality data 36 copyright LMS International Movie Quad Instrumentation Link 37 copyright LMS International

12 Software demo LMS Test.Xpress 38 copyright LMS International Movie Quad Measurement Link 39 copyright LMS International

13 Measurement results Example road surfaces 40 copyright LMS International Solutions seminar Spain 1 Scadas hardware 2 Durability data acquisition 3 Durability processing 4 Demonstration 41 copyright LMS International

14 LMS Durability engineering solutions Understanding Operational loads Target setting & Test Procedures Design Optimisation Virtual Product Validation Physical Product Optimisation & Validation Final Product Test Mobile data acquisition Data analysis Simulation Laboratory shaker trials Extensive field testing Scadas recorder Test.Xpress LMS TecWare Virtual.Lab LMS TecWare Scadas recorder Test.Xpress 42 copyright LMS International How to understand fatigue content of loads? Comparison of 2 measurements Most damaging? 43 copyright LMS International

15 LMS Durability engineering solutions Understanding Operational loads Target setting & Test Procedures Design Optimisation Virtual Product Validation Physical Product Optimisation & Validation Final Product Test Mobile data acquisition Data analysis Simulation Laboratory shaker trials Extensive field testing What to do with the acquired data? Calculate damage - predict fatigue life Use data for simulation input Replay measurement on a laboratory shaker 44 copyright LMS International Which parameters influence fatigue? Loads Load level Constant amplitude / variable amplitude Uni-axial / multi-axial Geometry Load configuration Notch severity Local stress state Material Basic properties Surface finish / manufacturing Residual stresses Temperature 45 copyright LMS International

16 How to understand fatigue content of loads? Variable loadings Loads (Stress) Geometry Material Rainflow counting Cycles SN-curve for CA loading Stressconcentration K f accumulation Fatigue life (=1/) 46 copyright LMS International How to understand fatigue content of loads? Endo (1965). Rainflow counting for variable loads Identification of Rainflow cycles as basic damaging events: classification into bins load history t from load level to load level Rainflow-Matrix: the number of cycles is cumulated in the from-to cells 47 copyright LMS International

17 How to understand fatigue content of loads? Variable loadings Loads (Stress) Geometry Material Rainflow counting Cycles SN-curve for CA loading Stressconcentration K f accumulation Fatigue life (=1/) 48 copyright LMS International What is an S-N-curve? Low cycle fatigue High cycle f. Infinite life S ut Fatigue strength [N/mm²] S e endurance limit Number of stress cycles N [-] 49 copyright LMS International

18 How to understand fatigue content of loads? Palmgren (1924)-Miner (1945). accumulation rule Assume that, during the service life, we have 500 loadings of type 1 (defined by mid-value and magnitude), 1000 loadings of type 2 and loadings of type 3, the Palmgren Miner rule states that failure occurs when where n i is the number of applied load cycles of type i, and N i is the pertinent fatigue life 50 copyright LMS International How to understand fatigue content of loads? Variable loadings Loads (Stress) Geometry Material Rainflow counting Cycles SN-curve for CA loading Stressconcentration K f accumulation Fatigue life (=1/) 51 copyright LMS International

19 How to use the measured load data? accumulation Fatigue life (=1/) CAE correlation Fatigue life prediction Accelerated testing 52 copyright LMS International How to use the measured load data? accumulation Fatigue life (=1/) CAE correlation Fatigue life prediction Accelerated testing 53 copyright LMS International

20 Fatigue life prediction Applied loading vs. structural strength wider = safer, but more expensive probability density applied loading structural strength (material + geometry) more scatter less scatter failure: loading > strength strength criterion 54 copyright LMS International How to use the measured load data? accumulation Fatigue life (=1/) CAE correlation Fatigue life prediction Accelerated testing 55 copyright LMS International

21 How can you accelerate a test? Increase the testing speed - compress the time series Increase the amplitude less repetitions needed for the same amount of damage Omit non-damaging events Simplify the test from variable loading to constant loading Worst-case scenario testing envelope of different user requirements Basic principle = conservation of damage 56 copyright LMS International Application case Driving 1.2 million kilometers in 8 weeks Accelerated durability testing cycles Meeting 1.2 million km durability requirement Real tests would take 3 years Large-scale customer data collection 5000 km Turkish public road data Ford Lommel proving ground Development of accelerated rig test Target setting Test schedule definition Resulting test schedule 8 weeks Test acceleration of factor 100 LMS engineers performed dedicated data collection, applied extensive load data processing techniques and developed a 6- to 8-week test track sequence and 4-week accelerated rig test scenario that matched the fatigue damage generated by 1.2 million km of road driving. 65 copyright LMS International

22 Real-life measurement setups 66 copyright LMS International Real-life measurement setups 67 copyright LMS International

23 Real-life measurement setups 68 copyright LMS International