Search results

Aircraft structures are mainly connected by riveting joints, whose quality and mechanical performance are directly determined by vertical accuracy of riveting holes. This paper proposed a combined vertical accuracy compensation method for drilling and riveting of aircraft panels with great variable curvatures.

The vertical accuracy compensation method combines online and offline compensation categories in a robot riveting and drilling system. The former category based on laser ranging is aimed to correct the vertical error between actual and theoretical riveting positions, and the latter based on model curvature is used to correct the vertical error caused by the approximate plane fitting in variable-curvature panels.

The vertical accuracy compensation method is applied in an automatic robot drilling and riveting system. The result reveals that the vertical accuracy error of drilling and riveting is within 0.4°, which meets the requirements of the vertical accuracy in aircraft assembly.

The proposed method is suitable for improving the vertical accuracy of drilling and riveting on panels or skins of aerospace products with great variable curvatures without introducing extra measuring sensors.

The purpose of this paper is to present a methodology for calculating eddy current losses in the core of a single-phase power voltage transformer, which, unlike a standard power transformer, has an open-type core (I-type core). In those apparatus, reduction of core losses is achieved by using a multipart open-type core that is created by merging a larger number of leaner cores.

3D FEM approach for calculation of eddy current losses in open-type cores based on a weak AλA formulation is presented. Method in which redundant degrees of freedom are eliminated is shown. This enables faster convergence of the simulation. The results are benchmarked using simulations with standard AVA formulation.

Results using weak AλA formulation with elimination of redundant degrees of freedom are in agreement with both simulation using only weak AλA formulation and with simulation based on AVA formulation.

The presented methodology is valid in linear cases, whereas the nonlinear case will be part of future work.

Presented procedure can be used for the optimization when designing the open-type core of apparatus like power voltage transformers.

The presented method is specifically adapted for calculating eddy currents in the open-type core. The method is based on a weak formulation for the magnetic vector potential A and the current vector potential λ, incorporating numerical homogenization and a straightforward elimination of redundant degrees of freedom, resulting in faster convergence of the simulation.

The simulation of eddy currents in laminated iron cores by the finite element method (FEM) is of great interest in the design of electrical devices. Modeling each laminate by finite elements leads to extremely large nonlinear systems of equations impossible to solve with present computer resources reasonably. The purpose of this study is to show that the multiscale finite element method (MSFEM) overcomes this difficulty.

A new MSFEM approach for eddy currents of laminated nonlinear iron cores in three dimensions based on the magnetic vector potential is presented. How to construct the MSFEM approach in principal is shown. The MSFEM with the Biot–Savart field in the frequency domain, a higher-order approach, the time stepping method and with the harmonic balance method are introduced and studied.

Various simulations demonstrate the feasibility, efficiency and versatility of the new MSFEM.

The novel MSFEM solves true three-dimensional eddy current problems in laminated iron cores taking into account of the edge effect.

This work introduces an efficient and accurate technique to solve the eddy current problem in laminated iron cores considering vector hysteresis.

The mixed multiscale finite element method based on the based on the T,Φ-Φ formulation, with the current vector potential T and the magnetic scalar potential Φ allows the laminated core to be modelled as a single homogeneous block. This means that the individual sheets do not have to be resolved, which saves a lot of computing time and reduces the demands on the computer system enormously.

As a representative numerical example, a single-phase transformer with 4, 20 and 184 sheets is simulated with great success. The eddy current losses of the simulation using the standard finite element method and the simulation using the mixed multiscale finite element method agree very well and the required simulation time is tremendously reduced.

The vector Preisach model is used to account for vector hysteresis and is integrated into the mixed multiscale finite element method for the first time.

Detection of hidden defects of aluminum alloy plate with damping coating is a challenging problem. At present, only a few non-destructive testing methods exist to address this engineering problem. Without the restriction of skin effect, remote field eddy current (RFEC) overcomes the interference caused by the damping coating. The RFEC, which has potential advantages for detecting the hidden defects of aluminum plate with damping coating, can penetrate the metal plate to detect buried depth defects. This study aims to test how thick the RFEC sensor can penetrate the metal plate to detect the buried defects.

The magnetic field distribution characteristics are analyzed, the magnetic field intensity distribution is calculated, and the structure and parameters of the coil, magnetic circuit and shielding damping are determined through the two- and three-dimensional finite element simulation methods. Optimal excitation frequency is obtained, and the distance between the excitation coil and detection coil is determined by analyzing the relationship between excitation frequency and remote field points.

Simulation and experimental results verify the feasibility of applying the RFEC detection technology in detecting the hidden defects of aluminum alloy plate with damping coating.

In this paper, the RFEC testing model of hidden defects in aluminum plate sample with damping coating is established by using the finite element method.

The purpose of this paper is to examine a solution strategy for coupled nonlinear magnetic-thermal problems and apply it to the heating process of a thin moving steel sheet. Performing efficient numerical simulations of induction heating processes becomes ever more important because of faster production development cycles, where the quasi steady-state solution of the problem plays a pivotal role.

To avoid time-consuming transient simulations, the eddy current problem is transformed into frequency domain and a harmonic balancing scheme is used to take into account the nonlinear BH-curve. The thermal problem is solved in steady-state domain, which is carried out by including a convective term to model the stationary heat transport due to the sheet velocity.

The presented solution strategy is compared to a classical nonlinear transient reference solution of the eddy current problem and shows good convergence, even for a small number of considered harmonics.

Numerical simulations of induction heating processes are necessary to fully understand certain phenomena, e.g. local overheating of areas in thin structures. With the presented approach it is possible to perform large 3D simulations without excessive computational resources by exploiting certain properties of the multiharmonic solution of the eddy current problem. Together with the use of nonconforming interfaces, the overall computational complexity of the problem can be decreased significantly.

This paper presents a comparative study of different stator-segmentation topologies of a permanent magnet synchronous machine (PMSM) used in traction drives and their effect on iron losses. Using stator segmentation allows one to achieve more significant copper fill factors, resulting in increased power densities and efficiencies. The segmentation of the stators creates additional air gaps and changes the soft magnetic material’s material properties due to the cut edge effect. The aim of this paper is to present an in-depth analysis of the influence of stator segmentation on iron losses. The main goal was to compare various segmentation methods under equal excitation conditions in terms of their influence on iron loss.

A transient finite element method analysis combined with an extended iron-loss model was used to evaluate discussed effects on the stator’s iron losses. The workflow to obtain a homogenized airgap length accounting for cut edge effects was established.

The paper concludes that the segmentation in most cases slightly decreases the iron losses in the stator because of the overall reduced magnetic flux density B due to the additional air gaps in the magnetic circuit. An increase of the individual components, as well as total power loss, was observed in the Pole Chain segmentation design. In general, segmentation did not change the total iron losses significantly. However, different segmentation methods resulted in the different distortion of the magnetic field and, consequently, in different iron loss compositions. The analysed segmentation methods exhibited different iron loss behaviour with respect to the operation points of the machine. The final finding is that analysed stator segmentations had a negligible influence on the total iron loss. Therefore, applying segmentation is an adequate measure to improve PMSMs as it enables, e.g. increase of the winding fill factor or simplifying the assembly processes, etc.

The influence of stator segmentation on iron losses was analysed. An in-depth evaluation was performed to determine how the discussed changes influence the individual iron loss components. A workflow was developed to achieve a computationally cheap homogenized model.

The purpose of this paper is to investigate the applicability of a direct current (DC) hysteresis measurement on power transformer terminals for the subsequent hysteresis model parametrization in transformer grey box topology models.

Two transformer topology models with two different hysteresis models are used together with a DC hysteresis measurement via the power transformer terminals to parameterize the hysteresis models by means of an optimization. The calculated current waveform with the derived model in the transformer no-load condition is compared to the measured no-load current waveforms to validate the model.

The proposed DC hysteresis measurement via the power transformer terminals is suitable to parametrize two hysteresis models implemented in transformer topology models to calculate the no-load current waveforms.

Different approaches for the measurement and utilization of transformer terminal measurements for the hysteresis model parametrization are discussed in literature. The transformer topology models, derived with the presented approach, are able to reproduce the transformer no-load current waveform with acceptable accuracy.

The purpose of this paper is to report on the developments in manufacturing soft magnetic materials using laser powder bed fusion (L-PBF).

Ternary soft magnetic Fe-49Co-2V powder was produced by gas atomization and used in an L-PBF machine to produce samples for material characterization. The L-PBF process parameters were optimized for the material, using a design of experiments approach. The printed samples were exposed to different heat treatment cycles to improve the magnetic properties. The magnetic properties were measured with quasi-static direct current and alternating current measurements at different frequencies and magnetic flux densities. The mechanical properties were characterized with tensile tests. Electrical resistivity of the material was measured.

The optimized L-PBF process parameters resulted in very low porosity. The magnetic properties improved greatly after the heat treatments because of changes in microstructure. Based on the quasi-static DC measurement results, one of the heat treatment cycles led to magnetic saturation, permeability and coercivity values comparable to a commercial Fe-Co-V alloy. The other heat treatments resulted in abnormal grain growth and poor magnetic performance. The AC measurement results showed that the magnetic losses were relatively high in the samples owing to formation of eddy currents.

The influence of L-PBF process parameters on the microstructure was not investigated; hence, understanding the relationship between process parameters, heat treatments and magnetic properties would require more research.

The relationship between microstructure, chemical composition, heat treatments, resistivity and magnetic/mechanical properties of L-PBF processed Fe-Co-V alloy has not been reported previously.

This study aims to study the gas film stiffness of the spiral groove dry gas seal.

The present study represents the first attempt to calculate gas film stiffness in consideration of the slipping effect by using the new test technology for dry gas seals. First, a theoretical model of modified generalized Reynolds equation is derived with slipping effect of a micro gap for spiral groove gas seal. Second, the test technology examines micro-scale gas film vibration and stationary ring vibration to determine gas film stiffness by establishing a dynamic test system.

An optimum value of the spiral angle and groove depth for improved gas film stiffness is clearly seen: the spiral angle is 1.34 rad (76.8º) and the groove depth is 1 × 10^–5 m. Moreover, it can be observed that optimal structural parameters can obtain higher gas film stiffness in the experiment. The average error between experiment and theory is less than 20%.

The present study represents the first attempt to calculate gas film stiffness in consideration of the slipping effect by using the new test technology for dry gas seals.