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Significant improvements in module performance are possible via implementation of multi-wire electrodes. This is economically sound as long as the mechanical yield of the production is maintained. While flat ribbons have a relatively large contact area to exert forces onto the solar cell, wires with round cross section reduce this contact area considerably – in theory to an infinitively thin line. Therefore, the local stresses induced by the electrodes might increase to a point that mechanical production yields suffer unacceptably.
In this paper, we assess this issue by an analytical mechanical model as well as experiments with an encapsulant-free N.I.C.E. test setup. From these, we can derive estimations for the relationship between lay-up accuracy and expected breakage losses. This paves the way for cost-optimized choices of handling equipment in industrial N.I.C.E.-wire production lines.
We describe a prototype for power line communi- cation for grid monitoring. The PLC receiver is used to gain information about the PLC channel and the current state of the power grid. The PLC receiver uses the communication signal to obtain an accurate estimate of the current channel and provides information which can be used as a basis for further processing with the aim to detect partial discharges and other anomalies in the grid. This monitoring of the power grid takes advantage of existing PLC infrastructure and uses the data signals, which are transmitted anyway to obtain a real-time measurement of the channel transfer function and the received noise signal. Since this signal is sampled at a high sampling rate compared to simpler measurement sensors, it contains valuable information about possible degradations in the grid which need to be addressed. While channel measurements are based on a received PLC signal, information about partial discharges or other sources of interference can be gathered by a PLC receiver in the absence of a transmit signal. A prototype based on Software Defined Radio has been developed, which implements the simultaneous communication and sensing for a power grid.
This study aims to investigate the individual response concerning BRFs for AT when the mid-sole hardness underneath the rearfoot was systematically altered. We first identified FGs based on the footwear condition that minimised the risk for AT across BRFs. We then tested the FGs for differences in anthropometrics, footwear comfort, and running characteristics.
For some years now, additive manufacturing (AM) has offered an alternative to conventional manufacturing processes. The strengths of AM are primarily the rapid implementation of ideas into a usable product and the ability to produce geometrically complex shapes. It has also significantly advanced the lightweight design of products made of plastic. So far, the strength of printed components made of polymers is previously very limited.
Recently, new AM processes have become available that allow the embedding of short and also long fibers in polymer matrix. Thus, the manufacturing of components that provide a significant increase in strength becomes possible. In this way, both complex geometries and sophisticated applications can be implemented. This paper therefore investigates how this new technology can be implemented in product development, focusing on sports equipment. An extensive literature research shows that lightweight design plays a decisive role in sports equipment. In addition, the advantages of AM in terms of individualized products and low quantities can be fully exploited.
An example of this approach is the steering system for a seat sled used by paraplegic athletes in the Olympic discipline of Nordic paraskiing. A particular challenge here is the placement and alignment of the long carbon fibers within the polymer matrix and the verification of the strength by means of Finite-Element-Analysis (FEA). In addition, findings from bionics are used to optimize the lightweight design of the steering system. Using this example, it can be shown that the weight of the steering system can be drastically reduced compared to conventional manufacturing. At the same time, a number of parts can be saved through function integration and thus the manufacturing and assembly effort can be reduced significantly.
Offenburg university of Applied Sciences offers pre-study extracurricular preparatory courses for future engineering students in mathematics and physics. Due to pandemic restrictions, the two-week preparatory physics course preceeding winter term 2020/21 was presented as an online -only course.
Students enrolled to the course attended eight online lect ures of approximately 90 minutes duration followed by a group assignment. Both lectures and tutoring to the group assignment used a videoconference system with group sizes of 120 (lecture) and 6 (peer instruction and group assignments). The eight lectures focused on the high school physics curriculum of mechanics, electricity, thermodynamics and optics. Each lecture included four “peer instruction” questions to improve student activation. Student responses were collected using an audience response online tool.
The “peer instruction” questions were discussed by the students in online groups of six students. These groups also received written group assignments consisting of common textbook exercises and additional problems with incomplete information. To solve these problems, groups were encouraged to discuss possible solutions. The on-line course attendance was monitored and showed a characteristic exponential “decay” curve with a half-life of approximately 18 lectures which is comparable to conventional courses: Around 73% of the students enrolled in the preparatory course attended all eight lectures. In addition to the attendance, the progress of the participants was monitored by two online tests: A pre-course online test the first course day and a post -course online test on the last day.
The completion of both tests was highly recommended, but not a formal requirement for the students. The fraction of students completing the pre-course, but not the post-course test was used as an estimate for the drop-out rate of (34±3)%.
The twin concept is increasingly used for optimization tasks in the context of Industry 4.0 and digitization. The twin concept can also help small and medium-sized enterprises (SME) to exploit their energy flexibility potential and to achieve added value by appropriate energy marketing. At the same time, this use of flexibility helps to realize a climate-neutral energy supply with high shares of renewable energies. The digital twin reflects real production, power flows and market influences as a computer model, which makes it possible to simulate and optimize on-site interventions and interactions with the energy market without disturbing the real production processes. This paper describes the development of a generic model library that maps flexibility-relevant components and processes of SME, thus simplifying the creation of a digital twin. The paper also includes the development of an experimental twin consisting of SME hardware components and a PLC-based SCADA system. The experimental twin provides a laboratory environment in which the digital twin can be tested, further developed and demonstrated on a laboratory scale. Concrete implementations of such a digital twin and experimental twin are described as examples.
Ein tiefgreifendes Verständnis des zyklischen Plastizitätsverhaltens metallischer Werkstoffe ist sowohl für die Optimierung der Materialeigenschaften als auch für die industrielle Auslegung und Fertigung von Bauteilen von hoher Relevanz. Insbesondere moderne Legierungen wie Duplex-Stähle zeigen unter Lastumkehr aufgrund des komplexen mehrphasigen Gefüges sowie der Neigung zu verschiedenen Ausscheidungsreaktionen einen ausgeprägten Bauschinger-Effekt, welcher bei technischen Umformvorgängen berücksichtigt werden muss. Der Bauschinger-Effekt begründet sich maßgeblich in der Entstehung von Rückspannungen, welche aus dem unterschiedlichen Plastizitätsverhalten der austenitischen und ferritischen Phase resultieren. Instrumentierte Mikroindenter-Versuche in ausgewählten Ferrit- und Austenitkörnern haben gezeigt, dass austenitische Gefügebestandteile durch einen deutlich früheren Fließbeginn sowie eine stärkere Rückplastifizierung während der Entlastung charakterisiert sind. Zudem wurde nachgewiesen, dass Ausscheidungen im Rahmen einer 475°C-Versprödung diesen Phasenunterschied verstärken und somit in einem höheren Bauschinger-Effekt resultieren.
Do you know that for each banana bunch the complete plant must be cut as well? Only in Brazil 440 million trees are planted annually. With an average weight of 30 kg per banana plant you can estimate about 13,5 million tons of banana residues per year. Although there exist some projects to use these residues for the production of valuable products (e.g fibers for textile and paper production) most of this organic waste material is unused and left for composting on the farmland.
The basic idea of this project is to evaluate this organic waste material for converting it to a renewable and CO2 neutral fuel. Therefore, the different parts of the banana plant (heart, leaves and pseudo stem) were analyzed regarding their biogas potential (specific biogas yield and biogas production kinetics). In further studies the effect of mechanical and enzymatic pretreatments of the different parts of the plants was investigated. This examination could then be the basis for an energetic usage of this organic residue.
The biogas batch experiments were performed according to the german guideline VDI 4630 in 2-L-Batch reactors at 37°C. As biogas substrates, the heart, the leaves and the pseudo stem of the banana plant residue with and without enzymatic/mechanical pretreatment were used.
The different parts of the banana plants result in a specific biogas production yield in the range of 260-470 norm liters per kg organic dry mass.
To determine the influence of the mechanical pretreatment (particle size 1-15 mm) on the biogas production kinetics, the kinetic constants were defined and calculated. The reduction of the particle size leads to an improved biogas production kinetics. Therefore experiments will demonstrate, if the results from the batch experiments can be converted in the continuous fed biogas reactor. The experiments of the enzymatic pretreatment are still under investigation.
Environmentally-friendly implementation of new technologies and eco-innovative solutions often faces additional secondary ecological problems. On the other hand, existing biological systems show a lesser environmental impact as compared to the human-made products or technologies. The paper defines a research agenda for identification of underlying eco-inventive principles used in the natural systems created through evolution. Finally, the paper proposes a comprehensive method for capturing eco-innovation principles in biological systems in addition and complementary to the existing biomimetic methods and TRIZ methodology and illustrates it with an example.
Cross-industry innovation is commonly understood as identification of analogies and interdisciplinary transfer or copying of technologies, processes, technical solutions, working principles or models between industrial sectors. In general, creative thinking in analogies belongs to the efficient ideation techniques. However, engineering graduates and specialists frequently lack the skills to think across the industry boundaries systematically. To overcome this drawback an easy-to-use method based on five analogies has been evaluated through its applications by students and engineers in numerous experiments and industrial case studies. The proposed analogies help to identify and resolve engineering contradictions and apply approaches of the Theory of Inventive Problem Solving TRIZ and biomimetics. The paper analyses the outcomes of the systematized analogies-based ideation and outlines that its performance continuously grows with the engineering experience. It defines metrics for ideation efficiency and ideation performance function.
This book constitutes the refereed proceedings of the 20th International TRIZ Future Conference, TFC 2020, held online at the University Cluj-Napoca, Romania, in October 2020 and sponsored by the International Federation for Information Processing.
34 chapters were carefully peer reviewed and selected from 91 conference submissions. They are organized in the following thematic sections: computing TRIZ; education and pedagogy; sustainable development; tools and techniques of TRIZ for enhancing design; TRIZ and system engineering; TRIZ and complexity; and cross-fertilization of TRIZ for innovation management.
Additive manufacturing is a rapidly growing manufacturing process for which many new processes and materials are currently being developed. The biggest advantage is that almost any shape can be produced, while conventional manufacturing methods reach their limits. Furthermore, a lot of material is saved because the part is created in layers and only as much material is used as necessary. In contrast, in the case of machining processes, it is not uncommon for more than half of the material to be removed and disposed of. Recently, new additive manufacturing processes have been on the market that enables the manufacturing of components using the FDM process with fiber reinforcement. This opens up new possibilities for optimizing components in terms of their strength and at the same time increasing sustainability by reducing materials consumption and waste. Within the scope of this work, different types of test specimens are to be designed, manufactured and examined. The test specimens are tensile specimens, which are used both for standardized tensile tests and for examining a practical component from automotive engineering used in student project. This project is a vehicle designed to compete in the Shell Eco-marathon, one of the world’s largest energy efficiency competitions. The aim is to design a vehicle that covers a certain distance with as little fuel as possible. Accordingly, it is desirable to manufacture the components with the lowest possible weight, while still ensuring the required rigidity. To achieve this, the use of fiber-reinforced 3D-printed parts is particularly suitable due to the high rigidity. In particular, the joining technology for connecting conventionally and additively manufactured components is developed. As a result, the economic efficiency was assessed, and guidelines for the design of components and joining elements were created. In addition, it could be shown that the additive manufacturing of the component could be implemented faster and more sustainably than the previous conventional manufacturing.
Interaction and capturing information from the surrounding is dominated by vision and hearing. Haptics on the other side, widens the bandwidth and could also replace senses (sense switching) for impaired. Haptic technologies are often limited to point-wise actuation. Here, we show that actuation in two-dimensional matrices instead creates a richer input. We describe the construction of a full-body garment for haptic communication with a distributed actuating network. The garment is divided into attachable-detachable panels or add-ons that each can carry a two dimensional matrix of actuating haptic elements. Each panel adds to an enhanced sensoric capability of the human- garment system so that together a 720° system is formed. The spatial separation of the panels on different body locations supports semantic and theme-wise separation of conversations conveyed by haptics. It also achieves directional faithfulness, which is maintaining any directional information about a distal stimulus in the haptic input.
Konstrukteure im Maschinenbau stehen häufig vor der Problemstellung, hochfest vorgespannte Schraubenverbindungen und einen durchgehenden Korrosionsschutz zu vereinen. Die Normen und Richtlinien bieten hierzu Stand heute keine ausreichenden Antworten. Die Hochschule Offenburg befasst sich im Rahmen einer industriellen Gemeinschaftsforschung mit der Fragestellung, welchen Einfluss organische Beschichtungen auf die Vorspannkraft insbesondere bei erhöhten Umgebungstemperaturen haben. In dieser Arbeit werden die ersten Ergebnisse zum Einfluss der Einzelschichtstärke des Beschichtungssystems präsentiert.
The PHOTOPUR project aims to develop a photocatalytic process as a type of AOPs (Advanced Oxidation Processes) for the elimination of plant protection products (PPP) of the cleaning water used to wash sprayers. At INES a PV based energy supply for the photocatalytic cleaning system was developed within the framework of two bachelor theses and assembled as a demonstration unit. Then the system was step by step extended with further process automation features and pushed to a remote operating device. The final system is now available as a mobile unit mounted on a lab table. The latest step was the photocatalytic reactor module which completed the first PHOTOPUR prototype. The system is actually undergoing an intensive testing phase with performance checks at the consortium partners. First results give an overview about the successful operation.
Growing demands for cleaner production and higher eco-efficiency in process engineering require a comprehensive analysis of technical and environmental outcomes of customers and society. Moreover, unexpected additional technical or ecological drawbacks may appear as negative side effects of new environ-mentally friendly technologies. The paper conceptualizes a comprehensive ap-proach for analysis and ranking of engineering and ecological requirements in process engineering in order to anticipate secondary problems in eco-design and to avoid compromising the environmental or technological goals. For this purpose, the paper presents a method based on integration of the Quality Func-tion Deployment approach with the Importance-Satisfaction Analysis for the requirements ranking. The proposed method identifies and classifies compre-hensively the potential engineering and eco-engineering contradictions through analysis of correlations within requirements groups such as stakehold-er requirements (SRs) and technical requirements (TRs), and additionally through cross-relationship between SRs and TRs.
The 40 Altshuller Inventive Principles with numerous sub-principles remain over decades the most frequently applied tool of the Theory of Inventive Problem Solving TRIZ for systematic idea generation. However, their application often requires a concentrated, creative and abstract way of thinking that can be fairly challenging for the newcomers to TRIZ. This paper describes an approach to reduce the abstraction level of inventive sub-principles and presents the results of the idea generation experiment conducted with three groups of undergraduate and graduate students from different years of study in mechanical and process engineering. The students were asked to generate and to record their individual ideas for three design problems using a pre-defined set of classical and modified sub-principles within 10 minutes. The overall outcomes of the experiment support the assumption that the less abstract wording of the modified sub-principles leads to higher number of ideas. The distribution of ideas between the fields of MATCHEM-IBD (Mechanical, Acoustic, Thermal, Chemical, Electrical, Magnetic, Intermolecular, Biological and Data processing) differs significantly between groups using modified and abstract sub-principles.
Classification of TRIZ Inventive Principles and Sub-Principles for Process Engineering Problems
(2019)
The paper proposes a classification approach of 40 Inventive Principles with an extended set of 160 sub-principles for process engineering, based on a thorough analysis of 155 process intensification technologies, 200 patent documents, 6 industrial case studies applying TRIZ, and other sources. The authors define problem-specific sub-principles groups as a more precise and productive ideation technique, adaptable for a large diversity of problem situations, and finally, examine the anticipated variety of ideation using 160 sub-principles with the help of MATCEM-IBD fields.
Industrie 4.0 bedeutet nicht nur einen Wandel der technischen Möglichkeiten und Arbeitsbedingungen, sondern auch einen Bedarf an neuen, sich kontinuierlich weiterentwickelnden Kompetenzen und die Bereitschaft der Beschäftigten, Veränderungen mitzugestalten. Spielerische Ansätze der Kompetenzentwicklung können v.a. bei weiterbildungsfernen Mitarbeitern hilfreich sein, um das komplexe Thema verständlich zu vermitteln. Der Beitrag beschreibt ein Seminarkonzept mit integriertem Brettspiel, mit dem Teilnehmer anhand eines fiktiven Unternehmens (Müller GmbH) die Transformation eines Unternehmens in die Industrie 4.0 spielerisch nachvollziehen. Dieses Konzept erweist sich in einer ersten Evaluation als durchaus vielversprechend.
The ability to change aerodynamic parameters of airfoils during flying can potentially save energy as well as reducing the noise made by the unmanned aerial vehicles (UAV) because of sharp edges of the airfoil and its rudders. In this paper, an approach for the design of an adaptive wing using a multi-material 3D printer is shown. In multi-material 3D printing, up to six different materials can be combined in one component. Thus, the user can determine the mixture and the spatial arrangement of this “digital material” in advance in the pre-processing software. First, the theoretical benefits of adaptive wings are shown, and already existing adaptive wings and concepts are explicated within a literature review. Then the additive manufacturing process using photopolymer jetting and its capabilities to print multiple materials in one part are demonstrated. Within the scope of a case study, an adaptive wing is developed and the necessary steps for the product development and their implementation in CAD are presented. This contribution covers the requirements for different components and sections of an adaptive wing designed for additive manufacturing using multiple materials as well as the single steps of development with its different approaches until the final design of the adaptive wing. The developed wing section is simulated, and qualitative tests in a wind tunnel are carried out with the wing segment. Finally, the additively manufactured wing segment is evaluated under technical and economic aspects.
Model-based analysis of Electrochemical Pressure Impedance Spectroscopy (EPIS) for PEM Fuel Cells
(2019)
Electrochemical impedance spectroscopy (EIS) is a widely-used diagnostic technique to characterize electrochemical processes. It is based on the dynamic analysis of two electrical observables, that is, current and voltage. Electrochemical cells with gaseous reactants or products, in particular fuel cells, offer an additional observable, that is, the gas pressure. The dynamic coupling of current or voltage with gas pressure gives rise to a number of additional impedance definitions, for which we have previously introduced the term electrochemical pressure impedance spectroscopy (EPIS) [1,2]. EPIS shows a particular sensitivity towards transport processes of gas-phase or dissolved species, in particular, diffusion coefficients and transport pathway lengths. It is as such complementary to standard EIS, which is mainly sensitive towards electrochemical processes. First EPIS experiments on PEM fuel cells have recently been shown [3].
We present a detailed modeling and simulation analysis of EPIS of a PEM fuel cell. We use a 1D+1D continuum model of a fuel/air channel pair with GDL and MEA. Backpressure is dynamically varied, and the resulting simulated oscillation in cell voltage is evaluated to yield the ▁Z_( V⁄p_ca ) EPIS signal. Results are obtained for different transport situations of the fuel cell, giving rise to very complex EPIS shapes in the Nyquist plot. This complexity shows the necessity of model-based interpretation of the complex EPIS shapes. Based on the simulation results, specific features in the EPIS spectra can be assigned to different transport domains (gas channel, GDL, membrane water transport).
HPTLC (High Performance Thin Layer Chromatography) is a well known and versatile separation method which shows a lot of advantages and options in comparison to other separation techniques. The method is fast and inexpensive and does not need time-consuming pretreatments. Using fiber-optic elements for controlled light-guiding, the TLC-method was significantly improved: the new HPTLC-system is able to measure simultaneously at different wavelengths without destroying the plate surface or the analytes on the surface. For registration of the sample distribution on a HPTLC-plate we developed a new and sturdy diode-array HPTLC- scanner which allows registration of spectra on the TLC- plates in the range of 198 nm to 610 nm with a spectral resolution better than 1.2 nm. The spatial resolution on plate is better than 160 micrometers . In the spectral mode, the new HPTLC-scanner delivers much more information than the commonly used TLC-scanner. The measurement of 450 spectra of one separation track does not need more than three minutes. However, in the fixed wavelength mode the contour plot can be measured within 15 seconds. In this case, the signal will be summarized and averaged over a spectral range having FWHM from 10 nm to 25 nm depending on the substance under test. The new diode-array HPTLC-scanner makes various chemometric applications possible. The new method can be used easily in clinical diagnostic systems easily, e.g. for blood and uring investigations. In addition, new applications are possible. For example, the rich structured PAHs were studied. Although the separation is incomplete the 16 compounds can be quantified using suitable wavelengths.
HPTLC (High Performance Thin Layer Chromatography) is a well known and versatile separation method which shows many advantages when compared to other separation techniques. The method is fast and inexpensive and does not need time-consuming pretreatments. For visualisation of the sample distribution on a HPTLC-plate we developed a new and sturdy HPTLC-scanner. The scanner allows simultaneous registrations of spectra in a range from 198 nm to 612 nm with a spectral resolution of better than 0.8 nm. The on-plate spatial resolution is better than 160 μm. The measurement of 450 spectra in one separation track does not need more than two minutes. The new diode-array scanner offers a fast survey over a TLC-separation and makes various chemometric applications possible. For compound identification a cross-correlation function is described to compare UV sample spectra with appropriate library data. The cross-correlation function herein described can also be used for purity testing. Unresolved peaks can be virtually separated by use of a least squares fit algorithm. In summary, the diode arry system delivers much more information than the commonly used TLC-scanner.
A prototype multiwavelength sensor able to characterise soot emissions in Diesel exhaust in terms of size and concentration has been tested against other methods for diesel particle measurements like electrical mobility sizing (SMPS) and raw exhaust gravimetric sampling (RES). Measurements carried out with the prototype sensor were correlated with the SMPS by assuming spherical and/or fractal aggregate morphology of the particles. Correlation of RES gravimetric data against the sensor and the SMPS led to the calculation of the solid density for soot particles to be 2.3 gr/cm3.
With the need for automatic control based supervisory controllers for complex energy systems, comes the need for reduced order system models representing not only the non-linear behaviour of the components but also certain unknown process dynamics like their internal control logic. At the Institute of Energy Systems Technology in Offenburg we have built a real-life microscale trigeneration plant and present in this paper a rational modelling procedure that satisfies the necessary characteristics for models to be applied in model predictive control for grid-reactive optimal scheduling of this complex energy system. These models are validated against experimental data and the efficacy of the methodology is discussed. Their application in the future for the optimal scheduling problem is also briefly motivated.
Im Rahmen der Konstruktionsausbildung an der Hochschule Offenburg wird die Lehre im Fach Technische Dokumentation fortlaufend optimiert. In der vorliegenden Laborstudie wurde das visuelle Wahrnehmen von 34 Maschinenbaustudierenden (2w + 32m) im Alter von 19 bis 29 Jahren mithilfe der Eye-Tracking-Technik und einer Videokamera bei der Analyse einer Baugruppenzeichnung beobachtet.
Hot work tools are subjected to complex thermal and mechanical loads during hot forming processes. Locally, the stresses can exceed the material’s yield strength in highly loaded areas as e.g. in small radii in die cavities. To sustain the high loads, the hot forming tools are typically made of martensitic hot work steels. While temperatures for annealing of the tool steels usually lie in the range between 400 and 600 °C, the steels may experience even higher temperatures during hot forming, resulting in softening of the material due to coarsening of strengthening particles. In this paper, a temperature dependent cyclic plasticity model for the martensitic hot work tool steel 1.2367 (X38CrMoV5-3) is presented that includes softening due to particle coarsening and that can be applied in finite-element calculations to assess the effect of softening on the thermomechanical fatigue life of hot work tools. To this end, a kinetic model for the evolution of the mean size of secondary carbides based on Ostwald ripening is coupled with a cyclic plasticity model with kinematic hardening. Mechanism-based relations are developed to describe the dependency of the mechanical properties on carbide size and temperature. The material properties of the mechanical and kinetic model are determined on the basis of tempering hardness curves as well as monotonic and cyclic tests.
In this paper the fatigue life of three cast iron materials, namely EN-GJS-700, EN-GJV-450 and EN-GJL-250, is predicted for combined thermomechanical fatigue and high cycle fatigue loading. To this end, a mechanism-based model is used, which is based on microcrack growth. The model considers crack growth due to low frequency loading (thermomechanical and low cycle fatigue) and due to high cycle fatigue. To determine the model parameters for the cast iron materials, fatigue tests are performed under combined loading and crack growth is measured at room temperature using the replica technique. Superimposed high cycle fatigue leads to an accelerated crack growth as soon as a critical crack length and thus the threshold stress intensity factor is exceeded. The model takes this effect into account and predicts the fatigue lives of all cast iron materials investigated under combined loadings very well.
HiSiMo cast irons are frequently used as material for high temperature components in engines as e.g. exhaust manifolds and turbo chargers. These components must withstand severe cyclic mechanical and thermal loads throughout their life cycle. The combination of thermal transients with mechanical load cycles results in a complex evolution of damage, leading to thermomechanical fatigue (TMF) of the material and, after a certain number of loading cycles, to failure of the component. In Part I of the paper, a fracture mechanics model for TMF life prediction was developed based on results of uniaxial tests. In this paper (Part II), the model is formulated for three-dimensional stress states, so that it can be applied in a post-processing step of a finite-element analysis. To obtain reliable stresses and (time dependent plastic) strains in the finite-element calculation, a time and temperature dependent plasticity model is applied which takes non-linear kinematic hardening into account. The material properties of the model are identified from the results of the uniaxial test. The plasticity model and the TMF life model are applied to assess the lifetime of an exhaust manifold.
Höchste Korrosionsschutzanforderungen sind für bestimmte technische Produkte insbesondere im Offshore Anwendungsbereich, nach ISO 20340, zwingend zu erfüllen, um deren Funktion und Betriebssicherheit dauerhaft gewährleisten zu können. Bis heute werden viele dieser Produkte am Ende ihrer Wertschöpfungskette nass überlackiert, mit einer kompletten Kunststoffhaut, der Korrosionsschutz-Lackschicht, überzogen. Diese Lackierung ist unter anderem deshalb erforderlich, weil es im klassischen Maschinenbau, insbesondere in der Antriebstechnik, viele mechanische Schnittstellen gibt, die vor der endgültigen Produktmontage quasi metallisch blank bleiben müssen, um den erforderlichen und definierten geometrischen Oberflächenzustand nach Form und Lage als Pass- und Fügefläche zu gewährleisten. Eine dieser mechanischen Schnittstellen sind Schraubenverbindungen. Mit dem derzeit gültigen Regelwerk ist die Berechnung einer Schraubenverbindung mit Lackschichten in den Trennfugen oder auf der Kopf- und Mutternauflagefläche nicht möglich, da lackierte Bauteile in der derzeit geltenden VDI-Richtlinie 2230 nicht berücksichtigt sind. Nach einem Praxisbericht anhand von Stellantrieben für Industriearmaturen über deren Umstellung von Nasslackierung des Gesamtproduktes auf Pulverbeschichtung von Einzelteilen wird die experimentelle Validierung der Betriebs- und Funktionssicherheit von Schraubenverbindungen mit lackierten Bauteilen vorgestellt. Daraus resultierend wurde im März 2014 an der Hochschule Offenburg ein Forschungsprojekt gestartet, dessen Ziel es ist für die oben genannte Problemstellung einen systematischen Lösungsansatz zu erarbeiten. Künftig soll es Entwicklungsingenieuren und Konstrukteuren bereits in der Phase von Entwicklung und Konstruktion möglich sein Schraubenverbindungen mit lackierten Bauteilen zuverlässig zu berechnen und auszulegen oder diese in der Prototypenphase zuverlässig zu testen. Die letzten beiden Abschnitte geben den Lösungsansatz und den aktuellen Stand der Forschung wider.
Die Untersuchungen der Hochschule Offenburg zeigen, dass es durch organische Korrosionsschutzschichten im Kraftfluss von Schraubenverbindungen nicht zu einem verfrühten Abschalten der streckgrenzengesteuerten Schraubmontage kommt. Die fünf untersuchten Lacksysteme zeigten ein sehr unterschiedliches Reibverhalten, der Anzugsvorgang wurde jedoch zuverlässig bei Erreichen der Schraubenstreckgrenze beendet. Durch den ermittelten Drehmoment/Drehwinkelverlauf lässt sich das streckgrenzengesteuerte Anzugsverfahren als Analystetool einsetzen, wodurch für den jeweiligen Schraubfall auch Rückschlüsse auf anderen Anzugsverfahren getroffen werden können. Des Weiteren zeigte sich, dass Pulverlacksysteme widerstandsfähiger gegen die bei der Montage wirkenden Belastungen sind und eine Montage direkt auf Lack ermöglichen können.
HiSiMo cast irons are frequently used as material for high temperature components in engines as e.g. exhaust manifolds and turbo chargers. These components must withstand severe cyclic mechanical and thermal loads throughout their service life. The combination of thermal transients with mechanical load cycles results in a complex evolution of damage, leading to thermomechanical fatigue (TMF) of the material and, after a certain number of loading cycles, to failure of the component. In this paper (Part I), the low-cycle fatigue (LCF) and TMF properties of HiSiMo are investigated in uniaxial tests and the damage mechanisms are addressed. On the basis of the experimental results a fatigue life model is developed which is based on elastic, plastic and creep fracture mechanics results of short cracks, so that time and temperature dependent effects on damage are taken into account. The model can be used to estimate the fatigue life of components by means of finite-element calculations (Part II of the paper).
The uncertain and time-variant nature of renewable energy results in the need to deal with peaks in the production of energy. One approach is to achieve a load shift and thereby help balancing the grid by using thermally Activated Building Systems (TABS). Control systems currently in place do not exploit the full potential of TABS. This paper reviews how Model Predictive Control can possibly reduce the fluctuations of the demand and supply of (renewable) energy as it enables the TABS to react to the dynamics of weather and its impact on the grid at any time.
Combined heat and power production (CHP) based on solid oxide fuel cells (SOFC) is a very promising technology to achieve high electrical efficiency to cover power demand by decentralized production. This paper presents a dynamic quasi 2D model of an SOFC system which consists of stack and balance of plant and includes thermal coupling between the single components. The model is implemented in Modelica® and validated with experimental data for the stack UI-characteristic and the thermal behavior. The good agreement between experimental and simulation results demonstrates the validity of the model. Different operating conditions and system configurations are tested, increasing the net electrical efficiency to 57% by implementing an anode offgas recycle rate of 65%. A sensitivity analysis of characteristic values of the system like fuel utilization, oxygen-to-carbon ratio and electrical efficiency for different natural gas compositions is carried out. The result shows that a control strategy adapted to variable natural gas composition and its energy content should be developed in order to optimize the operation of the system.
In the course of the last few years, our students are becoming increasingly unhappy. Sometimes they stop attending lectures and even seem not to know how to behave correctly. It feels like they are getting on strike. Consequently, drop-out rates are sky-rocketing. The lecturers/professors are not happy either, adopting an “I-don’t-care” attitude.
An interdisciplinary, international team set in to find out: (1) What are the students unhappy about? Why is it becoming so difficult for them to cope? (2) What does the “I-don’t-care” attitude of professors actually mean? What do they care or not care about? (3) How far do the views of the parties correlate? Could some kind of mutual understanding be achieved?
The findings indicate that, at least at our universities, there is rather a long way to go from “Engineering versus Pedagogy” to “Engineering Pedagogy”.
Three real-lab trigeneration microgrids are investigated in non-residential environments (educational, office/administrational, companies/production) with a special focus on domain-specific load characteristics. For accurate load forecasting on such a local level, à priori information on scheduled events have been combined with statistical insight from historical load data (capturing information on not explicitly-known consumer behavior). The load forecasts are then used as data input for (predictive) energy management systems that are implemented in the trigeneration microgrids. In real-world applications, these energy management systems must especially be able to carry out a number of safety and maintenance operations on components such as the battery (e.g. gassing) or CHP unit (e.g. regular test runs). Therefore, energy management systems should combine heuristics with advanced predictive optimization methods. Reducing the effort in IT infrastructure the main and safety relevant management process steps are done on site using a Smart & Local Energy Controller (SLEC) assisted by locally measured signals or operator given information as default and external inputs for any advanced optimization. Heuristic aspects for local fine adjustment of energy flows are presented.
A former remote area power supply was converted to a smart cogeneration subnet with combined heat and power to develop and validate a forecast based energy management at the University of Applied Sciences in Offenburg/Germany. Locally processed weather forecasts and forecasted demand profiles are integrated to allow a precise reaction to changes of fluctuating power sources, changes in scheduled demand profiles and to improve the energy efficiency of the supply. The management of the electrical and thermal storages is influenced by the forecasted energy contributions and the forecasted demand. Further approaches should improve the accuracy of forecasting algorithms and integrate parameter models gained of a detailed monitoring to realize predictive controllers.
Modelling and Simulation of Microscale Trigeneration Systems Based on Real- Life Experimental Data
(2017)
For the shift of the energy grid towards a smarter decentralised system flexible microscale trigeneration systems will play an important role due to their ability to support the demand side management in buildings. However to harness their potential modern control methods like model predictive control must be implemented for their optimal scheduling and control. To implement such supervisory control methods, first, simple analytical models representing the behaviour of the components need to be developed. At the Institute of Energy System Technologies in Offenburg we have built a real-life microscale trigeneration plant and present in this paper the models based on experimental data. These models are qualitatively validated and their application in the future for the optimal scheduling problem is briefly motivated.
In diesem Beitrag wird die Anwendbarkeit von bereits in der Literatur beschriebenen und in der Praxis bewährten Entlastungsgeometrien für Wellenabsätze auf Zahnwellen mit freiem Auslauf mit der Methode der Finiten Elemente FEM untersucht. Dabei zeigte sich, dass eine direkte Verwendung der bestehenden Vorschläge nicht immer möglich war. Deshalb wurden diese Entlastungsnuten und -übergänge für eine beanspruchungsgerechte Anwendung im Bereich der Zahnwellen modifiziert und optimiert. Basierend auf den dabei erzielten Ergebnissen wurden neue konstruktive Möglichkeiten zur günstigsten Ausprägung der freien Auslaufgestaltung entwickelt und erforscht. Der beobachtete merkliche Abfall der Kerbspannung infolge von Entlastungsmöglichkeiten soll dem Konstrukteur einen Anlass geben, diese häufiger anzuwenden. Die Industrie, insbesondere kleinere Betriebe, können mithilfe der in diesem Aufsatz vorliegenden Erkenntnisse durch optimierte Dimensionierung der Profiwellen Kosten und Bauteilgewicht sparen.