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A smart energy concept was designed and implemented for a cluster of 5 existing multi-family houses, which combines heat pumps, photovoltaic (PV) modules and combined heat and power units (CHP) to achieve energy- and cost-efficient operation. Measurement results of the first year of operation show that the local power generation by PV modules and CHP unit has a positive effect on the electrical self-sufficiency by reducing electricity import from the grid. In winter, when the CHP unit operates continuously for long periods, the entire electricity for the heat pump and 91 % of the total electricity demand of the neighborhood are supplied locally. In summer, only 53 % is generated within the neighborhood. The use of a specifically developed energy management system EMS is intended to further increase this share. CO2 emissions for heating and electricity of the neighborhood are evaluated and amount to 18.4 kg/(m2a). Compared to the previous energy system consisting of gas boilers (29.1 kg/(m2a)), savings of 37 % are achieved with electricity consumption from the grid being reduced by 65 %. In the second construction stage, an additional heat pump, CHP unit and PV modules will be added. The measurement results indicate that the final district energy system is likely to achieve the ambitious CO2 reduction goal of -50% and further increase the self-sufficiency of the district.
The paper compares different anti-windup strategies for the current control of inverter-fed permanent magnet synchronous machines (PMSM) controlled by pulse-width modulation. In this respect, the focus is on the drive behavior with a relatively large product of stator frequency and sampling time. A requirement for dynamically high-quality anti-windup measures is, among other things, a sufficiently accurate decoupling of the stator current direct axis and quadrature axis components even at high stator frequencies. Discrete-time models of the electrical subsystem of the PMSM are well suited for this purpose, of which the method found to be the most accurate in a preliminary investigation is used as the basis for all anti-windup methods examined. Simulation studies and measurement results document the performance of the compared methods.
In this paper we report on further success of our work to develop a multi-method energy optimization which works with a digital twin concept. The twin concept serves to replicate production processes of different kinds of production companies, including complex energy systems and test market interactions to then use them for model predictive optimizing. The presented work finally reports about the performed flexibility assessment leading to a flexibility audit with a list of measures and the impact of energy optimizations made related to interactions with the local power grid i.e., the exchange node of the low voltage distribution grid. The analysis and continuous exploration of flexibilities as well as the exchange with energy markets require a “guide” leading to continuous optimization with a further tool like the Flexibility Survey and Control Panel helping decision-making processes on the day-ahead horizon for real production plants or the investment planning to improve machinery, staff schedules and production
infrastructure.
Turbocharger housings in internal combustion engines are subjected to severe mechanical and thermal cyclic loads throughout their life-time or during engine testing. The combination of thermal transients and mechanical load cycling results in a complex evolution of damage, leading to thermo-mechanical fatigue (TMF) of the material. For the computational TMF life assessment of high temperature components, the DTMF model can provide reliable TMF life predictions. The model is based on a short fatigue crack growth law and uses local finite-element (FE) results to predict the number of cycles to failure for a technical crack. In engine applications, it is nowadays often acceptable to have short cracks as long as they do not propagate and cause loss of function of the component. Thus, it is necessary to predict not only potential crack locations and the corresponding number of cycles for a technical crack, but also to determine subsequent crack growth or even a possible crack arrest. In this work, a method is proposed that allows the simulation of TMF crack growth in high temperature components using FE simulations and non-linear fracture mechanics (NLFM).
A NLFM based crack growth simulation method is described. This method starts with the FE analysis of a component. In this paper, the method is demonstrated for an automotive turbocharger housing subjected to TMF loading. A transient elastic-viscoplastic FE analysis is used to simulate four heating and cooling cycles of an engine test. The stresses, inelastic strains, and temperature histories from the FEA are then used to perform TMF life predictions using the standard DTMF model. The crack position and the crack plane of critical hotspots are then identified. Simulated cracks are inserted at the hotspots. For the model demonstrated, cracks were inserted at two hotspot locations. The ΔJ integral is computed as a fracture mechanics parameter at each point along the crack-front, and the crack extension of each point is then evaluated, allowing the crack to grow iteratively. The paper concludes with a comparison of the crack growth curves for both hotspots with experimental results.
Cast aluminum cylinder blocks are frequently used in gasoline and diesel internal combustion engines because of their light-weight advantage. However, the disadvantage of aluminum alloys is their relatively low strength and fatigue resistance which make aluminum blocks prone to fatigue cracking. Engine blocks must withstand a combination of low-cycle fatigue (LCF) thermal loads and high-cycle fatigue (HCF) combustion and dynamic loads. Reliable computational methods are needed that allow for accurate fatigue assessment of cylinder blocks under this combined loading. In several publications, the mechanism-based thermomechanical fatigue (TMF) damage model DTMF describing the growth of short fatigue cracks has been extended to include the effect of both LCF thermal loads and superimposed HCF loadings. This approach is applied to the finite life fatigue assessment of an aluminum cylinder block. The required material properties related to LCF are determined from uniaxial LCF tests. The additional material properties required for the assessment of superimposed HCF are obtained from the literature for similar materials. The predictions of the model agree well with engine dyno test results. Finally, some improvements to the current process are discussed.
To improve the building’s energy efficiency many parameters should be assessed considering the building envelope, energy loads, occupation, and HVAC systems. Fenestration is among the most important variables impacting residential building indoor temperatures. So, it is crucial to use the most optimal energy-efficient window glazing in buildings to reduce energy consumption and at the same time provide visual daylight comfort and thermal comfort. Many studies have focused on the improvement of building energy efficiency focusing on the building envelope or the heating, ventilation, and cooling systems. But just a few studies have focused on studying the effect of glazing on building energy consumption. Thus, this paper aims to study the influence of different glazing types on the building’s heating and cooling energy consumption. A real case study building located under a semi-arid climate was used. The building energy model has been conducted using the OpenStudio simulation engine. Building indoor temperature was calibrated using ASHRAE’s statistical indices. Then a comparative analysis was conducted using seven different types of windows including single, double, and triple glazing filled with air and argon. Tripleglazed and double-glazed windows with argon space offer 37% and 32% of annual energy savings. It should be stressed that the methodology developed in this paper could be useful for further studies to improve building energy efficiency using optimal window glazing.
The variable refrigerant flow system is one of the best heating, ventilation, and air conditioning systems (HVAC) thanks to its ability to provide thermal comfort inside buildings. But, at the same time, these systems are considered one of the most energy-consuming systems in the building sector. Thus, it is crucial to well size the system according to the building’s cooling and heating needs and the indoor temperature fluctuations. Although many researchers have studied the optimization of the building energy performance considering heating or cooling needs, using air handling units, radiant floor heating, and direct expansion valves, few studies have considered the use of multi-objective optimization using only the thermostat setpoints of VRF systems for both cooling and heating needs. Thus, the main aim of this study is to conduct a sensitivity analysis and a multi-objective optimization strategy for a residential building containing a variable refrigerant flow system, to evaluate the effect of the building performance on energy consumption and improve the building energy efficiency. The numerical model was based on the EnergyPlus, jEPlus, and jEPlus+EA simulation engines. The approach used in this paper has allowed us to reach significant quantitative energy saving by varying the cooling and heating setpoints and scheduling scenarios. It should be stressed that this approach could be applied to several HVAC systems to reduce energy-building consumption.
Plastics are used today in many areas of the automotive, aerospace and mechanical engineering industries due to their lightweight potential and ease of processing. Additive manufacturing is applied more and more frequently, as it offers a high degree of design freedom and eliminates the need for complex tools. However, the application of additively manufactured components made of plastics have so far been limited due to their comparatively low strength. For this reason, processes that offer additional reinforcement of the plastic matrix using fibers made of high-strength materials have been developed. However, these components represent a composite of different materials produced on the basis of fossil raw materials, which are difficult to recycle and generally not biodegradable.
Therefore, this paper will explore the potential for new composite materials whose matrix consists of a bio-based plastic. In this investigation, it is assumed that the matrix is reinforced with a fibrous material made of natural fiber to significantly increase the strength. This potential material should offer a lightweight yet strong structure and be biodegradable after use under controlled conditions. Therefore, the state of the art in the use of bio-based materials in 3D printing is first presented. In order to determine the economic boundary conditions, the growth potentials for bio-based materials are analyzed. Also, the recycling prospects for bio-based plastics will also be highlighted. The greenhouse gas emissions and land use to be expected when using bio-based materials are also estimated. Finally, the degradability of the composites is discussed.
In 4D printing an additively manufactured component is given the ability to change its shape or function under the influence of an external stimulus. To achieve this, special smart materials are used that are able to react to external stimuli in a specific way. So far, a number of different stimuli have already been investigated and initial applications have been impressively demonstrated, such as self-folding bodies and simple grippers. However, a methodical specification for the selection of the stimuli and their implementation was not yet in the foreground of the development.
The focus of this work is therefore to develop a methodical approach with which the technology of 4DP can be used in a solution- and application-oriented manner. The developed approach is based on the conventional design methodology for product development to solve given problems in a structured way. This method is extended by specific approaches under consideration of the 4D printing and smart materials.
To illustrate the developed method, it is implemented in practice using a problem definition in the form of an application example. In this example, which represents the recovery of an object from a difficult-to-access environment, the individual functions of positioning, gripping and extraction are implemented using 4D printing. The material extrusion process is used for additive manufacturing of all components of the example. Finally, the functions are successfully tested. The developed approach offers an innovative and methodical approach to systematically solve technical complex problems using 4DP and smart materials.
4D printing (4DP) is an evolutionary step of 3D printing, which includes the fourth dimension, in this case the time. In different time steps the printed structure shows different shapes, influenced by external stimuli like light, temperature, pH value, electric or magnetic field. The advantage of 4DP is the solution of technical problems without the need for complex internal energy supply via cables or pipes. Previous approaches to 4D printing with magnetoresponsive materials only use materials with limited usability (e.g. hydrogels) and complex programming during the manufacturing process (e.g. using magnets on the nozzle). The 4D printing using unmagnetized particles and the later magnetization allows the use of a standard 3D printer and has the advantage of being easily reproducible and relatively inexpensive for further application. Therefore, a magnetoresponsive feedstock filament is produced which shows elastic and magnetic properties. In a first step, pellets are produced by compounding polymer with magnetic particles. In a second step, those pellets are extruded in form of filament. This filament is printed using a conventional printing system for Material Extrusion (MEX-TRB/P). Various prototypes have been printed, deformed and magnetized, which is called programming. In comparison to shape memory polymers (SMP) the repeatability of the movement is better. The results show the possibilities of application and function of magnetoresponsive materials. In addition, an understanding of the behaviour of this novel material is achieved.