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In order to maximize the possible travel distance of battery electric vehicles with one battery charge, it is mandatory to adjust all components of the powertrain carefully to each other. While current vehicle designs mostly simplify the powertrain rigorously and use an electric motor in combination with a gearbox with only one fixed transmission ratio, the use of multi-gear systems has great potential. First, a multi-speed system is able to improve the overall energy efficiency. Secondly, it is able to reduce the maximum momentum and therefore to reduce the maximum current provided by the traction battery, which results in a longer battery lifetime. In this paper, we present a systematic way to generate multi-gear gearbox designs that—combined with a certain electric motor—lead to the most efficient fulfillment of predefined load scenarios and are at the same time robust to uncertainties in the load. Therefore, we model the electric motor and the gearbox within a Mixed-Integer Nonlinear Program, and optimize the efficiency of the mechanical parts of the powertrain. By combining this mathematical optimization program with an unsupervised machine learning algorithm, we are able to derive global-optimal gearbox designs for practically relevant momentum and speed requirements.
The utilization of phase change material (PCM) for latent heat storage and thermal control of spacecraft has been demonstrated in the past in few missions only. One limiting factor was the fact that all concepts developed so far envisioned the PCM to be applied as an additional capacitor, encapsulated in its own housing, leading to mass, efficiency and accommodation challenges. Recently, the application of PCM within the scan cavity of a GEOS type satellite has been suggested, in order to tackle thermal issues due to direct sun intrusion (Choi, M., 2014). However, the application of PCM in such complex mechanical structures is extremely challenging. A new concept to tackle this issue is currently under development at the FH Aachen University of Applied Sciences. The concept "Infused Thermal Solutions (ITS)" is based on the idea to 3D print metallic structures in their regular functional shape, but double walled with internal lattice support structures, allowing the infusion of a PCM layer directly into the voids and eliminating the need for additional parts and interfaces. Together with OHB System, FH Aachen theoretically studied the application of this technology to the Meteosat Third Generation (MTG) Infra-Red Sounder (IRS) instrument. The study focuses on the scan cavity and entrance baffling assembly (EBA) of the IRS. It consists of thermal analyses, 3D-redesign and bread boarding of a scaled and PCM infused EBA version. In the thermal design of the alternative EBA, PCM was applied directly into the EBA, simulating the worst hot case sun intrusion of the mission. By applying 4kg of PCM (to a 60kg baffle) the EBA temperature excursions during sun intrusion were limited from 140K to 30K, leading to a significant thermo-opto-elastic performance gain. This paper introduces the ITS concept development status.
The optical performance of a 2-axis solar concentrator was simulated with the COMSOL Multiphysics® software. The concentrator consists of a mirror array, which was created using the application builder. The mirror facets are preconfigured to form a focal point. During tracking all mirrors are moved simultaneously in a coupled mode by 2 motors in two axes, in order to keep the system in focus with the moving sun. Optical errors on each reflecting surface were implemented in combination with the solar angular cone of ± 4.65 mrad. As a result, the intercept factor of solar radiation that is available to the receiver was calculated as a function of the transversal and longitudinal angles of incidence. In addition, the intensity distribution on the receiver plane was calculated as a function of the incidence angles.
The 2012 Emilia-Romagna earthquake, that mainly struck the homonymous Italian region provoking 28 casualties and damage to thousands of structures and infrastructures, is an exceptional source of information to question, investigate, and challenge the validity of seismic fragility functions and loss curves from an empirical standpoint. Among the most recent seismic events taking place in Europe, that of Emilia-Romagna is quite likely one of the best documented, not only in terms of experienced damages, but also for what concerns occurred losses and necessary reconstruction costs. In fact, in order to manage the compensations in a fair way both to citizens and business owners, soon after the seismic sequence, the regional administrative authority started (1) collecting damage and consequence-related data, (2) evaluating information sources and (3) taking care of the cross-checking of various reports. A specific database—so-called Sistema Informativo Gestione Europa (SFINGE)—was devoted to damaged business activities. As a result, 7 years after the seismic events, scientists can rely on a one-of-a-kind, vast and consistent database, containing information about (among other things): (1) buildings’ location and dimensions, (2) occurred structural damages, (3) experienced direct economic losses and (4) related reconstruction costs. The present work is focused on a specific data subset of SFINGE, whose elements are Long-Span-Beam buildings (mostly precast) deployed for business activities in industry, trade or agriculture. With the available set of data, empirical fragility functions, cost and loss ratio curves are elaborated, that may be included within existing Performance Based Earthquake Engineering assessment toolkits.
The results of a statistical investigation of 42 fixed-wing, small to medium sized (20 kg−1000 kg) reconnaissance unmanned air vehicles (UAVs) are presented. Regression analyses are used to identify correlations of the most relevant geometry dimensions with the UAV’s maximum take-off mass. The findings allow an empirical based geometry-build up for a complete unmanned aircraft by referring to its take-off mass only. This provides a bridge between very early design stages (initial sizing) and the later determination of shapes and dimensions. The correlations might be integrated into a UAV sizing environment and allow designers to implement more sophisticated drag and weight estimation methods in this process. Additional information on correlation factors for a rough drag estimation methodology indicate how this technique can significantly enhance the accuracy of early design iterations.
A hybrid-electric propulsion system combines the advantages of fuel-based systems and battery powered systems and offers new design freedom. To take full advantage of this technology, aircraft designers must be aware of its key differences, compared to conventional, carbon-fuel based, propulsion systems. This paper gives an overview of the challenges and potential benefits associated with the design of aircraft that use hybrid-electric propulsion systems. It offers an introduction of the most popular hybrid-electric propulsion architectures and critically assess them against the conventional and fully electric propulsion configurations. The effects on operational aspects and design aspects are covered. Special consideration is given to the application of hybrid-electric propulsion technology to both unmanned and vertical take-off and landing aircraft. The authors conclude that electric propulsion technology has the potential to revolutionize aircraft design. However, new and innovative methods must be researched, to realize the full benefit of the technology.
Rapid Tooling
(2019)
The chapter initially provides a summary of the contents of Eurocode 8, its aim being to offer both to the students and to practising engineers an easy introduction into the calculation and dimensioning procedures of this earthquake code. Specifically, the general rules for earthquake-resistant structures, the definition of design response spectra taking behaviour and importance factors into account, the application of linear and non-linear calculation methods and the structural safety verifications at the serviceability and ultimate limit state are presented. The application of linear and non-linear calculation methods and corresponding seismic design rules is demonstrated on practical examples for reinforced concrete, steel and masonry buildings. Furthermore, the seismic assessment of existing buildings is discussed and illustrated on the example of a typical historical masonry building in Italy. The examples are worked out in detail and each step of the design process, from the preliminary analysis to the final design, is explained in detail.
Industrial units consist of the primary load-carrying structure and various process engineering components, the latter being by far the most important in financial terms. In addition, supply structures such as free-standing tanks and silos are usually required for each plant to ensure the supply of material and product storage. Thus, for the earthquake-proof design of industrial plants, design and construction rules are required for the primary structures, the secondary structures and the supply structures. Within the framework of these rules, possible interactions of primary and secondary structures must also be taken into account. Importance factors are used in seismic design in order to take into account the usually higher risk potential of an industrial unit compared to conventional building structures. Industrial facilities must be able to withstand seismic actions because of possibly wide-ranging damage consequences in addition to losses due to production standstill and the destruction of valuable equipment. The chapter presents an integrated concept for the seismic design of industrial units based on current seismic standards and the latest research results. Special attention is devoted to the seismic design of steel thin-walled silos and tank structures.
Manufacturing Process Simulation for the Prediction of Tool-Part-Interaction and Ply Wrinkling
(2019)
In this paper, an approach to propulsion system modelling for hybrid-electric general aviation aircraft is presented. Because the focus is on general aviation aircraft, only combinations of electric motors and reciprocating combustion engines are explored. Gas turbine hybrids will not be considered. The level of the component's models is appropriate for the conceptual design stage. They are simple and adaptable, so that a wide range of designs with morphologically different propulsive system architectures can be quickly compared. Modelling strategies for both mass and efficiency of each part of the propulsion system (engine, motor, battery and propeller) will be presented.
Flexible Fuel Operation of a Dry-Low-Nox Micromix Combustor with Variable Hydrogen Methane Mixtures
(2019)
Application of Low NOx Micro-mix Hydrogen Combustion to 2MW Class Industrial Gas Turbine Combustor
(2019)
Though weir flow has been studied for centuries, there still remains some nuances of weir flow that are not well understood. Therefore, an international study was conducted in which 20 different hydraulics laboratories from around the world built and tested two linear weirs (quarter-round and half-round crested weirs) of common geometry. The only unconstrained dimension was the weir length, which could be adjusted to match the width of the test flume. Participating laboratories used the instrumentation and data collection methodologies of their choosing for head and discharge measurements.
The experimental results found significant variability in the discharge coefficients as a function of dimensionless upstream head, as well as in the head-discharge relationships (as much as 50% in some cases). Potential sources contributing to the scatter may have included head meter instrumentation, flow meter instrumentation, approach flow length (flume length upstream of weir), head measurement location, nappe behavior, laboratory measurement methods and experimental setup, and the care and skill of the investigator (human error). Analyzing the data as a function of instrumentation types, approach length, and head measurement location did not provide any insight regarding the variations. Nappe behavior (e.g., aeration), which could be influenced by laboratory-specific conditions, varied among the datasets primarily for the half-round crested weir (about 20%).
Sensitivity Analysis of General Aviation Aircraft with Parallel Hybrid-Electric Propulsion Systems
(2019)
Laser-based Additive Manufacturing (AM) processes for the use of metals out of the powder bed have been investigated profusely and are prevalent in industry. Although there is a broad field of application, Laser Powder Bed Fusion (LPBF), also known as Selective Laser Melting (SLM) of glass is not fully developed yet. The material properties of glass are significantly different from the investigated metallic material for LPBF so far. As such, the process cannot be transferred, and the parameter limits and the process sequence must be redefined for glass. Starting with the characterization of glass powders, a parameter field is initially confined to investigate the process parameter of different glass powder using LPBFprocess. A feasibility study is carried out to process borosilicate glass powder. The effects of process parameters on the dimensional accuracy of fabricated parts out of borosilicate and hints for the post-processing are analysed and presented in this paper.