The thesis deals with vibrations caused by geometric defect and fatigue damage of rolling element bearing. Hardware for vibration measurement is tested on 25 new pieces of NJ 304. Second part of the thesis examines if measuring of bearing vibration can help to detect a geometric defect. Geometric defects are detected according to a spectrum of vibration but the results are not absolutely exact. The possibility to detect geometric defects by measuring vibration has not been proven. The end of project tests diagnostic methods for rolling element bearings. The bearing defect was simulated to demonstrate bearing failure frequencies, envelope method and vibration spectrum.

Diploma thesis aims on mechanical design of new concept of Zetor UŘ III engine with displacement increase and solves calculations of main and pin hydrodynamic bearings of crankshaft. Creo 2 CAD software is used for preparing mechanical design of this new concept. For computation and analysis of hydrodynamic bearings multibody model of crankshaft mechanism is used with flexible FEM model of crankshaft for solving dynamics of mechanism and performing hydrodynamic analysis of bearings in FEV Virtual Engine. Results of this diploma thesis demonstrate the feasibility of new concept of engine and serve as a basis for next engineering tasks before realization of concept.

This master’s thesis deals with design of spindle for small three axis milling machine. The first part of this thesis includes research in milling spindles and overview of several spindles from different manufacturers. The second part deals with calculation of necessary parameters, design of spindle and subsequent simulation verification. This thesis also includes a 3D model of spindle, assembly drawing and four manufacturing drawings.

Diploma thesis is aimed on construction design of single cylinder four stroke engine. Conception of engine with cylinder capacity 450 cm3 meets the rules of Enduro E2 class and is adapt for application for motorcycle with extremely long swing arm according to the patent owned by Ing. Frantisek Krnavek. In the beginning of this thesis is analysis of engines this category and specific engine layouts in the motorcycles. After is design and simulation of engine parameters from which are created and described 3D models of engine parts. Conclusion is about durability calculation of main bearings.

Die quantitative Abschätzung des Einflusses geometrischer Abweichungen auf die Betriebseigenschaften von Maschinenelementen stellt für die Produktentwicklung einen wesentlichen Bestandteil zur Sicherung der Funktionalität dar. An einem radialen zylindrischen Gleitlager wird gezeigt, wie der Einfluss der Rundheit in Form eines Gleichdickes die Betriebsparameter verändert. Durch die Simulation mit ALP3T und die Auswertung der Ergebnisse mit MATLAB kann eine mögliche Vorgehensweise für den Umgang mit Formabweichungen bei der Entwicklung und der Qualitätssicherung aufgezeigt werden. Ferner gilt es andere geometrische Abweichungen (Position, Richtung) zu untersuchen, um die Funktionalität des Gesamtsystems sicherzustellen.

The choice of the topic addressed in this thesis aims to improve the service and maintenance on ceramic ball bearings in a specific test dynamometer and through an engineering approach develop tools for condition monitoring. The company connected to this thesis, AVL, is the world's largest privately owned company for development, simulation and testing technology of powertrains for passenger cars, trucks and large engines. Engine testing is a critical part of the business at AVL Sweden and unexpected bearing failure can result in long repair times and great economic losses due to loss of the testing time. In short terms, the methodological approach followed the following steps; first a thorough information retrieval regarding bearings and analysis was conducted. The search was deepened around areas such as hybrid ball bearings, bearing failure mechanisms, bearing defect frequencies, signal analysis and condition monitoring. After this a table for bearing damage detection was developed and a “step by step” guidance for condition monitoring. The tools where afterwards verified by simple testing to detect complications within the chosen system. The existing condition monitoring system that is used today revealed weaknesses as it lacked the feature of taking preventive measures. The system that is based on temperature measurements isn’t satisfactory enough, especially when it’s missing visual clarity. Service and maintenance according to specifications from the manufacturer should be scheduled to ensure operational and guarantees. Currently mounted accelerometers on the housing of the Dynas3 engine should be connected for collecting data and the total sum of energy should be calculated for simple monitoring of historical progression. This should be done by following the guidance in order to ensure proper data acquisition. The best way to implement condition monitoring showed to be by performing multi-parameter monitoring. The design of the condition monitoring system is highly connected to what to monitor and at what stage. One main consideration to keep in mind is that it’s very rare that manufacturing defects are the reason for bearing failure. Instead it derives from improper storage, transport, handling or dimensional errors and even in some cases by improperly implemented force analysis prior to bearing selection. / Huvudämnet som behandlas i detta examensarbete syftar till att förbättra service och underhåll på keramiska kullager i en viss testdynamometer och genom ett ingenjörsmässigt tillvägagångsätt utveckla verktyg för tillståndsövervakning. Företaget som är ansluten till detta examensarbete är AVL som är världens största privatägda företag för utveckling, simulering och testteknik för drivlinor för personbilar, lastbilar och stora motorer. Motorprovning är en viktig del av verksamheten vid AVL Sverige, och ett oväntat lagerhaveri kan leda till långa reparationstider och stora ekonomiska förluster på grund av utebliven test tid. I korta termer följde den metod som använts följande steg, först genomfördes en grundlig informationssökning om lager och tillhörande analyser. Efter det fördjupades sökande kring områden som hybrida kullager, lagerskademekanismer, frekvenser kopplade till lagerskador, signalanalys och tillståndsövervakning. Efter detta framställdes en tabell för detektering av lagerskador, samt en ”steg för steg” guide för tillståndsövervakning. Verktygen för tillståndsövervakning kontrolleras efteråt, genom att enkla tester genomfördes för att upptäcka komplikationer inom det valda systemet. Det övervakningssystem som används idag avslöjade svagheter genom att sakna funktionen att vidta förebyggande åtgärder. System som är baserat på temperaturmätningar är inte tillräckligt tillfredsställande, speciellt när det saknar en visuell tydlighet. Den service och underhåll som enligt tillverkarens föreskrifter påvisas bör planeras för att säkerställa drift och garantier. Nuvarande monterade accelerometrar fästa vid motorhöljet bör anslutas för att insamla data, och den totala summan av energin bör beräknas för en enkel övervakning av det historiska utvecklingsförloppet. Detta bör göras genom att följa de riktlinjer som framställts för att säkerställa korrekt datainsamling. Det bäst passande sättet att genomföra tillståndsövervakning på i detta fall visade sig vara att utföra multiparameterövervakning. Framställningen av tillståndsövervakningssystemet är starkt förknippat med vad som skall övervakas och i vilket skede. En huvudsaklig bidragande faktor att komma ihåg är att det är mycket ovanligt att fabrikationsfel är orsaken till lagerhaveri. Istället härstammar haveriet från felaktig förvaring, transportering, hantering eller dimensioneringsfel och i vissa fall av felaktigt genomförd kraftanalys inför lagerval.

The field of monitoring is one of rapid development. Advances in sensor technologies, in data communication paradigms and data processing algorithms all influence the possibilities of Structural Health Monitoring, damage detection, traffic monitoring and other implementations of monitoring systems. Bridges are a very critical part of a country’s infrastructure, they are expensive to build and maintain, and many uncertainties surround important factors determining the serviceability and deterioration of bridges. As such, bridges are good candidates for monitoring. Monitoring can extend the service life and avoid or postpone replacement, repair or strengthening work. Many bridges constitute a bottleneck in the transport network they serve with few or no alternative routes. The amount of resources saved, both to the owner and the users, by reducing the amount of non-operational time can easily justify the extra investment in monitoring. This thesis consists of an extended summary and three appended papers. The thesis presents advances in sensor technology, damage identification algorithms and Bridge Weigh-In-Motion techniques. Two case studies are carried out. In the first a bridge and traffic monitoring system is implemented in a highway suspension bridge to study the cause of unexpected wear in the bridge bearings. In the second a fully operational Bridge Weigh-In-Motion system is developed and deployed in a steel railway bridge. The gathered data was studied to obtain a characterization of the site specific traffic. / QC 20111122

Die Dynamik von axialen Magnetlagern ist im besonderen Maße von den eingesetzten Materialien abhängig. Axiale Flussverläufe machen eine Blechung von Stator und Rotor unwirksam und hohe induzierte Spannungen rufen im Magnetkreis wirbelstrombedingte Gegenfelder hervor. Zusätzliche kompensierende Magnetisierungsströme lassen den messbaren Strom der Steuerspule dem kraftbildenden Hauptfluss vorauseilen. Durch Einsatz von Pulververbundwerkstoffen lässt sich dieser Effekt reduzieren. Aus mechanischen Gründen wird die rotierende Axiallager-Scheibe in konventionellen Anwendungen dennoch aus Stahl gefertigt. In dieser Diplomarbeit werden alternative Materialien und Ausführungsformen untersucht und die auftretenden Unterschiede im dynamischen Verhalten mit der Eisenkreiszeitkonstante quantifiziert. Neben dem zu Grunde liegenden analytischen Modell soll eine fortgeschrittene Systembeschreibung vorgestellt werden, die das atypische Übertragungsverhalten der Regelstrecke berücksichtigt. Dieses setzt sich aus Differenziergliedern gebrochen-rationaler Ordnung zusammen und bildet ein sogenanntes „Fractional-Order-System“. Die Modelle werden mittels FEM-Simulationen und Experimenten am eigens konstruierten Versuchslager verifiziert. / The dynamics of axial magnetic bearings are characterized by an above-average dependency on the used materials. Axially directed fields render laminated stators and rotors ineffective. High induced voltages inside the magnetic core evoke eddy currents and opposing fields, which are compensated by an additional magnetizing current. Therefore a significant delay between the measurable coil current and the force-related magnetic flux is observed. The use of soft magnetic composites can minimize this effect, though the bearing disk usually is manufactured from conventional steel for mechanical reasons in a wide range of applications. In this diploma thesis alternative materials and embodiments are considered and the occurring differences regarding the dynamic behavior will be quantified by means of the magnetic circuit time constant. Beside its underlying analytical model, an advanced system description is introduced to include the atypical transfer function of the closed loop control system, characterized by so-called Fractional-Order-Derivatives. All models will be verified by FE-analysis and experiments on a newly constructed magnetic bearing.

Dans l’industrie manufacturière, la consommation d’énergie électrique est considérée comme l'un des problèmes majeurs qui est malheureusement liée systématiquement à l'émission de gaz contenant du dioxyde de carbone et amenant à l’effet de serre. Des études sur l’estimation de l’énergie électrique consommée par les machines outils sont développées par des chercheurs au cours des dernières décennie pour proposer des modèles d’estimation de cette énergie. Ces modèles sont soit empiriques soit théoriques et se limitent à tenir compte du comportement dynamique du système de coupe lors des opérations d’usinage. La contribution fondamentale de cette thèse de doctorat est la caractérisation du comportement non linéaire des efforts de coupe et du système de guidage lors de l’estimation de l’énergie consommée par une machine outil. La modélisation repose sur la détermination de l’effort de coupe et de l’effort des roulements qui sont variables en fonction du temps et qui sont déduites de l’écriture de l’équation de mouvement du système (broche ou machine-outil)discrétisé en éléments finis en utilisant la méthode de Newark couplée avec l’algorithme de Newton Raphson. Ces efforts de coupe et de roulements sont utilisés pour calculer la puissance puis l’énergie consommée par la table d’avance, la broche et par conséquent la machine outil. Afin de valider notre approche, la puissance et l’énergie obtenues à partir du modèle développé sont comparées avec la puissance et l’énergie obtenues avec un dispositif expérimental. Une étude paramétrique est réalisée pour mettre l’accent sur l’impact de la variation des paramètres de coupe sur la valeur de la puissance et de l’énergie consommées. On introduit par la suite des défauts d’usure et de montage au niveau des roulements et nous présentons leurs impacts sur le comportement énergétique de la machine. Une attention particulière a également été consacrée à développer un modèle d’optimisation des mouvement d’une machine outil globale minimisant à la fois l’énergie consommée, le temps de production, le coût et la rugosité de surface en respectant les consignes technologiques. / In manufacturing, the electrical energy consumption is considered as one of the major problems which are systematically related to the gas emission containing carbon dioxide and leading to the greenhouse effect. Studies based on the estimation of the machine tools energy consumption become the interest of researchers in recent decades.As a result, different models for energy estimating are developed in order to minimize the quantity of consumed energy. These models are either empirical or theoretical and are limited to taking into account the dynamic behavior of the cutting system during machining operations. The fundamental contribution of this doctoral thesis is the characterization of the nonlinear behavior of cutting and rolling forces during estimating the consumed energy by a machine tool. The developed approach is based on the determination of the variable cutting forces and bearings forces which are function of time. These forces are deduced by solving the equation of motion based on finite element method using Newark's method coupled with Newton Raphson's algorithm. These forces are used to calculate the power then the consumed energy by the axis feed, the spindle and therefore the machine tool. In order to validate our approach, the power and energy obtained from the model developed are compared with the power and energy obtained with an experimental device. A parametric study is carried out to focus on the impact of the variation of the cutting parameters on the value of the consumed power and energy. An interest is given for different types of defect (innerring spalling, outer ring spalling, eccentricity and unbalance) in order to study their impact on the spindle consumed power during approach and cutting phases under different rotating conditions. Particular attention has also been devoted to develop a global model for optimizing machine too lmovements that minimizes the consumed energy, the production time, the cost and the surface roughness with respect of the technological constraints.

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