京都大学 / 新制・課程博士 / 博士(工学) / 甲第24845号 / 工博第5162号 / 新制||工||1986(附属図書館) / 京都大学大学院工学研究科機械理工学専攻 / (主査)教授 平山, 朋子, 教授 松原, 厚, 教授 小森, 雅晴 / 学位規則第4条第1項該当 / Doctor of Philosophy (Engineering) / Kyoto University / DFAM

Electric machines are widely used in for instance the automotive industry in electric vehicles and in wind turbines. The electrical machines have mechanical bearings as an integral part used to transmit power and load. In addition, the main function includes reducing friction between interacting surfaces. However, it is one of the most failing machine elements in these machines. To improve operational sustainability and reduce maintenance costs, understanding bearing failure mechanisms under electrical influence is important. One of the main reasons of bearing failure is linked to high frequency power switches typically used to enhance electric machines’ efficiency. The increase in switching rate induces more frequent common mode voltage fluctuations making the system vulnerable to bearing currents. A small voltage difference of a few ten volts can induce significant electric stress on the bearing depending on the lubricant film thickness and related tribological parameters. The electric charge build-up leads to electric current conduction (arc discharge which happens when the voltage exceeds the breakdown voltage) ultimately damaging the bearing. There are different mitigation strategies which are used to restrict bearing currents through grounding or using completely insulative bearings such as ceramic ones. However, at the moment, there are no satisfactory solutions and there is a need for efficient and economical solutions to the problem. On the other hand, various filters are used to reduce the amplitude and its frequency of bearing currents, but they only partly solve the problem. Similarly, the insulative surface coatings provides high electrical resistance but start acting as capacitors. At a sufficiently high voltage difference, the current passes through the system. Therefore, mitigation strategies are still being explored to improve system performance and service-life. To understand the bearing discharge activity and electrical breakdowns, an electrified ball bearing rig is developed with the ability of testing different electrical properties of lubricants and running conditions. To be able to characterize the electrical properties of a bearing, two electrical circuits are designed. Experimental tests are carried out with PAO-15 and an electrical conductivity-enhanced PAO-15/P-SiSO lubricant with addition of ionic liquids. The influence of different tribological parameters such as rotational speed and viscosity are compared with respect to discharge activity. In addition, two fully formulated experimental oils are compared and evaluated in terms of their electrical performance. The bearing is found to be in different states showing electric-field dependent insulation breakdown ranging from resistive to resistive-capacitive to capacitive states. The electric characterization shows a difference between the boundary, mixed and full film lubrication regimes. Conclusively, the electrical behavior of a mechanical bearing is characterized experimentally to understand discharge problem and roadmap solution opportunities.

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<p>Detta examensarbete har utförts på Fläktwoods AB i Växjö, som producerar stora axialfläktar för olika industriapplikationer. Syftet är att öka kunskapen om fettsmorda axiella kullager genom FE analyser.</p><p>Projektet har genomförts i fem delsteg för att avgöra påverkan av en eller några få parametrar i taget. De studerade parametrarna är: elementstorlek, kontaktstyvhet, last, lagergeometri (dvs. oskulation), ickelinjär geometri och ickelinjära materialegenskaper (dvs. plasticitet).</p><p>Slutsatsen är att elementstorleken bör väljas fint nog för att ge ett jämnt resultat men grovt nog för att beräkningstiden skal vara rimlig. Kontaktstyvheten har inte stor, men tydlig, inverkan på kontakttrycket och penetrationen. Förändringar av oskulationen leder till förändringar i kontaktellipsens form medan olika laster inte påverkar formen på ellipsen, utan snarare storleken. När det handlar om plasticitet är sträckgränsen den viktigaste faktorn att beakta.</p> / <p>This thesis project was carried out at Fläktwoods AB in Växjö who produces large axial fans for different industry applications. The purpose is to increase the knowledge of grease lubricated axial ball bearings through FE analyses.</p><p>The project was executed into five sub steps to determine the influence of one or few parameters at a time. The studied parameters are: mesh density, contact stiffness, load, bearing geometry (i.e. osculation), geometrical nonlinearity and material nonlinearity (i.e. plasticity).</p><p>It is concluded that the mesh density should be selected fine enough to give a smooth result but course enough to give a reasonable calculation time. The contact stiffness has not a major, but a clear, impact on the contact pressure and penetration. Changes of the osculation lead to changes of the contact ellipse shape and applying different load level does not affect the shape of the ellipse but rather the size. When dealing with plasticity the yield strength is the most important factor to take in consideration.</p>

Ce travail de recherche s'inscrit dans le cadre de la surveillance des machines tournantes en régime non stationnaire et plus particulièrement la détection des défauts de roulement. Il se focalise sur la modélisation et l'analyse des variations de la vitesse de rotation instantanée. Les modèles numériques développés s'appuient sur une approche originale dite " angulaire " qui introduit explicitement les degrés de rotation libres de la machine et permet de s'affranchir de condition de fonctionnement en régime stationnaire. Un modèle de roulement à billes à gorge profonde a été développé couplant les efforts de contact normaux et tangentiels grâce à l'introduction du phénomène de résistance au roulement. Ce couplage permet d'expliquer l'origine des fluctuations de vitesse de rotation en présence de défaut de bague extérieure, phénomènes constatés expérimentalement : la présence d'un défaut sur une bague modifie périodiquement le couple de frottement. La modélisation de la liaison par engrenages est plus classique, la problématique a été de s'assurer qu'elle était compatible avec l'approche angulaire utilisée dans ces travaux. Le couplage des éléments de roulement et d'engrenage dans un modèle simple a montré que la présence de défauts de roulement provoque des variations des efforts radiaux ce qui modifie les efforts d'engrènement et en conséquence perturbe également la vitesse de rotation. Un modèle simplifié d'une éolienne a été réalisé et utilisé pour tester et valider des indicateurs spectraux de surveillance en conditions de fonctionnement non stationnaires. La comparaison avec des mesures expérimentales issues d'une éolienne a montré la robustesse du modèle. Il peut donc être exploité comme un outil d'analyse phénoménologique et de test d'indicateurs de surveillance. Il a par exemple permis de montrer l'importance des conditions de fonctionnement (charge et vitesse) sur le niveau des indicateurs utilisés en surveillance. Si besoin, les développements proposés peuvent être étendus sans difficulté à des modèles plus complexes de roulements, d'engrènements et de structures d'accueil de ces éléments technologiques. / This work has been developed within the framework of non-stationary rotating machinery surveillance with emphasis on the detection of roller bearing defects. It focuses on the modeling and analysis of instantaneous angular speed variations. The numerical models developed are based on an ``angular" approach which introduces explicitly the machine's free body rotation degrees of freedom allowing simulations in non stationary operating conditions. A deep groove ball bearing model has been developed coupling tangential and normal forces by taking into account the rolling resistance phenomenon. This coupling allows to explain the origin of angular speed fluctuations in the presence of outer race roller bearing defects, phenomena that has been observed experimentally: a roller bearing defect periodically modifies the friction torque. The description of the gear mesh has been performed by means of a classic approach where the scientific issue has been to verify the compatibility with the angular modeling, cornerstone of this dissertation. Integration of the roller bearing and the gear modeling approaches into a simple mechanical architecture has shown that the presence of bearing defects provoking variations in the rolling element-races normal forces, modifies the gear mesh forces leading to perturbations of the angular speed. A simplified wind turbine model has been used for the test and validation of non stationary surveillance spectral indicators. The robustness of the model has been shown by means of a comparison with measurements performed on a wind turbine. It has allowed to show the importance of the operating conditions (load and speed), on the level of indicators used. This means the model may be used as a tool for phenomenological analyses as well as a device to test surveillance indicators. If needed, the approaches presented may be easily extended into more complex models of bearings, gears, casings and foundations.

Dans un marché aéronautique en plein essor marqué par une croissance rapide du parc d’avions utilisées à travers le monde, l’optimisation de la maintenance devient une préoccupation pour les avionneurs. Il s’agit de maximiser la disponibilité des aéronefs tout en réduisant les couts directs d’exploitation sans compromis sur la sécurité des hommes et en respectant les contraintes environnementales. Une stratégie possible pour relever ce challenge est de renforcer la capacité à anticiper les défaillances afin de recourir à des actions préventives le plus juste possible sur les composants les plus critiques comme les roulements à billes. La mise en œuvre de processus de Prognostic Health Management (PHM) prend ainsi une part grandissante et le processus de pronostic est considéré comme l’un des principaux leviers d’action. Son déploiement requiert que le comportement du système étudié puisse être observés. Il peut ainsi bénéficier de l’apport des récentes avancées dans le domaine des microsystèmes autonomes en énergie permettant des mesures intelligentes et un transfert de données d’une manière distribuée, sans aucune aide externe. L’association de ses deux champs de recherche mène naturellement vers le roulement intelligent qui pourrait être la transition d’une maintenance programmée à une maintenance prédictive. Cependant les solutions de PHM autour du roulement et le roulement intelligent, ne restent pas moins le fruit de l’évolution des techniques et technologies de surveillance, de récupération d’énergie et de connectivité. C’est dans ce cadre que s’inscrit ce mémoire de thèse par Validation des Acquis de l’Expérience (VAE). Il s’articule en trois parties principales : motivations du VAE, état de l’art autour du roulement mécatronique et exemple de contributions autour de la récupération d’énergie et la communication sans fil à des fins de surveillance. / The aeronautic market is growing and the aircraft fleet size is becoming bigger. Maintenance optimization is a key focus for liner since objectives are to maximize the aircraft availability and to reduce the direct cost of ownership with no compromise on the flight security and safety with respect to environmental standards. To meet this challenge one possible strategy is to apply a PHM approach using the recent advance in the autonomous embedded microsystem field. This PhD work presents some work done around energy harvesting and wireless sensor to enable a smart bearing able to measure the usage and health data from the component in the purpose of predictive mainteance.

Detta examensarbete har utförts på Fläktwoods AB i Växjö, som producerar stora axialfläktar för olika industriapplikationer. Syftet är att öka kunskapen om fettsmorda axiella kullager genom FE analyser. Projektet har genomförts i fem delsteg för att avgöra påverkan av en eller några få parametrar i taget. De studerade parametrarna är: elementstorlek, kontaktstyvhet, last, lagergeometri (dvs. oskulation), ickelinjär geometri och ickelinjära materialegenskaper (dvs. plasticitet). Slutsatsen är att elementstorleken bör väljas fint nog för att ge ett jämnt resultat men grovt nog för att beräkningstiden skal vara rimlig. Kontaktstyvheten har inte stor, men tydlig, inverkan på kontakttrycket och penetrationen. Förändringar av oskulationen leder till förändringar i kontaktellipsens form medan olika laster inte påverkar formen på ellipsen, utan snarare storleken. När det handlar om plasticitet är sträckgränsen den viktigaste faktorn att beakta. / This thesis project was carried out at Fläktwoods AB in Växjö who produces large axial fans for different industry applications. The purpose is to increase the knowledge of grease lubricated axial ball bearings through FE analyses. The project was executed into five sub steps to determine the influence of one or few parameters at a time. The studied parameters are: mesh density, contact stiffness, load, bearing geometry (i.e. osculation), geometrical nonlinearity and material nonlinearity (i.e. plasticity). It is concluded that the mesh density should be selected fine enough to give a smooth result but course enough to give a reasonable calculation time. The contact stiffness has not a major, but a clear, impact on the contact pressure and penetration. Changes of the osculation lead to changes of the contact ellipse shape and applying different load level does not affect the shape of the ellipse but rather the size. When dealing with plasticity the yield strength is the most important factor to take in consideration.

It is an established fact that segregation during casting affects the physical properties of carbon-based ferro alloys; this motivates the study of the segregation behaviour of carbon and carbide-forming solute elements. In this context, this thesis investigates two different situations: the effects of cooling rate and turbulence on the precipitation behaviour of the graphite nodules in nodular cast iron; the nature of carbide precipitation in a bearing steel grade and the effects of subsequent soaking on these carbides. The structures of boiling water reactor inserts cast by the uphill and downhill casting of nodular cast iron were examined. The samples were taken from representative locations in the top, middle and bottom cross sections of the castings. It was observed that in uphill-cast inserts the nodules were larger but fewer in number the bottom section, whereas in downhill-cast inserts the nodules in the bottom section were smaller, but greater in number. Variation in volume fraction of the graphite nodules across the inserts was also observed. The probable cause of this variation was the difference in cooling rate in different sections of the insert. Between the steel tubes located at the central part of the casting, the fraction of graphite was lower, which could be the result of carburization of the steel tubes. To study the effects of melt stirring during the solidification of nodular cast iron, several experiments were conducted at variable cooling rates and for different stirring times. Examination of the microstructure was conducted using Light Optical Microscope (LOM) and Scanning Electron Microscope (SEM). It was observed that during stirring the melt oxidized and oxide nuclei were formed. The number of nucleation sites for the precipitation of graphite nodules increased, which raised the nodule count and the fraction of the graphite precipitated. The matrix transformed from pearlite to ferrite, which could be due to the fact that more carbon had diffused out of the matrix. The segregation behaviour in hypereutectoid bearing steel produced by ingot casting was also studied. The effects of soaking on micro and macro segregation was investigated in samples taken from as cast and soaked ingots; emphasis was laid on the bulk matrix and A-segregation channels. Samples were also taken from ingots which were soaked and then hot worked. The micro and macro examination of the microstructure was conducted using LOM and SEM. Quantitative and qualitative composition analysis was performed using Energy-dispersive X-ray spectroscopy (EDX) and an electron micro probe analyzer (EMPA). It was observed that M3C, M2C and M6C had precipitated. The carbide morphology in the bulk matrix was different to that in the A-segregation channels. All the primary carbides in the bulk matrix were found to have dissolved after 4 hours of soaking at 1200oC. / Det är ett faktum att segringar som uppstår under gjutning påverkar materialegenskaperna hos kolbaserade järnlegeringar; detta utgör motivationen till studien av segringsuppträdandet hos kol och karbidbildande ämnen. Denna avhandling behandlar två olika aspekter inom ramen för detta ämne: påverkan av kylningshastighet och turbulens på kärnbildningen av grafitnoduler i nodulärt gjutjärn samt karbidbildning i kullagerstål och dess påverkan på den efterföljande värmebehandlingen av dessa karbider. Strukturen hos rör till vattenkokare som tillverkats av nodulärt gjutjärn som gjutits med fyllning från botten eller från toppen undersöktes. Prover togs från representativa tvärsnittspositioner från toppen, mitten och botten av de gjutna ämnena. Resultaten visade att användandet av bottenfyllda kokiller gav upphov till större men färre karbider i nedre delen av ämnet, medans användandet av toppfyllda kokiller gav upphov till mindre men fler karbider i nedre delen av ämnet. Variationer av volymfraktionen av grafitnoduler längs tvärsnitten observerades också. Den mest sannolika orsaken till denna variation var skillnaden i kylhastighet i de olika områdena av tvärsnitten. Hos rör tillverkade av det centrala delen av ämnet så var fraktionen grafit lägre, vilket kan bero på en uppkolning av rören. Ett flertal experiment utfördes med varierande kylningshastigheter och olika omrörningstider för att studera inverkan av omrörning av smältan på stelningen av nodulärt gjutjärn. Studier av mikrostrukturen genomfördes med ljusoptisk mikroskopi och svepelektronmikroskopi. Resultaten visade att smältan oxiderades under omrörningen, vilket resulterade i bildandet av oxider. Detta ledde till en ökning av kärnbildningsområden för grafitnoduler, vilket ledde till en ökning av antalet noduler samt fraktionen av grafit som fälldes ut. Strukturen omvandlades från perlit till ferrit, vilket troligen orsakades av att kol hade diffunderat ut från strukturen. Segringsbeteendet hos hypereutektoida kullagerstål tillverkade genom götgjutning undersöktes också. Effekten av värmebehandling på mikro- och makrosegringar undersöktes i prover tagna från gjutna och värmebehandlade ämnen. Fokus var på att studera strukturen i ämnena samt A-segringar. Dessutom togs prover från ämnen som först värmebehandlats och därefter varmbearbetats. Både mikro- och makroundersökningar av mikrostrukturen utfördes med ljusoptisk mikroskopi och svepelektronmikroskopi. Dessutom så genomfördes kvantitativa sammansättningsbestämningar med energidispersiv röntgenspektroskopi och elektronmikroprobsanalys. Resultaten visade att M3C, M2C och M6C karbider hade fällts ut. Karbidmorfologin i huvuddelen av strukturen skiljde sig från den som återfanns i A-segringar. Samtliga primära karbider i huvuddelen av strukturen hade lösts upp efter 4 timmars värmebehandling vid 1200oC. / <p>QC 20180523</p>

Une des voies d’amélioration des véhicules hybrides et électriques est l’utilisation de moteurs tournant plus vite, jusqu’à plus de 42.000tr/min. Le but est d’augmenter la densité de puissance et le rendement des groupes motopropulseurs. Pour utiliser ces moteurs de nouveaux réducteurs mécaniques doivent être développés. Cela doit se faire sans générer de surcoût important face aux solutions utilisées à basse vitesse et en assurant un niveau de performance énergétique élevé. Cette thèse se situe en amont de la phase de conception d’un réducteur haute vitesse lubrifié par barbotage. Elle a pour but d’identifier les problèmes d’échauffement et de pertes de puissance ainsi que de proposer des pistes d’amélioration énergétique. Ce travaille propose la modélisation thermomécanique de l’étage grande vitesse (GV) du réducteur, réalisée à l’aide de la méthode des réseaux thermiques. Ce modèle couple les pertes de puissance avec les températures. Une attention particulière est portée sur la modélisation des roulements de l’arbre GV. Un nouveau modèle thermomécanique de roulement est développé. Les pertes par barbotage deviennent importantes à grande vitesse. Une méthode permettant de fortement les réduire est caractérisée. / A way to improve both electric and hybrid vehicles is to use high speed motors, operating over than 42.000rpm. The goal is to increase the power density and the efficiency of powertrains. Using these new motors, new gearboxes should be developed. This must be done without generating significant additional cost regarding already mastered low speed solutions. High energy performance level also has to be maintained. This PhD comes before the design phase of a high-speed oil bath lubricated gearbox. It aims to identify the warm-up and power loss problems, and propose ways to improve efficiency. This work proposes a thermomechanical modelling of the gearbox’s first stage, using the thermal network method. This model links power losses with temperatures. Particular attention is paid to high speed bearing modelling. A new thermomechanical model of rolling element bearing is developed. As churning losses being significant at high speeds, a method to greatly reduce this power loss is characterized.

In this thesis analysis and inovation of electric machines for cars is discused. There are described principles of basics DC and AC electric machines. In detail this thesis deals with small electric machines used in cars. At least, electro motor for wiper is investigated and possibilities of its inovation in different ways are also mantioned.