This thesis presents an approach to modelling dynamic mass capture which is applied to a number of system models. The models range from a simple 2D Euler-Bernoulli beam with point masses for the end-effector and target to a 3D Timoshenko beam model (including torsion) with rigid bodies for the end-effector and target. In addition, new models for torsion, as well as software to derive the finite element equations from first principles were developed to support the modelling. Results of the models are compared to a simple experiment as done by Ben Rhody. Investigations of offset capture are done by simulation to show why one would consider using a 3D model that includes torsion. These problems have relevance to both terrestrial robots and to space based robotic systems such as the manipulators on the International Space Station capturing payloads such as the SpaceX Dragon capsule. One could increase production in an industrial environment if industrial robots could pick up items without having to establish a zero relative velocity between the end effector and the item. To have a robot acquire its payload in this way would introduce system dynamics that could lead to the necessity of modelling a previously ‘rigid’ robot as flexible.

The reliability of modern gas turbine engines is largely due to careful damage tolerant design a method of structural design based on the assumption that flaws (cracks) exist in any structure and will continue to grow with usage. With proper monitoring, largely in the form of periodic inspections at conservative intervals reliability and safety is maintained. These methods while reliable can lead to the early retirement of some components and unforeseen failure if design assumptions fail to reflect reality. With improvements to sensor and computing technology there is a growing interest in a system that could continuously monitor the health of structural aircraft as well as forecast future damage accumulation in real-time. Through the use of two-dimensional and three-dimensional numerical modeling the initial goals and findings for this continued work include: (a) establishing measurable parameters directly linked to the health of the blade and (b) the feasibility of detecting accumulated damage to the structural material and thermal barrier coating as well as the onset of damage causing structural failure.

Conventional construction of Jointed Plain Concrete Pavements (JPCP) in Canada consists of placing a round steel epoxy-coated dowel at the mid height of the pavement. Steel dowels reduce stepping at the joint to improve comfort and reduce the stress concentration on the support layer beneath the pavement. Most importantly they transfer load and are commonly referred to as load transfer devices. Problems with dowel bar deterioration, including corrosion causes the slab joint to lock and cause stress concentrations as the slab expands and or contracts and curls due to thermal and shrinkage straining occurring in the concrete. In this research, alternative joint load transfer devices are presented and compared to conventional steel dowels. Four device alternatives are developed and evaluated: a Glass Fibre Reinforced Polymer (GFRP) I-beam placed directly on the base material; GFRP tapered plates; a continuous horizontal V device; and a continuous horizontal pipe device both placed directly on the support layer. The two devices that are continuous run the length of the joint similar to a shear key. The GFRP tapered plate and I-beam, as well as conventional steel dowels, were analyzed in a wheel path sized three dimensional finite element model for wheel loading and static loading applied to either side of the joint. An experimental testing program was developed to test joint load transfer capabilities of each device when subjected to a static wheel load applied to either side of the joint. The GFRP tapered plates and I-beams were shown to transfer load based on the results from the wheel path finite element model and experimental testing program. The differential joint deflection, stress concentrations and plastic straining occurring in the concrete is not reduced with either the tapered plate or I-beam compared to a dowel under wheel loading. In addition, a similar plastic straining area identified in the finite element models were noticed as an area of damage in the experimental testing program. All of the devices developed are analyzed in a quarter slab three dimensional finite element model with shrinkage and thermal strains as well as wheel loading applied to the slab to simulate service loading. A detailed investigation into the stress distribution around the devices and the differential deflection at the joint through the service loading applied is presented in this paper. Similarly to the wheel path investigation the stress concentration in the tapered plate and I-beams are greater than conventional dowels and also have greater differential deflection occurring at the joint. Both the continuous Horizontal V and Horizontal Pipe device reduce stress and plastic straining in the concrete during the service load analysis compared to dowels. During daytime wheel loading the differential deflection in the joint is the lowest with no noticeable stepping occurring at the joint with the Horizontal V device; however is greater than conventional steel dowels under nighttime wheel load application. The differential deflection with the Horizontal Pipe during day and night straining and wheel loading is similar to conventional steel dowels.

The reliability of modern gas turbine engines is largely due to careful damage tolerant design a method of structural design based on the assumption that flaws (cracks) exist in any structure and will continue to grow with usage. With proper monitoring, largely in the form of periodic inspections at conservative intervals reliability and safety is maintained. These methods while reliable can lead to the early retirement of some components and unforeseen failure if design assumptions fail to reflect reality. With improvements to sensor and computing technology there is a growing interest in a system that could continuously monitor the health of structural aircraft as well as forecast future damage accumulation in real-time. Through the use of two-dimensional and three-dimensional numerical modeling the initial goals and findings for this continued work include: (a) establishing measurable parameters directly linked to the health of the blade and (b) the feasibility of detecting accumulated damage to the structural material and thermal barrier coating as well as the onset of damage causing structural failure.

This thesis investigates the strength behavior of a representative highly skewed and horizontally curved bridge as well as analysis and design procedures for these types of structures. The bridge responses at and above a number of limits in the AASHTO (2007) Specifications are considered. The study includes the evaluation of various attributes of the elastic analysis of the subject bridge. These attributes include: (1) the accuracy of 3-D grid versus 3-D FEA models, (2) first-order versus second-order effects during the construction, (3) the ability to predict layover at bearing lines using simplified equations and (4) the benefit of combining the maximum and concurrent major-axis and flange lateral bending values due to live load compared to combining the maximums due to different live loads when checking the section resistances. The study also addresses the ability of different AASHTO 2007 resistance equations to capture the ultimate strength behavior. This is accomplished by comparing the results from full nonlinear 3-D FEA studies to the elastic design and analysis results. Specifically the use of the 2007 AASHTO moment based one-third rule equations is evaluated for composite sections in positive bending.

The Pebble Bed Modular Reactor (PBMR) is one of the most technologically advanced developments in South Africa. In order to build a commercially viable demonstration power plant, all the specifically and uniquely designed equipment must first be qualified. All the prototype equipment is tested at the Helium Test Facility (HTF) at Pelindaba. One of the largest components that are tested is the Core Unloading Device (CUD). The main function of the CUD is to unload fuel from the bottom of the reactor core to enable circulation of the fuel core. The CUD housing vessel forms part of the reactor pressure boundary. Pebble-directing valves and other moving machinery are installed inside its machined inner surface. It is essential that the interior surfaces of the CUD are case hardened to provide a corrosion- and wear-resistant layer. Cold welding between the moving metal parts and the machined surface must also be prevented. Nitriding is a case hardening process that adds a hardened wear- and corrosion-resistant layer that will also prevent cold welding of the moving parts in the helium atmosphere. Only a few nitriding furnaces exist that can house a forging as large as the CUD of the PBMR. Commercial nitriding furnaces in South Africa are all too small and have limited flexibility in terms of the nitriding process. The nitriding of a vessel as large as the CUD has not yet been carried out commercially. The aim of this work was to design and develop a custom-made nitriding plant to perform the nitriding of the first PBMR/HTF CUD. Proper process control is essential to ensure that the required nitrided case has been obtained. A new concept for a gas nitriding plant was developed using the nitrided vessel interior as the nitriding process chamber. Before the commencement of detail design, a laboratory test was performed on a scale model vessel to confirm concept feasibility. The design of the plant included the mechanical design of various components essential to the nitriding process. A special stirring fan with an extended length shaft was designed, taking whirling speed into account. Considerable research was performed on the high temperature use of the various components to ensure the safe operation of the plant at temperatures of up to 600°C. Nitriding requires the use of hazardous gases such as ammonia, oxygen and nitrogen. Hydrogen is produced as a by-product and therefore safety was the most important design parameter. Thermohydraulic analyses, i.e. heat transfer and pressure drop calculations in pipes, were also performed to ensure the successful process design of the nitriding plant. The nitriding plant was subsequently constructed and operated to verify the correct design. A large amount of experimental and operating data was captured during the actual operation of the plant. This data was analysed and the thermohydraulic analyses were verified. Nitrided specimens were subjected to hardness and layer thickness tests. The measured temperature of the protruding fan shaft was within the limits predicted by Finite Element Analysis (FEA) models. Graphs of gas flow rates and other operation data confirmed the inverse proportionality between ammonia supply flow rate and measured dissociation rate. The design and operation of the nitriding plant were successful as a nitride layer thickness of 400 μm and hardness of 1 200 Vickers hardness (VHN) was achieved. This research proves that a large pressure vessel can successfully be nitrided using the vessel interior as a process chamber. / Thesis (M.Ing. (Mechanical Engineering))--North-West University, Potchefstroom Campus, 2010.

The Pebble Bed Modular Reactor (PBMR) is one of the most technologically advanced developments in South Africa. In order to build a commercially viable demonstration power plant, all the specifically and uniquely designed equipment must first be qualified. All the prototype equipment is tested at the Helium Test Facility (HTF) at Pelindaba. One of the largest components that are tested is the Core Unloading Device (CUD). The main function of the CUD is to unload fuel from the bottom of the reactor core to enable circulation of the fuel core. The CUD housing vessel forms part of the reactor pressure boundary. Pebble-directing valves and other moving machinery are installed inside its machined inner surface. It is essential that the interior surfaces of the CUD are case hardened to provide a corrosion- and wear-resistant layer. Cold welding between the moving metal parts and the machined surface must also be prevented. Nitriding is a case hardening process that adds a hardened wear- and corrosion-resistant layer that will also prevent cold welding of the moving parts in the helium atmosphere. Only a few nitriding furnaces exist that can house a forging as large as the CUD of the PBMR. Commercial nitriding furnaces in South Africa are all too small and have limited flexibility in terms of the nitriding process. The nitriding of a vessel as large as the CUD has not yet been carried out commercially. The aim of this work was to design and develop a custom-made nitriding plant to perform the nitriding of the first PBMR/HTF CUD. Proper process control is essential to ensure that the required nitrided case has been obtained. A new concept for a gas nitriding plant was developed using the nitrided vessel interior as the nitriding process chamber. Before the commencement of detail design, a laboratory test was performed on a scale model vessel to confirm concept feasibility. The design of the plant included the mechanical design of various components essential to the nitriding process. A special stirring fan with an extended length shaft was designed, taking whirling speed into account. Considerable research was performed on the high temperature use of the various components to ensure the safe operation of the plant at temperatures of up to 600°C. Nitriding requires the use of hazardous gases such as ammonia, oxygen and nitrogen. Hydrogen is produced as a by-product and therefore safety was the most important design parameter. Thermohydraulic analyses, i.e. heat transfer and pressure drop calculations in pipes, were also performed to ensure the successful process design of the nitriding plant. The nitriding plant was subsequently constructed and operated to verify the correct design. A large amount of experimental and operating data was captured during the actual operation of the plant. This data was analysed and the thermohydraulic analyses were verified. Nitrided specimens were subjected to hardness and layer thickness tests. The measured temperature of the protruding fan shaft was within the limits predicted by Finite Element Analysis (FEA) models. Graphs of gas flow rates and other operation data confirmed the inverse proportionality between ammonia supply flow rate and measured dissociation rate. The design and operation of the nitriding plant were successful as a nitride layer thickness of 400 μm and hardness of 1 200 Vickers hardness (VHN) was achieved. This research proves that a large pressure vessel can successfully be nitrided using the vessel interior as a process chamber. / Thesis (M.Ing. (Mechanical Engineering))--North-West University, Potchefstroom Campus, 2010.

The reliability of modern gas turbine engines is largely due to careful damage tolerant design a method of structural design based on the assumption that flaws (cracks) exist in any structure and will continue to grow with usage. With proper monitoring, largely in the form of periodic inspections at conservative intervals reliability and safety is maintained. These methods while reliable can lead to the early retirement of some components and unforeseen failure if design assumptions fail to reflect reality. With improvements to sensor and computing technology there is a growing interest in a system that could continuously monitor the health of structural aircraft as well as forecast future damage accumulation in real-time. Through the use of two-dimensional and three-dimensional numerical modeling the initial goals and findings for this continued work include: (a) establishing measurable parameters directly linked to the health of the blade and (b) the feasibility of detecting accumulated damage to the structural material and thermal barrier coating as well as the onset of damage causing structural failure.

Conventional construction of Jointed Plain Concrete Pavements (JPCP) in Canada consists of placing a round steel epoxy-coated dowel at the mid height of the pavement. Steel dowels reduce stepping at the joint to improve comfort and reduce the stress concentration on the support layer beneath the pavement. Most importantly they transfer load and are commonly referred to as load transfer devices. Problems with dowel bar deterioration, including corrosion causes the slab joint to lock and cause stress concentrations as the slab expands and or contracts and curls due to thermal and shrinkage straining occurring in the concrete. In this research, alternative joint load transfer devices are presented and compared to conventional steel dowels. Four device alternatives are developed and evaluated: a Glass Fibre Reinforced Polymer (GFRP) I-beam placed directly on the base material; GFRP tapered plates; a continuous horizontal V device; and a continuous horizontal pipe device both placed directly on the support layer. The two devices that are continuous run the length of the joint similar to a shear key. The GFRP tapered plate and I-beam, as well as conventional steel dowels, were analyzed in a wheel path sized three dimensional finite element model for wheel loading and static loading applied to either side of the joint. An experimental testing program was developed to test joint load transfer capabilities of each device when subjected to a static wheel load applied to either side of the joint. The GFRP tapered plates and I-beams were shown to transfer load based on the results from the wheel path finite element model and experimental testing program. The differential joint deflection, stress concentrations and plastic straining occurring in the concrete is not reduced with either the tapered plate or I-beam compared to a dowel under wheel loading. In addition, a similar plastic straining area identified in the finite element models were noticed as an area of damage in the experimental testing program. All of the devices developed are analyzed in a quarter slab three dimensional finite element model with shrinkage and thermal strains as well as wheel loading applied to the slab to simulate service loading. A detailed investigation into the stress distribution around the devices and the differential deflection at the joint through the service loading applied is presented in this paper. Similarly to the wheel path investigation the stress concentration in the tapered plate and I-beams are greater than conventional dowels and also have greater differential deflection occurring at the joint. Both the continuous Horizontal V and Horizontal Pipe device reduce stress and plastic straining in the concrete during the service load analysis compared to dowels. During daytime wheel loading the differential deflection in the joint is the lowest with no noticeable stepping occurring at the joint with the Horizontal V device; however is greater than conventional steel dowels under nighttime wheel load application. The differential deflection with the Horizontal Pipe during day and night straining and wheel loading is similar to conventional steel dowels.

This thesis presents an approach to modelling dynamic mass capture which is applied to a number of system models. The models range from a simple 2D Euler-Bernoulli beam with point masses for the end-effector and target to a 3D Timoshenko beam model (including torsion) with rigid bodies for the end-effector and target. In addition, new models for torsion, as well as software to derive the finite element equations from first principles were developed to support the modelling. Results of the models are compared to a simple experiment as done by Ben Rhody. Investigations of offset capture are done by simulation to show why one would consider using a 3D model that includes torsion. These problems have relevance to both terrestrial robots and to space based robotic systems such as the manipulators on the International Space Station capturing payloads such as the SpaceX Dragon capsule. One could increase production in an industrial environment if industrial robots could pick up items without having to establish a zero relative velocity between the end effector and the item. To have a robot acquire its payload in this way would introduce system dynamics that could lead to the necessity of modelling a previously ‘rigid’ robot as flexible.