A large structural weldment has been designed to serve as the new star tracker bridge for the Dark Energy Experiment upgrade to the Hobby-Eberly Telescope at McDonald Observatory. The modeling approach, analysis techniques and design details will be of interest to designers of large structures where stiffness is the primary design driver. The design includes detailed structural analysis using finite element models to maximize natural frequency response and limit deflections and light obscuration. Considerable fabrication challenges are overcome to allow integration of precision hardware required for positioning the corrector optics to a precision of less than 5 microns along the 4-meter travel range. This thesis provides detailed descriptions of the bridge geometry, analysis results and challenging fabrication issues. / text

During vibration of engineering structures, fatigue cracks may exhibit repetitive crack open-close breathing like phenomenon. In this thesis, the concept of entropy is employed to quantify this bi-linearity/irregularity of the vibration response so as to evaluate crack severity. To increase the sensitivity of the entropy calculation to detect the damage severity, entropy is merged with wavelet transformation (WT). A cantilever beam with a breathing crack is studied to asses proposed crack identification method under two vibration conditions: sinusoidal and random excitations. Through numerical simulations and experimental testing, the breathing crack identification under sinusoidal excitation is studied first and proven to be effective. Then, the crack identification sensitivity under lower excitation frequencies is further improved by parametric optimization of sample entropy and WT. Finally, breathing crack identification under general random excitations are experimentally studied and realized using frequency response functions (FRFs) as an add-in tool with the proposed crack identification technique. / October 2016

This master thesis has been executed at Scania CV AB in Södertälje, Sweden. Scania is a manufacturer of heavy transport solutions, an industry which is changing rapidly in order to meet stricter regulations, ensuring a sustainable future. Continuous product improvements and new technologies are required to increase performance and to meet markets requirements. By implementing design optimization in the design process it enables the potential of supporting design exploration, which is beneficial when products with high performance are developed. The purpose was to show the potential of design optimization supported by simulation driven design as a tool in the development process. To examine an alternative way of working for design engineers, elaborating more competitive products in terms of economical and performance aspects. Furthermore, to minimize time and iterations between divisions by developing better initial concept proposals. The alternative working method was developed iteratively in parallel with a case study. The case study was a suction strainer and were used for method improvements and validation, as well as decision basis for the included sub-steps. The working method for implementing design optimization and simulation driven design ended up with a procedure consisted of three main phases, concept generation, detail design and verification. In the concept generation phase topology optimization was used, which turned out to be a beneficial method to find optimized solutions with few inputs. The detail design phase consisted of a parameterized CAD model of the concept which then was shape optimized. The shape optimization enabled design exploration of the concept which generated valuable findings to the product development. Lastly the optimized design was verified with more thorough methods, in this case verification with FE-experts. The working method was tested and verified on the case study component, this resulted in valuable knowledge for future designs for similar components. The optimized component resulted in a performance increase where the weight was decrease by 54% compared with a reference product.

O trabalho apresentado tem como objetivo principal propor uma metodologia para obtenção dos parâmetros da máquina síncrona, baseada em ensaio de resposta em frequência, utilizando-se de um inversor e da aplicação de técnicas numéricas de ajuste de curvas. Dedicam-se tópicos à consolidação de aspectos físicos resultantes das características construtivas das máquinas que devem ser considerados na modelagem. Também se analisam as derivações matemáticas dos modelos. Posteriormente se estudam os vários tipos de ensaios praticados para determinação dos parâmetros dos modelos apresentados. Particular ênfase é dada ao Ensaio Estático de Resposta em Frequência. São levantadas as vantagens e desvantagens da aplicação desse tipo de ensaio, suas dificuldades e limitações bem como é apresentada uma metodologia para sua execução. Por fim, o trabalho compila os resultados conseguidos com uma aplicação em bancada, onde foram utilizados equipamentos disponíveis em laboratórios didáticos de máquinas elétricas. É outro objetivo desse estudo a comparação de ensaios de resposta em frequência com ensaios tradicionais (saturação em vazio e curto-circuito permanente, curto-circuito abrupto, etc...). / The presented work has as main objective to propose a methodology for obtaining the synchronous machines parameters, based on frequency response test, by means of a frequency converter and the application of numerical curve fitting routines. Topics are dedicated to the consolidation of physical aspects resulting of the machines constructive characteristics which must be considered in the modeling. Mathematical developments of the models are also studied. Thereafter, the tests that are usually performed for the determination of the synchronous machines parameters are analyzed. Particular emphasis is given to the Standstill Frequency Response Test. Positive and negative points for this specific type of test are raised. Difficulties and limitations are also defined, and a methodology for its implementation is presented. Finally, this work compiles the results achieved in a bench application, where equipment available in didactic laboratories of electric machines was used. The comparison of the Standstill Frequency Response Test with traditional tests (no-load saturation, permanent short-circuit, sudden short-circuit, etc) is also scope of this work.

Determinar as forças que estão agindo em um dado sistema é uma questão frequente em dinâmica estrutural, de modo que a reconstrução ou a identificação de carregamento se torna um importante problema de engenharia. Quando um sistema é exposto a um carregamento desconhecido e/ou não se é possível medir diretamente a força atuante nesse sistema, se torna necessária a utilização de métodos inversos. Esta metodologia consiste essencialmente na aplicação de cargas dinâmicas pontuais nos modelos de estudo e posterior recuperação de estimativas dessas cargas nos pontos de interesse. Na prática, há situações em que o número de pontos de interesse diferem do número de pontos testados, sendo assim, a matriz da função de resposta de freqüência (FRF) do sistema resulta retangular, fazendo-se necessário o uso da pseudo-inversa de Moore-Penrose. No presente trabalho, essa metodologia é aplicada a modelos númericos a fim de testar sua eficácia. Os resultados dos processos de reconstrução de carregamento dinâmico utilizando a presente metodologia foram obtidos a partir de aplicações analíticas e numéricas. Além disso, diretrizes para utilização da pseudo-inversa de Moore-Penrose na reconstrução de carregamento dinâmico são apresentadas ao final deste trabalho. / Determining the forces acting on a given system is a frequent issue in structural dynamics, so that load reconstruction or load identification becomes an important engineering problem. When a system is exposed to an unknown load and/or if it is not possible to directly measure the force acting on that system, it is necessary to use inverse methods. This methodology consists essentially in the application of punctuals dynamics load in the study models and later recovery of estimates of these loads at points of interest. In practice, there are situations where the number of points of interest differ from the number of points tested, so the matrix of the frequency response function (FRF) of the system is rectangular, making it necessary to use the pseudo-inverse of Moore-Penrose. In the present work, this methodology is applied to numerical models in order to test their effectiveness. The results of the dynamic load reconstruction processes using the present methodology were obtained from analytical and numerical applications. In addition, guidelines for using Moore-Penrose pseudo-inverse in the dynamic load reconstruction are presented at the end of this work.

O trabalho apresentado tem como objetivo principal propor uma metodologia para obtenção dos parâmetros da máquina síncrona, baseada em ensaio de resposta em frequência, utilizando-se de um inversor e da aplicação de técnicas numéricas de ajuste de curvas. Dedicam-se tópicos à consolidação de aspectos físicos resultantes das características construtivas das máquinas que devem ser considerados na modelagem. Também se analisam as derivações matemáticas dos modelos. Posteriormente se estudam os vários tipos de ensaios praticados para determinação dos parâmetros dos modelos apresentados. Particular ênfase é dada ao Ensaio Estático de Resposta em Frequência. São levantadas as vantagens e desvantagens da aplicação desse tipo de ensaio, suas dificuldades e limitações bem como é apresentada uma metodologia para sua execução. Por fim, o trabalho compila os resultados conseguidos com uma aplicação em bancada, onde foram utilizados equipamentos disponíveis em laboratórios didáticos de máquinas elétricas. É outro objetivo desse estudo a comparação de ensaios de resposta em frequência com ensaios tradicionais (saturação em vazio e curto-circuito permanente, curto-circuito abrupto, etc...). / The presented work has as main objective to propose a methodology for obtaining the synchronous machines parameters, based on frequency response test, by means of a frequency converter and the application of numerical curve fitting routines. Topics are dedicated to the consolidation of physical aspects resulting of the machines constructive characteristics which must be considered in the modeling. Mathematical developments of the models are also studied. Thereafter, the tests that are usually performed for the determination of the synchronous machines parameters are analyzed. Particular emphasis is given to the Standstill Frequency Response Test. Positive and negative points for this specific type of test are raised. Difficulties and limitations are also defined, and a methodology for its implementation is presented. Finally, this work compiles the results achieved in a bench application, where equipment available in didactic laboratories of electric machines was used. The comparison of the Standstill Frequency Response Test with traditional tests (no-load saturation, permanent short-circuit, sudden short-circuit, etc) is also scope of this work.

The increased penetration of renewable energy sources poses new challenges for grid stability. The stochastic and uncontrollable generation of solar and wind power cannot be adjusted to match the load profile, and the transition away from traditional synchronous generators is reducing the grid capacity to arrest and recover from frequency disturbances. Additionally, the distributed nature of many renewable energy sources makes centralized control of generation more complicated. The traditional power system paradigm balances the supply and demand of electricity on the grid by regulating generation. As this becomes more difficult, one alternative is to adjust the load instead. This is not entirely novel, and utilities have incentivized large industrial customers to reduce consumption during peak hours for years. However, the residential sector, which constitutes 37% of electricity consumption in the U.S., currently has very little capacity for load control. Smart electric water heaters provide utilities with an appliance that can be remotely controlled and serves as a form of energy storage. They have very fast response times and make up a large amount of residential energy consumption, making them useful for load peak shifting as well as other ancillary grid services. As smart appliances become increasingly widespread, more and more devices can be brought into the utility's control network and aggregated into a flexible resource on a megawatt scale. This work demonstrates the usefulness of aggregated electric water heaters for peak shifting and frequency response. Because a large number of assets are required, emulators are developed based on observations of real devices. Emulated water heaters are then connected to an energy resource aggregator using an internet-of-things network. The aggregator successfully uses these assets to shift consumption away from peak hours. An algorithm was developed for detecting upward frequency disturbances in real-time. The aggregator uses this algorithm to show that an aggregation of water heaters is well-suited to respond to these frequency disturbances by quickly adding a large amount of load to the grid.

The handling of variability effects in structural models is a natural and necessary extension of deterministic analysis techniques. In the context of finite element and uncertainty modelling, the stochastic finite element method (SFEM), grouping the perturbation SFEM, the spectral SFEM and the Monte-Carlo simulation, has by far received the major attention. <br> The present work focuses on second moment approaches, in which the first two statistical moments of the structural response are estimated. Due to its efficiency for handling problems involving low variability levels, the perturbation method is selected for characterising the propagation of the parameter variability from an uncertain dynamic model to its structural response. A dynamic model excited by a time-harmonic loading is postulated and the extension of the perturbation SFEM to the frequency domain is provided. This method complements the deterministic analysis by a sensitivity analysis of the system response with respect to a finite set of random parameters and a response surface in terms of a Taylor series expansion truncated to the first or second order is built. Taking into account the second moment statistical data of the random design properties, the response sensitivities are appropriately condensed in order to obtain an estimation of the response mean value and covariance structure. <br> In order to handle a wide definition of variability, a computational tool is made available that is able to deal with material variability sources (material random variables and fields) as well as shape uncertainty sources. This second case requires an appropriate shape parameterisation and a shape design sensitivity analysis. The computational requirements of the tool are studied and optimised, by reducing the size of the random dimension of the problem and by improving the performances of the underlying deterministic analyses. In this context, modal approaches, which are known to provide efficient alternatives to direct approaches in frequency domain analyses, are developed. An efficient hybrid procedure, coupling the perturbation and the Monte-Carlo simulation SFEM, is proposed and analysed. <br> Finally, the developed methods are validated, by resorting mainly to the Monte-Carlo simulation technique, on different numerical applications: a cantilever beam structure, a plate bending problem (involving a 3-dimensional model), an articulated truss structure and a problem involving a plate with a random flatness default. The propagation of the model uncertainty in the response FRFs and the effects involved by random field modelling are examined. Some remarks are stated pertaining to the influence of the parameter PDF in simulation-based methods. <br> <br> La gestion de la variabilité présente dans les modèles structuraux est une extension naturelle et nécessaire des techniques de calcul déterministes. En incorporant la modélisation de l'incertitude dans le calcul aux éléments finis, la méthode des éléments finis stochastiques (groupant l'approche perturbative, l'approche spectrale et la technique de simulation Monte-Carlo) a reçu une large attention de la littérature scientifique. <br> Ce travail est orienté sur les approches dites de second moment, dans lesquelles les deux premiers moments statistiques de la réponse de la structure sont estimés. De par son aptitude à traiter des problèmes caractérisés par de faibles niveaux de variabilité, la méthode perturbative est choisie pour propager la variabilité des paramètres d'un modèle dynamique incertain sur sa réponse. Un modèle sous chargement dynamique harmonique est supposé et l'extension dans le domaine fréquentiel de l'approche perturbative est établie. Cette méthode complète l'analyse déterministe par une analyse de sensibilité de la réponse du système par rapport à un ensemble fini de variables aléatoires. Une surface de réponse en termes d'un développement de Taylor tronqué au premier ou second ordre peut alors être écrit. Les sensibilités de la réponse sont enfin condensées, en tenant compte des propriétés statistiques des paramètres de design aléatoires, pour obtenir une estimation de la valeur moyenne et de la structure de covariance de la réponse. <br> Un outil de calcul est développé avec la capacité de gestion d'une définition large de la variabilité: sources de variabilité matérielle (variables et champs aléatoires) ainsi que géométrique. Cette dernière source requiert une paramétrisation adéquate de la géométrie ainsi qu'une analyse de sensibilité à des paramètres de forme. Les exigences calcul de cet outil sont étudiées et optimisées, en réduisant la dimension aléatoire du problème et en améliorant les performances des analyses déterministes sous-jacentes. Dans ce contexte, des approches modales, fournissant une alternative efficace aux approches directes dans le domaine fréquentiel, sont dérivées. Une procédure hybride couplant la méthode perturbative et la technique de simulation Monte-Carlo est proposée et analysée. <br> Finalement, les méthodes étudiées sont validées, principalement sur base de résultats de simulations Monte-Carlo. Ces résultats sont relatifs à plusieurs applications numériques: une structure poutre-console, un problème de flexion de plaque (modèle tridimensionnel), une structure en treillis articulé et un problème de plaque présentant un défaut de planéité aléatoire. La propagation de l'incertitude du modèle dans les fonctions de réponse fréquentielle ainsi que les effets propres à la modélisation par champs aléatoires sont examinés. Quelques remarques relatives à l'influence de la loi de distribution des paramètres dans les méthodes de simulation sont évoquées.

Further improvements of the thermal efficiency of gas turbine cycle are closely coupled to the increase of turbine inlet temperature. This requires intensive and efficient cooling of the blades. In this perspective, experimental investigations of the gas temperature and heat transfer distribution around the airfoil are of primary importance. The present work aims at the development of two measurement techniques based on applications of the thin film sensors: the two-layer gauge for the wall heat transfer determination and the dual thin film probe for flow temperature measurements. Both techniques are used in short duration tunnels of the von Karman Institute (VKI) under engine representative conditions and are able to resolve both time-averaged component and time-resolved component i.e. periodic blade passing events at ~5-7 kHz with harmonics up to 50 kHz. In order to derive the wall heat flux with the two-layer gauge, the unsteady conduction equation is solved in the two-layer substrate using the measured value of the wall temperature as a boundary condition. The gauges are extensively calibrated and the data reduction method is validated on a blade of the second stator of the VKI turbine. A very good repeatability is achieved. Measurements are also performed on the complex geometry of a blade tip in a cascade configuration revealing the high three dimensionality of the flow. The dual thin film probe combines the operation of two thin films and determines the flow temperature from two independent heat flux measurements. The probe is calibrated and then validated with measurements downstream a cascade. The robustness and the reliability of the probe are also demonstrated by measurements downstream of the rotor and the second stator of the VKI turbine.

Engine components are exposed to vibrations which may lead to fatigue damage. Accurate dynamic simulations are necessary especially during the development process, in order to find a satisfactory component. Currently Scania uses a standard method for dynamic calculations that is based on a frequency response approach. A measured or calculated excitation yields a certain response through the transfer function of the system. The transfer function is obtained through an eigenfrequency calculation and an experience-based estimate of the modal damping. An obvious drawback of this method is that the estimated modal damping strongly affects the calculated response of the system. In this thesis, the method outlined above is compared to an alternative, so-called, inverse method in which the excitation of the system is calculated using a measured response. The advantage is that the modal damping does not affect the result directly since the excitation has been adjusted according to the response. As a demonstration object a charge air pipe and its bracket are used. Acceleration response data is collected from an engine vibration measurement. The calculated safety factor of the demonstration object is reasonable for both the standard method and the inverse method. An estimate of the quality of the model is obtained for the inverse method through statistical measures, which is not the case for the standard method. The excitation for the inverse method is adjusted to the estimated modal damping which is a major advantage since damping is notoriously difficult to quantify in engineering practice. The inverse method has proven to be a useful simulation method for calculations when a prototype of the engine component of interest already exists.