With the coming of Generation IV systems, there is a need for thermal-hydraulic codes to model such advanced reactors. Codes for High Temperature Gas-cooled Reactors (HTGRs) already exist, but often suffer from insufficient validation and little user experience. Therefore, some existing codes created for Light Water Reactors are updated with HTGR related features. In this study, the feasibility of providing the TRACE thermal-hydraulics code with those features is analysed. Two models were used, one of a pebble bed core, one of a prismatic block reactor. For this purpose the effective conductivity test of the High Temperature Test Unit was taken as a benchmark for the pebble bed core. For the prismatic block reactor a model of the GEMINI+ reactor was created. This would allow to simulate not only steady state, but also Depressurised Loss of Forced Cooling scenarios. For both models the effective conductivity is known to play a major role and, consequently, a model to incorporate such feature was developed and implemented within TRACE's control system module. Results show that TRACE has a good potential for HTGR simulation, but currently available models still provide unstable solutions. It is concluded that TRACE needs additional adjustments in order to be employed for HTGR safety analyses in the future. / Med fjärde generationens system på ingång, finns det ett behov av termisk-hydrauliska koder för att modellera sådana avancerade reaktorer. Koder för gaskylda högtemperaturreaktorer (HTGR) finns redan, men lider ofta av otillräcklig validering och liten användarupplevelse. Därför uppdateras vissa befintliga koder som skapats för lättvattenreaktorer med HTGR-relaterade funktioner. I denna studie analyseras möjligheten att tillhandahålla TRACE termisk-hydraulisk kod med dessa funktioner. Två modeller användes, den ena av en pebble-bed reaktor, den andra av en prismatisk blockreaktor. För detta ändamål togs det effektiva konduktivitetstestet för högtemperaturtestenheten som ett riktmärke för pebble-bedens härd. För den prismatiska blockreaktorn skapades en modell av GEMINI+-reaktorn. Detta skulle göra det möjligt att simulera inte bara steady state, utan även scenarier med trycklös förlust av forcerad kylning. För båda modellerna är den effektiva konduktiviteten känd för att spela en stor roll och följaktligen utvecklades och implementerades en modell för att införliva en sådan funktion inom TRACEs kontrollsystemmodul.. Resultaten visar att TRACE har en god potential för HTGR-simulering, men för närvarande tillgängliga modeller ger fortfarande instabila lösningar. Slutsatsen är att TRACE behöver ytterligare justeringar för att kunna användas för HTGR-säkerhetsanalyser i framtiden.

The friction process occurs in most structures, especially in contact between two faces with relative motion. The process of friction and abrasion affects the productivity and performance of equipment. In this study, the simulations and experimentations are formed to understand the friction and wear properties of hydraulic rubber seals. The tribometer test rig is developed to investigate rubber samples' friction and abrasion properties with different contact conditions. An observation structure to measure the contact area of the rubber sample also was constructed. The experiments are performed with different contact conditions (dry contact, wet contact, mud contact), different geometry of sample (half-cylinder, half-sphere), quite different contact directions (sliding direction axial and sliding direction lateral), fillet radius, contact angle or rubber material with different sliding velocities and normal forces. In addition, the contact process of rubber seals is simulated and equations for seal wear for the specific experimental conditions are formulated.:CHAPTER 1 Introduction .....................................................................................1 1.1 Motivation and objectives of the thesis…………….………..…..….........…….1 1.2 Structure of the dissertation.........................................................................3 CHAPTER 2 State of the Art………………………………………………...………....4 2.1 Water hydraulic seal.....................................................................................4 2.2 Fundamental tribology..................................................................................7 2.3 Experimental Investigation...........................................................................15 2.4 Simulation....................................................................................................19 CHAPTER 3 Test setup........................................................................................21 3.1 Tribometer test rig........................................................................................21 3.2 Setup for experimental investigation with rubber block……….........………...24 3.3 Setup for experimental investigation with a hydraulic seal………........……..32 3.4 Setup for Simulation………………………………………………..…................37 CHAPTER 4 Friction characteristics of the rubber block………………..…...….38 4.1 Influences on friction characteristic…………………………….…...........…….39 4.2 Test configuration and analysis of measured data…………………..............42 4.3 Results of experiments................................................................................44 4.4 Summary ……………………………………………….……………..............….58 CHAPTER 5 Experimental investigation with hydraulic seals……………….…..60 5.1 Test configuration…………………………………………………….................60 5.2 Result of experimental investigation ………………………….............………64 5.3 Summary…………………………………………………………..............…..….82 CHAPTER 6 Simulation…………………………………………….......……….…..83 6.1 Contact model………………………………………………….............………..83 6.2 Results of simulation……………………………………….…….............….…..85 6.3 Wear equation………………………………………………….............……...…94 6.4 Summary ………………………………………………………...............………102 CHAPTER 7 Conclusions and Recommendations …………….…………………..104 7.1 Summary and conclusion ……………………………………..................……104 7.2 Recommendations…………………….………………………............…….….108 References………………………………………………...…………….....……...…..109

I denna rapport beskrivs en undersökning och jämförelse av två olika sorters segjärn. Detvå materialen som har studerats har varit det segjärnet som används i Parker Hannifinsnuvarande hydraulikmotorer och ett nytt segjärn, vars mekaniska egenskaper har påståttsvara mer fördelaktiga. Målet med arbetet var att få fram en tillförlitlig jämförelse av de olikamaterialen och avgöra om det fanns ett tydligt underlag för att inleda processen av ett byteav material i vissa komponenter i Parker Hannifins produkter.Det utfördes jämförelser mellan de olika materialens mekaniska egenskaper baserade delspå information som redan fanns om materialen och dels på data insamlad vid tester medskärande bearbetning. Förslitning på verktygen vid fräsning studerades tillsammans medskärkraften med olika sorters skärdata. Restspänningar efter ingreppen i de båda materialenmättes med en röntgendiffraktometer.Resultaten gav inga signifikanta indikationer på att ett materialbyte skulle innebära en lägreproduktionskostnad, dock visade analyser att det nya materialet tål att bearbetas fortare ändet traditionella segjärnet och att fler undersökningar bör göras. Efter att ha analyseratmekaniska egenskaper så som hållfasthet, hårdhet, hårdhetsspridning och styvhet kundeslutsatser dras. Det visade sig att det nya segjärnet hade högre hållfasthet och jämnarehårdhet, men det hade även lägre styvhet. Styvheten i materialet är en viktig faktor dåläckage kan uppstå i hydraulikmotorer om materialen inte har tillräckligt hög styvhet.Mätningarna av skärkraften hos de båda materialen tydde på att det kunde uppstå högrestandardavvikelse, eller variationer av skärkraften vid fräsning av det traditionella segjärnet.Eftersom dessa variationer endast visade sig ett fåtal gånger går det inte att entydigtkonstatera att det nya materialet har mer fördelaktiga bearbetningsegenskaper. För att draen sådan slutsats hade det krävts ytterligare analyser på fler detaljer. / This report describes a study and comparison of two different types of ductile iron. Thetwo materials that have been studied have been the ductile iron used in Parker Hannifin'scurrent hydraulic motors and a new ductile iron, whose mechanical properties are said tobe more advantageous. The goal of this study was to obtain a reliable comparison of thedifferent materials and determine if there were clear grounds for initiating the process of achange of material in certain components of Parker Hannifin’s products.Comparisons between the mechanical properties of the materials were based partly oninformation that was already available and partly on data collected through machining trails.The wear on the tools after milling was studied along with the cutting force from variouskinds of cutting data. Residual stresses after the operation in both materials were measuredby an X-ray diffractometer.The results yielded no significant indication that a change of material would result in lowerproduction cost, however, analyses showed that the new material can withstand beingprocessed faster than the traditional ductile iron and that more studies should beconducted. After analyzing the mechanical properties, such as strength, hardness, hardnessvariation and stiffness, conclusions could be drawn. It turned out that the new ductile ironhad higher strength and more uniform hardness, but it also had lower stiffness. Thestiffness of the material is an important factor because if the materials do not havesufficient rigidity, leakage can occur in hydraulic motors. Measurements of the cutting forceof the two materials indicated that there could be a higher standard deviation, orfluctuation of the cutting force during milling of the traditional ductile iron. Since thesevariations only appeared a few times, it is difficult to conclude that the new ductile ironwould be more advantageous when it comes to machining. To be able to draw that kind ofconclusion would require more collected data.

The system code TRACE is the latest development of the U.S. Nuclear Regulatory Commission (US NRC). TRACE, developed for the analysis of operational conditions, transients and accidents of light water reactors (LWR), is a best-estimate code with two fluid, six equation models for mass, energy, and momentum conservation, and related closure models. Since TRACE is mainly applied to LWR specific issues, the validation process related to innovative nuclear systems (liquid metal cooled systems, systems operated with supercritical water, etc.) is very limited, almost not existing. In this work, essential contribution to the validation of TRACE related to lead and lead alloy cooled systems as well as systems operated with supercritical water is provided in a consistent and corporate way. In a first step, model discrepancies of the TRACE source code were removed. This inconsistencies caused the wrong prediction of the thermo physical properties of supercritical water and lead bismuth eutectic, and hence the incorrect prediction of heat transfer relevant characteristic numbers like Reynolds or Prandtl number. In addition to the correction of the models to predict these quantities, models describing the thermo physical properties of lead and Diphyl THT (synthetic heat transfer medium) were implemented. Several experiments and numerical benchmarks were used to validate the modified TRACE version. These experiments, mainly focused on wall-to-fluid heat transfer, revealed that not only the thermo physical properties are afflicted with inconsistencies but also the heat transfer models. The models for the heat transfer to liquid metals were enhanced in a way that the code can now distinguish between pipe and bundle flow by using the right correlation. The heat transfer to supercritical water was not existing in TRACE up to now. Completely new routines were implemented to overcome that issue. The comparison of the calculations to the experiments showed, on one hand, the necessity of these changes and, on the other hand, the success of the new implemented routines and functions. The predictions using the modified TRACE version were close to the experimental data. After validating the modified TRACE version, two design studies related to the Generation IV International Forum (GIF) were investigated. In the first one, a core of a lead-cooled fast reactor (LFR) was analyzed. To include the interaction between the thermal hydraulic and the neutron kinetic due to temperature and density changes, the TRACE code was coupled to the program system ERANOS2.1. The results gained with that coupled system are in accordance with theory and helped to identify sub-assemblies with the highest loads concerning fuel and cladding temperature. The second design which was investigated was the High Performance Light Water Reactor (HPLWR). Since the design of the HPLWR is not finalized, optimization of vital parameters (power, mass flow rate, etc.) are still ongoing. Since most of the parameters are affecting each other, an uncertainty and sensitivity analysis was performed. The uncertainty analysis showed the upper and lower boundaries of selected parameters, which are of importance from the safety point of view (e.g., fuel and cladding temperature, moderator temperature). The sensitivity study identified the most relevant parameters and their influence on the whole system.

Mit dem Begriff "Schachtüberfall" wird eine Hochwasserentlastungsanlage bezeichnet, bei der Überschußwasser von einem horizontalen, im Grundriß meist kreisförmigen Überfall in einen senkrechten oder schrägen Schacht geleitet und durch einen Stollen mit geringem Gefälle ins Unterwasser abgeführt wird. Der Fallschacht hat in der Regel Kreisquerschnitt und ist durch einen 90°-Krümmer mit dem Ablaufstollen verbunden. Schachtüberfälle werden in zunehmenden Maße zur Hochwasserentlastung bei Erd- und Steindämmen verwendet. Sie werden getrennt vom Dammbauwerk im Hang oder als freistehende Türme im Becken errichtet. (...):1. Einleitung S. 4 2. Aufgabenstellung S. 7 3. Grundlagen der hydraulischen Berechnung von Schachtüberfällen S. 9 4. Gestaltung und hydraulische Berechnung des Schachteinlaufes S. 16 5. Gestaltung und hydraulische Berechnung des senkrechten Fallschachtes S. 25 6. Gestaltung und hydraulische Berechnung des Krümmers, Ablaufstollens und Tosbeckens S. 101 7. Versuche S. 118 8. Anwendung der Ergebnisse der Arbeit auf dag Beispiel des Schachtüberfalles der Steinbachtalgperre, Westdeutschland S. 148 9. Zusammenfassung und Ausblick S. 157 10. Literaturverzeichnis S. 161 Anlagen

Machine builder integrate products from different suppliers in their machines or production lines. Today, most of the information is supplier-specific. The major challenge is to extract the necessary information from all products from different suppliers. [... aus dem Text]

Nordhydraulic är ett företag i Kramfors som tillverkar hydrauliska ventiler. Hydrauliska ventiller används inom en mängd olika områden för att styra hydrauliska maskiner. För att hydrauliska ventiler ska fungera korrekt måste dessa vara täta. På Nordhydraulic används en täthetsprovare av modell Nolek S9 N för att göra täthetstester. Täthetsprovaren fyller upp ventilerna med ett förbestämt tryck och mäter sedan flödet av luft in till ventilen som krävs för att bibehålla trycket. Idag har denna metod stora problem med falskt negativa resultat i monteringslinan, vilket innebär att täta ventiler ibland ger ett resultat som visar läckage och därför bildar en flaskhals i monteringen. Detta beror på att det finns många utrymmen i ventilen där luften har svårt att ta sig in. Syftet med det här arbetet var att ta fram ett bättre testprogram, alltså tidsinställningar av de olika parametrarna som används, till Nolek S9 N för att användas i täthetsprovningen för att minska stopp i monteringen. Framtagningen av detta program gjordes genom att göra mätningar med olika tidsinställningar samt anslutningsmetoder för att hitta de viktigaste parametrarna till programmet. Därefter gjordes mätningar på ventiler med monterings- och gjutfel för att se vilket flöde läckaget har vid dessa fel.  Arbetet resulterade i tre olika program för ventilen RS210 som vid tester i monteringen uppnådde godkäna resultat snabbare än det tidigare programmet som användes och med färre falskt negativa resultat. Slutsatsen är att de program som har tagits fram bör ge en förbättring av täthetsprovningen samt att den nuvarande gräns för godkända läckage kan höjas till 50 mm^3/s utan att missa de monteringsfel som kan uppstå. / Nordhydraulic is a company in Kramfors that manufactures hydraulic valves. Hydraulic valves are used in a variety of areas to control hydraulic machines. For hydraulic valves to function properly, they must be tight. At Nordhydraulic, a leak tester called Nolek S9 N is used to determine if valves are tight. The leak tester fills the valves with a predetermined pressure and then measures the flow of air into the valve required to maintain the pressure. Today, this method has major problems with false negative results in the assembly line, which means that tight valves may give a result that indicates leakage and thus can lead to a bottleneck in the assembly. This is because there are many spaces in the valve that are difficult to reach by the air. The purpose of this work was to develop a better program for the Nolek S9 N to be used in the leak test to reduce assembly stops. The development of this program is done by making measurements with different time settings as well as connection methods to find the most important parameters of the program. Then, measurements are made on valves assembly errors and casting errors to see what flow the leakage has at these errors. The work resulted in three different programs for the RS210 valve, which in tests in the assembly achieved approved results faster than the previous program and with fewer false negative results. The conclusion is that the developed program could provide an improvement of the leak test and that the current limit for approved leakage can be increased to 50 mm^3/s  without missing the assembly errors that may occur.

Today’s electric excavators uses standard hydraulics to control external tools. To increase the degree of freedom the excavator is equipped with a tiltrotator placed between arm and bucket. The combination of electronics and hydraulics proves to be less beneficial for the final operating time and shall thereby, if possible, be replaced with other options.  The study is conducted in purpose to present combinations of motors and drives which can apply and resist necessary forces. The solution replaces today’s hydraulic motor and worm drive powered by a hydraulic system existing of pump, hoses, and valves.  The transition can initially be motivated out of earlier studies which shows that electrification of hydraulic components has the potential to reduce the energy usage. In combination with this, excavators with an electric driveline becomes more and more popular which places increasing requirements on underlying systems.  Conduction of this work uses an analysis of earlier studies where identified components are evaluated out of geometric and characteristic features. Apart from this an analysis of strength in combination with required dimensions is made. The final solutions are compared with a hydraulic system to define potential energy savings.  Results shows two suitable solutions, one based on a DC motor and the other based on the patented technique for PMSM; the motors are combined with cycloid drives in two and one stages. The results shows that the solutions can be designed to apply necessary force as well as withstand external ones.

Denna rapport omfattar konstruktionen av ett fristående drivkort med tillhörande mobilapplikation för styrning och konfiguration av ett hydraulsystem. Projektets syfte var att på beställaren Bosch Rexroth ABs begäran undersöka om pump control module (PCM) - en del ur det existerande Spider 3 styrsystemet - kunde användas som en fristående modul. Hårdvara med en Bluetoothmodul skapades och kopplades mot PCM för att möjliggöra kommunikation via Bluetooth. En mobilapplikation utvecklades i Android studio för att tillåta konfiguration från en mobil enhet. Mjukvaran i PCM modifierades för att kommunicera med Bluetooth-hårdvaran över CAN och även för att tillåta analog styrning av pumpen via en strömstyrd ingång. De grundläggande kraven för systemet uppfylldes och en fungerande prototyp kunde uppvisas vid projektets slut. Prototypen visade stor potential men saknade dock viss funktionalitet som vore önskvärd hos en kommersiell produkt. / This report encompasses the development of a standalone drive card with an accompanying mobile application for control and configuration of a hydraulic system. The purpose of the project was to - according to an inquiry from the client Bosch Rexroth - investigate whether the pump control module (PCM) from the existing Spider 3 control system could be used as a standalone module. Hardware including a Bluetooth module was assembled and connected to the PCM to allow communication over Bluetooth Low Energy (BLE). A mobile application where developed in Android Studio to allow configuration from a mobile device. The software of the PCM were modified to communicate with the Bluetooth hardware over CAN and also for allowing analog control of the hydraulic pump through a current controlled input.The basic demands for the system were met and a working prototype could be demonstrated at the end of the project. The prototype did show large potential but was lacking some functionality which would be desirable for a commercial product.

ST Aerospace located at Arlanda airport maintain and repair aircraft components. The maintenance activities that the workshop conducts require testing of the component’s function. For a long time the repair shop has experienced problems with the efficiency in this hydraulic testing. The efficiency problems are partially derived by the fact that the manufacturer’s component maintenance manuals (CMM) are not adapted to the specific test equipment that the shop uses. A lack of suitable training material also causes problems for new operators. The purpose of this thesis work was therefore to streamline this part of ST Aerospace’s operation, first by rewriting the test section of the manuals but also to produce a basic description of the test bench that is used in the testing activities. By studying the operator’s work with component testing a fundamental understanding of the test bench was obtained along with the specific knowledge that was required in order to rewrite the manuals to a version that ST can use with their specific test equipment. Along with the training material a total of four rewritten component manuals were produced on ST’s behalf. Since the purpose of this work was to streamline the company’s entire testing business, there are post-doubts about whether the correct way to address the issue was chosen. As the work continued it became increasingly more obvious that a more appropriate way of handling the efficiency problems should have been to fully focus on the training material for the test bench. By performing the work this way around the future rewriting of the hundreds of component manuals can be drastically simplified and more efficient, therefore the time required for rewriting can be drastically reduced. / ST Aerospace på Arlanda underhåller och reparerar flygplanskomponenter. I de underhållsåtgärder som verkstaden bedriver krävs testning av komponenternas funktion. Under en lång tid har verkstaden upplevt problem med effektiviteten i denna hydrauliska provning. Problemen med effektiviteten härstammar till viss del av att komponenttillverkarens testningsmanualer inte är anpassade till den specifika testutrustning som verkstaden använder sig av. Problemen härstammar också till viss del av att verkstaden haft problem med att utbilda nya operatörer av testutrustningen då lättförståeligt utbildningsmaterial till den avancerade utrustningen saknats. Syftet med detta examensarbete var därför att effektivisera denna del av ST Aerospace:s verksamhet genom att dels skriva om manualers testavsnitt men även att tillverka en lättförståelig beskrivning av verkstadens testutrustning i utbildningssyfte. Genom att följa operatörerna i deras arbete med av företaget utvalda komponenttester kunde en grundläggande förståelse både för testbänken men även för de utvalda testerna erhållas. Erfarenheten från testningen användes till att producera en lättförståelig beskrivning av provbänken samt till omskrivning av de utvalda komponentmanualerna. Utöver utbildningsmaterialet producerades totalt fyra omskrivna komponentmanualer för ST:s räkning. Då syftet med arbetet var att effektivisera hela ST:s provningsverksamhet är det i efterhand tveksamt till om angripningssättet av effektiviseringsproblemen varit rätt. Alltefter arbetets gång insågs i ökande grad att ett mer lämpligt angripningssätt hade varit att lägga all arbetstid på utbildningsmaterialet till provbänken för att på så sätt förenkla de framtida omskrivningarna av komponentmanualer. Ett mer utförligt utbildningsmaterial till testutrustningen kan effektivisera produceringen av omskrivna komponentmanualer betydligt då företaget i dagsläget testar hundratals komponenter.