The thesis is performed in order to improve the curvic coupled engagement of a dog clutch situated in the transfer case of a truck. The dog clutch is used to engage the so called all-wheel-drive system of the truck. If the driver tries to engage the all-wheel-drive when truck’s rear wheels already skid, due to a slippery surface a relative rotational speed in the dog clutch will occur. This relative rotational speed will cause the dog clutch to bounce back of itself before engagement, or to not engage at all. The dog clutch has been redesigned to prevent this. Dynamic simulations using MD Adams have been made for the existing model, for the models created in previous works, and for the new model in order to figure out which of them will show the most stable engagement, at high relative rotational speed. The implemented simulations show that better results can be obtained. Separation into two parts of the disc pushed by the fork, shows that dog clutch’s engagement is faster and more stable, comparing to the original model and the other created models. The new model shows better coupling in the whole range of the relative rotational speed from 50 up to 120rpm.

Industrial robot manipulators are general-purpose machines used for industrial automation in order to increase productivity, flexibility, and product quality. Other reasons for using industrial robots are cost saving, and elimination of hazardous and unpleasant work. Robot motion control is a key competence for robot manufacturers, and the current development is focused on increasing the robot performance, reducing the robot cost, improving safety, and introducing new functionalities.  Therefore, there is a need to continuously improve the mathematical models and control methods in order to fulfil conflicting requirements, such as increased performance of a weight-reduced robot, with lower mechanical stiffness and more complicated vibration modes. One reason for this development of the robot mechanical structure is of course cost-reduction, but other benefits are also obtained, such as lower environmental impact, lower power consumption, improved dexterity, and higher safety. This thesis deals with different aspects of modeling and control of flexible, i.e., elastic, manipulators. For an accurate description of a modern industrial manipulator, this thesis shows that the traditional flexible joint model, described in literature, is not sufficient. An improved model where the elasticity is described by a number of localized multidimensional spring-damper pairs is therefore proposed. This model is called the extended flexible joint model. The main contributions of this work are the design and analysis of identification methods, and of inverse dynamics control methods, for the extended flexible joint model. The proposed identification method is a frequency-domain non-linear gray-box method, which is evaluated by the identification of a modern six-axes robot manipulator. The identified model gives a good description of the global behavior of this robot. The inverse dynamics problem is discussed, and a solution methodology is proposed. This methodology is based on the solution of a differential algebraic equation (DAE). The inverse dynamics solution is then used for feedforward control of both a simulated manipulator and of a real robot manipulator. The last part of this work concerns feedback control. First, a model-based nonlinear feedback control (feedback linearization) is evaluated and compared to a model-based feedforward control algorithm. Finally, two benchmark problems for robust feedback control of a flexible manipulator are presented and some proposed solutions are analyzed.

Normally the trucks with four wheel drive option will be running in rear wheel drives and the front wheels will be rotating freely. In extreme tough driving conditions, the risk for getting stopped or slipping the rear wheels in mud is high. When the driver tries to engage the four wheel drive option and due to the difference in relative rotational speed of the dog clutch parts, there is a risk for slipping off or bouncing back of the dog clutch. After studying the importance of gear geometry and a few parameters, the team ended up with a new design and the performance of the design found satisfactory when simulated in MSC ADAMS.

Many engineering applications make use of fiber assemblies under compression. Unfortunately, this compression behavior is difficult to predict, due to nonlinear compliance, hysteresis, and anelasticity. The main objective of this research is to develop an algorithm which is capable of incorporating the microscale features of the fiber network into macroscopic scale applications, particularly the modeling of contact mechanics in multibody systems. In micromechanical approaches, the response of a fiber assembly to an external force is related to the response of basic fiber units as well as the interactions between these units, i.e. the mechanical properties of the constituent fibers and the architecture of the assembly will both have a significant influence on the overall response of the assembly to compressive load schemes. Probabilistic and statistical principles are used to construct the structure of the uniformly-distributed random network. Different micromechanical approaches in modeling felt, as a nonwoven fiber assembly with unique mechanical properties, are explored to gain insight into the key mechanisms that influence its compressive response. Based on the deformation processes and techniques in estimating the number of fiber contacts, three micromechanical models are introduced: (1) constitutive equations for micromechanics of three-dimensional fiberwebs under small strains, in which elongation of the fibers is the key deformation mechanism, adapted for large deformation ranges; (2) micromechanical model based on the rate theory of granular media, in which bending and torsion of fibers are the predominant elemental deformations used to calculate compliances of a particular contact; and (3) a mechanistic model developed using the general deformation theory of the fiber networks with fiber bending at the micro level and a binomial distribution of fiber contacts. A well-established mechanistic model, based on fiber-to-fiber friction at the micro level, is presented for predicting the hysteresis in compression behavior of wool fiberwebs. A novel algorithm is introduced to incorporate a hysteretic micromechanical model - a combination of the mechanistic model with microstructural fiber bending, which uses a binomial distribution of the number of fiber-to-fiber contacts, and the friction-based hysteresis idea - into the contact mechanics of multibody simulations with felt-lined interacting bodies. Considering the realistic case in which a portion of fibers slides, the fiber network can be treated as two subnetworks: one from the fibers with non-sliding contact points, responsible for the elastic response of the network, and the other consisting of fibers that slide, generating irreversible hysteresis phenomenon in the fiberweb compression. A parameter identification is performed to minimize the error between the micromechanical model and the elastic part of the loading-unloading experimental data for felt, then contribution of friction was added to the obtained mechanistic compression-recovery curves. The theoretical framework for constructing a mechanistic multibody dynamic model of a vertical piano action is developed, and its general validity is established using a prototype model. Dynamic equations of motion are derived symbolically for the piano action using a graph-theoretic formulation. The model fidelity is increased by including hammer-string interaction, backcheck wire and hammer shank flexibility, a sophisticated key pivot model, nonlinear models of bridle strap and butt spring, and a novel mathematical contact model. The developed nonlinear hysteretic micromechanical model is used for the hammer-string interaction to affirm the reliability and applicability of the model in general multibody dynamic simulations. In addition, dynamic modeling of a flexible hub-beam system with an eccentric tip mass including nonlinear hysteretic contact is studied. The model represents the mechanical finger of an actuator for a piano key. Achieving a desired finger-key contact force profile that replicates that of a real pianist's finger requires dynamic and vibration analysis of the actuator device. The governing differential equations for the dynamic behavior of the system are derived using Euler-Bernoulli beam theory along with Lagrange's method. To discretize the distributed parameter flexible beam in the model, the finite element method is utilized. Excessive vibration due to the arm flexibility and also the rigid-body oscillations of the arm, especially during the period of key-felt contact, is eliminated utilizing a simple grounded rotational dashpot and a grounded rotational dashpot with a one-sided relation. The effect on vibration behavior attributed to these additional components is demonstrated using the simulated model.

Linearized stability analysis methodologies, system identification algorithms and optimal control approaches that are applicable to large scale, flexible multibody dynamic systems are presented in this thesis. For stability analysis, two classes of closely related algorithms based on a partial Floquet approach and on an autoregressive approach, respectively, are presented in a common framework that underlines their similarity and their relationship to other methods. The robustness of the proposed approach is improved by using optimized signals that are derived from the proper orthogonal modes of the system. Finally, a signal synthesis procedure based on the identified frequencies and damping rates is shown to be an important tool for assessing the accuracy of the identified parameters; furthermore, it provides a means of resolving the frequency indeterminacy associated with the eigenvalues of the transition matrix for periodic systems. For system identification, a robust algorithm is developed to construct subspace plant models. This algorithm uniquely combines the methods of minimum realization and subspace identification. It bypasses the computation of Markov parameters because the free impulse response of the system can be directly computed in the present computational environment. Minimum realization concepts were applied to identify the stability and output matrices. On the other hand, subspace identification algorithms construct a state space plant model of linear system by using computationally expensive oblique matrix projection operations. The proposed algorithm avoids this burden by computing the Kalman filter gain matrix and model dependency on external inputs in a small sized subspace. Balanced model truncation and similarity transformation form the theoretical foundation of proposed algorithm. Finally, a forward innovation model is constructed and estimates the input-output behavior of the system within a specified level of accuracy. The proposed system identification algorithms are computationally inexpensive and consist of purely post processing steps that can be used with any multi-physics computational tool or with experimental data. Optimal control methodologies that are applicable to comprehensive large-scale flexible multibody systems are presented. A classical linear quadratic Gaussian controller is designed, including subspace plant identification, the evaluation of linear quadratic regulator feedback gain and Kalman filter gain matrices and online control implementation.

The first part of this dissertation focuses on the development, implementation and validation of models that capture the behavior of joints in a realistic manner. These models are presented within the framework of finite element based, nonlinear multibody dynamics formulations that ensure unconditional nonlinear stability of the computation for systems of arbitrary topology. The proposed approach can be divided into three parts. First, the joint configuration: this purely kinematic part deals with the description of the configuration of the joint and the evaluation of the relative distance and relative tangential velocity between the contacting bodies. Second, the contact conditions: in most cases, contact at the joint is of an intermittent nature. And finally, the contact forces: this last part deals with the evaluation of the forces that arise at the interface between contacting bodies. The advantage of the proposed approach is that the three parts of the problem can be formulated and implemented independently. Many articulated rotor helicopters use hydraulic dampers, which provide high levels of damping but are also associated with high maintenance costs and difficulties in evaluating their conditions due to the presence of seals, lubricants and numerous moving parts, all operating in a rotating frame. To avoid problems associated with hydraulic dampers, the industry is now switching to elastomeric lead-lag dampers that feature simpler mechanical design, lower part count, and result in "dry" rotors. However, the design of robust elastomeric dampers is hampered by the lack of reliable analytical tools that can predict their damping behavior in the presence of large multi-frequency motions experienced by the rotor and thus the damper. The second part of this dissertation focuses on the development of an elastomeric damper model which predicts the behavior of the elastomeric damper based on a continuum mechanics approach: the configuration of the damper is modeled using a finite element approach, and material behavior is represented by a set of nonlinear constitutive laws and material parameters. The validated finite element model of the elastomeric damper is then coupled with a comprehensive, multibody dynamics analysis code to predict the behavior of complex systems featuring elastomeric components.

Tires serve as important components of wheeled vehicles and their analytical modeling has drawn the attention of many researches in the past decades. A high-resolution finite element (FE) tire model contains detailed structural and material characteristics of a tire that exhibit degrees-of-freedom (DoF) in the order of 10⁵ or greater. However, such high-resolution models in their full detail are not practically applicable in multibody dynamic analysis of vehicles and a reduction in their order becomes necessary. In this research different formulations to construct condensed FE tire models suitable for multibody simulations are developed and their characteristics are discussed. In addition, two new and novel forms of substructuring are presented that aim at isolating the contact region of a tire without the need for keeping the boundary DoF which otherwise remain in the reduced system in the standard substructuring procedures. The new substructuring methods provide a great tool in constructing condensed FE tire models with much less total number of DoF compared to cases where a standard substructuring is used. In order to increase the computational efficiency of the condensed FE tire models even further, the possibility of model condensation in the contact region is studied. This research also addresses the applicability of available friction models into the condensed FE tire models. Different formulations of a condensed tire model presented in this research are used to construct several computational models. These models are utilized to simulate certain scenarios and the results are discussed.

Methods of component mode synthesis, such as Craig and Bampton reduction, are known to generally yield more accurate results in deformable multibody dynamics. The main shortcoming of those methods is that they are intuitively based. Recently Nikravesh developed a reduction method called mode condensation which is derived from the equations of motion and yields the same results as Craig and Bampton reduction. In this dissertation, it is proven that these two methods span the same column space; therefore, they should yield identical results. We propose that mode condensation provides an analytical justification for Craig and Bampton reduction. Test results suggest that Craig and Bampton reduction and mode condensation are appropriate for a broader range of applications because their column space matches up well with the conditions under which the deformable body is restrained. Although Guyan reduction preserves exact solutions for static problems, its applications shall be limited to low frequency excitation because of raised eigen-frequencies. Modal truncation is not recommended for use in multibody dynamic settings because it lacks the ability to receive forces and displacements at the moving boundary. Another issue addressed in this dissertation is the misconception that if mean axes are adopted as the moving reference frame, only free-free modes should be used for model reduction. It was not clear how a restrained deformable body with mean axes can be condensed properly. We have shown that the conventional (nodal-fixed) mode shapes can be used with mean axes as long as the transformation matrix has full rank and contains complete rigid-body mode shapes.

Many engineering applications make use of fiber assemblies under compression. Unfortunately, this compression behavior is difficult to predict, due to nonlinear compliance, hysteresis, and anelasticity. The main objective of this research is to develop an algorithm which is capable of incorporating the microscale features of the fiber network into macroscopic scale applications, particularly the modeling of contact mechanics in multibody systems. In micromechanical approaches, the response of a fiber assembly to an external force is related to the response of basic fiber units as well as the interactions between these units, i.e. the mechanical properties of the constituent fibers and the architecture of the assembly will both have a significant influence on the overall response of the assembly to compressive load schemes. Probabilistic and statistical principles are used to construct the structure of the uniformly-distributed random network. Different micromechanical approaches in modeling felt, as a nonwoven fiber assembly with unique mechanical properties, are explored to gain insight into the key mechanisms that influence its compressive response. Based on the deformation processes and techniques in estimating the number of fiber contacts, three micromechanical models are introduced: (1) constitutive equations for micromechanics of three-dimensional fiberwebs under small strains, in which elongation of the fibers is the key deformation mechanism, adapted for large deformation ranges; (2) micromechanical model based on the rate theory of granular media, in which bending and torsion of fibers are the predominant elemental deformations used to calculate compliances of a particular contact; and (3) a mechanistic model developed using the general deformation theory of the fiber networks with fiber bending at the micro level and a binomial distribution of fiber contacts. A well-established mechanistic model, based on fiber-to-fiber friction at the micro level, is presented for predicting the hysteresis in compression behavior of wool fiberwebs. A novel algorithm is introduced to incorporate a hysteretic micromechanical model - a combination of the mechanistic model with microstructural fiber bending, which uses a binomial distribution of the number of fiber-to-fiber contacts, and the friction-based hysteresis idea - into the contact mechanics of multibody simulations with felt-lined interacting bodies. Considering the realistic case in which a portion of fibers slides, the fiber network can be treated as two subnetworks: one from the fibers with non-sliding contact points, responsible for the elastic response of the network, and the other consisting of fibers that slide, generating irreversible hysteresis phenomenon in the fiberweb compression. A parameter identification is performed to minimize the error between the micromechanical model and the elastic part of the loading-unloading experimental data for felt, then contribution of friction was added to the obtained mechanistic compression-recovery curves. The theoretical framework for constructing a mechanistic multibody dynamic model of a vertical piano action is developed, and its general validity is established using a prototype model. Dynamic equations of motion are derived symbolically for the piano action using a graph-theoretic formulation. The model fidelity is increased by including hammer-string interaction, backcheck wire and hammer shank flexibility, a sophisticated key pivot model, nonlinear models of bridle strap and butt spring, and a novel mathematical contact model. The developed nonlinear hysteretic micromechanical model is used for the hammer-string interaction to affirm the reliability and applicability of the model in general multibody dynamic simulations. In addition, dynamic modeling of a flexible hub-beam system with an eccentric tip mass including nonlinear hysteretic contact is studied. The model represents the mechanical finger of an actuator for a piano key. Achieving a desired finger-key contact force profile that replicates that of a real pianist's finger requires dynamic and vibration analysis of the actuator device. The governing differential equations for the dynamic behavior of the system are derived using Euler-Bernoulli beam theory along with Lagrange's method. To discretize the distributed parameter flexible beam in the model, the finite element method is utilized. Excessive vibration due to the arm flexibility and also the rigid-body oscillations of the arm, especially during the period of key-felt contact, is eliminated utilizing a simple grounded rotational dashpot and a grounded rotational dashpot with a one-sided relation. The effect on vibration behavior attributed to these additional components is demonstrated using the simulated model.

Environmental, aesthetic and political pressures continue to push for siting off-shore wind turbines beyond sight of land, where waters tend to be deeper, and use of floating structures is likely to be considered. Savings could potentially be realized by reducing hull size, which would allow more compliance with the wind thrust force in the pitch direction. On the other hand, these structures with large-amplitude motions will make dynamic analysis both more challenging and more critical. Prior to the present work, there were no existing dynamic simulation tools specifically intended for compliant wind turbine design. Development and application of a new computational method underlying a new time-domain simulation tool is presented in this dissertation. The compliant floating wind turbine system is considered as a multibody system including tower, nacelle, rotor and other moving parts. Euler's equations of motion are first applied to the compliant design to investigate the large-amplitude motions. Then, a new formulation of multibody dynamics is developed through application of the conservation of both linear momentum and angular momentum to the entire system directly. A base body is prescribed within the compliant wind turbine system, and the equations of motion (EOMs) of the system are projected into the coordinate system associated with this body. Only six basic EOMs of the system are required to capture 6 unknown degrees of freedom (DOFs) of the base body when mechanical DOFs between contiguous bodies are prescribed. The 6 x 6 mass matrix is actually composed of two decoupled 3 x 3 mass matrices for translation and rotation, respectively. Each element within the matrix includes the inertial effects of all bodies. This condensation decreases the coupling between elements in the mass matrix, and so minimizes the computational demand. The simulation results are verified by critical comparison with those of the popular wind turbine dynamics software FAST. The new formulation is generalized to form the momentum cloud method (M- CM), which is particularly well suited to the serial mechanical N-body systems connected by revolute joints with prescribed relative rotation. The MCM is then expanded to multibody systems with more complicated joints and connection types.