<p>Establishing permanent and sustainable human settlements outside Earth presents numerous challenges. The Resilient Extra-Terrestrial Habitat Institute (RETHi) has been established to advance the fundamental knowledge needed to enable and design resilient habitats in deep space, that will adapt, absorb, and rapidly recover from expected and unexpected disruptions without fundamental changes in function or sacrifices in safety.</p> <p>Future extra-terrestrial habitats will rely on several subsystems working synergistically to ensure adequate power supply, life support to crew members, manage extreme environmental conditions, and monitor the health status of the equipment. To study extra-terrestrial habitats, a combination of modeling approaches and experimental validations is necessary, but deep-space conditions cannot be entirely reproduced in a laboratory setting (e.g., micro-gravity effects). To this end, real-time multi-physics cyber-physical testing is a novel approach of simulating and evaluating complex system-of-systems (SoS) that has been applied to investigate the behavior of extra-terrestrial habitats under different scenarios (e.g., meteorite strikes). One of the most critical components which determines the success of the cyber-physical testbed is the transfer system serving as an interface between the physical and cyber substructures.</p> <p>Through this work, a dedicated thermal transfer system has been designed and constructed to provide realistic thermal boundary conditions to the physical habitat according to the real-time simulation results from cyber substructure of the habitat. The extreme temperatures to be found at the interface between the external protective layer of the habitat (cyber) and the interior structural elements (physical) are emulated by means of a cryogenic chiller and an array of cooled panels that cover a dome-style structure. Moreover, the overall architecture of the cyber-physical testbed, the partitioning of the virtual and physical environments, and interface schemes were also established. The experimental results obtained from the thermal transfer system prototype setup were analyzed and interpreted to generate meaningful recommendations for future development and application of the full-sized testbed.</p>

The purpose of this study is to develop and analyze the possibilities of implementing a new crash test method for child bike trailers based on StVZO §67 Explanation 19 Appendix 2 at Thule Test Center or use an alternative method. The study is based on the following three problem statements: can a new method based on StVZO §67 Explanation 19 Appendix 2 replace TÜV and RISE test methods? Is it possible to implement a new test method in Thule Crash Lab using the acceleration sled track or using a different approach? How can crash testing contribute to optimizing the development of child bike trailers? This study began with background information and the problem description of Thule’s lack of test method and their need for a new alternative. The theorical background provides information about testing for product development. It also provides information about StVZO §67 Explanation 19 Appendix 2 which will be the basis for the study and the previous test methods Thule has used, which were RISE and TÜV.  Observations, analyzes and an interview from the previous test methods established the foundation for the concept study which included brainstorming sessions to generate concepts for the new test method. The concepts consisted both of methods with and without the acceleration sled track. Several workshops served as concept selections which filtered out concepts that exceeded limitations of the facilities at Thule Test Center. The concepts that could not fulfill the requirements from StVZO §67 Explanation 19 Appendix 2 was also filtered out.  To find out if the acceleration sled could be used as a test method, different tests were involved which included evaluation of test impulses and crash tests with handmade fixtures for the child bike trailer. This was carried out to ensure that the crash sled could operate under the variables that was calculated in preparation for the test and that the fixtures could handle the accelerations.  The study also included discussions and conclusions with suggestions for modifications to the concepts that could not be directly implemented due to the limitations in Thule facilities. Some of the modifications were also taken up as suggestions for further research. The study also included comparison between internal and external testing. The comparison explained the importance for Thule to have an internal test method and generally an alternative for crash testing their child bike trailers. As presented in the study, crash testing is crucial for an optimized development of new child bike trailers to ensure safe, qualitative and durable child bike trailers. It is also crucial to stay competitive in the market. To validate stresses and forces subjected onto the construction of the final test method, static calculations were performed which gave an indication of what dimensions the beams for the construction could have. As discussed, dynamic calculations could have been done to achieve a more precise and accurate result.  The final test method is an example of what Thule could use for crash testing their child bike trailers with the requirements from StVZO §67 Explanation 19 Appendix 2. Design changes are possible if it were to be implemented and the new test method gives Thule an internally option.

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The overall aim of this thesis was to identify valid, simple, and inexpensive physical tests that can be used for evaluation of firefighters’ physical work capacity. Paper I included fulltime- and part-time firefighters (n = 193), aged 20-60 years. Perceived physical demands of firefighting work tasks were ranked, and comparisons between subject groups rating were done with the Mann Whitney U-test and Binominal test. Papers II and III included male firefighters and civilian men and women (n = 38), aged 24-57 years. Laboratory and field tests of aerobic fitness, muscle strength and endurance, balance, and simulated firefighting work tasks were performed. Physical capacity comparisons between subject groups were done and bivariate correlations between physical tests and work capacity in the simulated firefighting work tasks analyzed. Paper IV included the same subjects as in Paper II-III (training-set), and additional 90 subjects (prediction-set), aged 20-50 years. Laboratory and field tests of aerobic fitness, muscle strength and endurance and balance, and simulated firefighting work tasks were included. Data from the training-set was used to build models for prediction of firefighters’ physical work capacity, using multivariate statistic. The prediction-set was used to externally validate the selected models. Several work tasks were rated as physically demanding and significant differences (p &lt; 0.05) in ratings were found between full-time and part-time firefighters (Paper I). Significant differences were found between subject groups in physical capacity, and work capacity (p &lt; 0.01) (Paper II-IV). Both laboratory and field tests were significantly (p &lt; 0.01) correlated with work capacity time (Paper II-III). The prediction (R2) and predictive power (Q2) of firefighters’ work capacity (Carrying hose baskets upstairs, Hose pulling, Demolition at or after a fire, Victim rescue, and Carrying hose baskets over terrain) was R2 = 0.74 to 0.91, and Q2 = 0.65 to 0.85, and the external validation ranged between R2: 0.38 to 0.80 (Paper IV). In conclusion, rowing 500 m (s), maximal handgrip strength (kg), endurance bench press (n), running 3000 m (s and s scaled to body weight) upright barbell row (n) and standing broad jump (m) together provides valid information about firefighters’ physical work capacity.

Thermally modified wood (TMW) contains no toxic components and is recommended for its durability, levels of equilibrium of moisture content, and dimensional stability performance. A limitation of TMW is the lack of market acceptance and products due to insufficient information regarding the performance of commercially available products. The goal of this project was to improve the market penetration and industrial processes of TMW. The first objective was to study the perception of TMW products from architects in North America using a survey instrument. Results revealed that information regarding TMW is not reaching the audience for TMW, and that providing knowledge regarding technical and marketing aspects of TMW is essential to increase the market share. The second objective consisted of the evaluation of the variability of the physical and mechanical properties of three thermally treated species manufactured in North America. Results showed that the performance of the commercially produced material was similar among the three companies, where only in seven out of 24 properties had statistical differences. Properties that were significantly different, did not have large enough differences in means to be realistically noticed by customers and all were highly different from untreated wood. The final objective involved the implementation of Lean thinking to the manufacturing process of TMW with the goal of improving the process with a direct impact on cost and waste reductions. Three companies were used as case studies for the production process. The implementation of Lean thinking in the process proposed a reduction in lead times from 55.47 days to 23.20 days, with an increase in value-added activities from 1% to 6%. Most of these gains were obtained through a reduction in inventory levels. / Master of Science / Thermally modified wood (TMW) contains no toxic components and is recommended for its durability, levels of equilibrium of moisture content, and dimensional stability performance. The current market for TMW encounters a lack market acceptance, due to insufficient information and performance measures. The main goal of this study was to increase market penetration and study the industrial processes for manufacturing TMW, using three specifics objectives. For the first objective, a survey was conducted to study the perception of TMW among architects. The results showed a that there was a lack of information regarding the technical and marketing aspects of TMW products, which needs to be addressed by distributors and producers. The second objective consisted of the evaluation of the variability of mechanical and physical properties of three thermally treated species manufactured in North America. The results showed that the performance from the commercial processes were similar, where only seven out of 24 cases showed statistical differences based on the Analysis of Variance (ANOVA). The final objective consisted of a Lean process strategy to produce TMW, improving the process with a direct impact on cost and waste reduction. To study the production process, three case study companies were used. The proposed Lean process reduced the lead times and value-added activities increased. The primary gain was seen in reducing inventory levels.

Résumé : Le développement des matériaux composites et leur utilisation dans le domaine du génie civil ont fait l’objet d’une recherche extensive sur le renforcement des structures en béton armé. Dans ce contexte, les études sur la compréhension du comportement structural des tubes en matériaux composites (Polymère renforcé en Fibre, PRF) sont indispensables. De fait que les matériaux composites sont innovateurs, cela nous exige de procéder à des investigations expérimentales approfondies pour vérifier les hypothèses et les théories, avant de les produire à échelle industrielle. Ce projet présente une étude expérimentale approfondie sur l’évaluation des propriétés physiques et mécaniques des nouveaux tubes en matériaux composites (PRF), et des tests sur la durabilité du matériau utilisé, et permet d’étudier l’influence de quelques facteurs environnementaux sur ces propriétés mécaniques, ces conditions sont simulées par une immersion prolongée en milieu aqueux et l'exposition à des cycles gel-dégel en milieu humide. Les tubes considérés sont produits par le procédé d’enroulement filamentaire à l’aide des fibres de verre (E) et de résine (Vinyle-Ester). Les expérimentations seront effectuées sur des échantillons normalisés prélevés à partir du tube. Les résultats de cette étude sont d’une importance cruciale pour comprendre le comportement structural (avant et après un vieillissement accéléré) des nouveaux tubes fabriqués entièrement en polymères renforcés de fibres par le procédé de l’enroulement filamentaire. // Abstract : The development of composite materials and their integration in the field of civil engineering has been the subject of extensive research on strengthening reinforced concrete structures. In the perspective of strengthening concrete structures by tubes made of composite materials. In this context, the need for knowledge of the structural behaviour of tubes made from fibre reinforced polymer (FRP) composite materials is prominent. The large using of innovativeFRP required extensive theoretical and experimental investigations. This project presents an experimental study to evaluate both the physical and mechanical properties of FRP-composites tubes, and to investigate the impact of some environmental factors on their mechanical properties. The tubes are produced by a filament winding process using fibre (E)-glass and vinyl-Ester resin. The experiments will be performed on standardized samples of the tube. The main objective of this project is to assess the physical and mechanical properties of laminated FRP composites, and then test the durability of the material used in the manufacture of the tubes. It leads to the study of the effects of some environmental factors on the mechanical properties of material. These conditions occur during an immersion in an aqueous medium and exposure to freeze-thaw cycles. The results of this study are crucial to understand the structural behavior (before and after accelerated aging) of new FRP tubes made by filament winding process.

<p>Real-time hybrid simulation (RTHS) has demonstrated certain advantages over conventional large-scale testing. In an RTHS, the system that is under study is partitioned into a numerical and a physical substructure, where the numerical part is comprised of those elements that are easier to model mathematically, while the physical part consists of those that present a complex behavior difficult to capture in a numerical model. The most complex part of this study is the isolation system, a technology used to protect structures against earthquakes by modifying how they respond to ground motions. Unbonded Fiber Reinforced Elastomeric Isolators (UFREIs) are devices that can accomplish this task and have gained attention in recent years because of their modest but valuable features that make them suitable for implementation in low-rise buildings and in developing countries because of their low cost. Our end goal for this work is to enable the testing of scaled versions of these elastomeric isolators to understand their behavior under shear tests and realistic loading. </p> <p>A testing instrument was designed and constructed to apply a uniaxial compressive force up to 22kN and a shear force of 8kN simultaneously to the specimens. A testing program was conducted where four primary sources of signal distortion were identified as caused by the servo-hydraulic system. From these results, a mechanics-based model was developed to understand better the dynamics that the sliding table can introduce to the measured signals accounting for inertial and dissipative forces. Two Bouc-Wen models were implemented to simulate the behavior of the UFREIs. The first only accounts for the hysteretic behavior of the isolator, and the second accounts for the additional nonlinearities found in the isolator’s behavior. These models were assembled in a virtual RTHS which is available to users interested in learning the applications of RTHS of a base-isolated structure with a nonlinear component.</p> <p>An RTHS experiment was conducted in the IISL where the control system comprised a delay compensator and a proportional-integral controller, which exhibited a good tracking performance with minimal delay and low RMSE. However, it can increase the distortion of the oil-column resonance in the measured signals. The simulation captures the behavior of the isolated structure for small displacements. However, it underestimates the displacement of the full-scale specimen for large displacements. The RTHS showed a better approximation of the displacement of the full-scale structure than the theoretical behavior approximated by the Bouc-Wen models.</p>

Hypoid gears have been used extensively in automobiles, aerospace, marine and other applications for decades. The special advantages of hypoid gears come with inherent contact complexities of varying curvature and sliding in both profile and lengthwise direction. Spalling failure is catastrophic and needs to be addressed with deeper roots in gear design. Analytical methods present several limitations. Iterative development from experimentation is expensive and time consuming with different nonlinear parameters difficult to interpret. This thesis aims to develop a method to calculate contact fatigue life for initiation of spalling using finite element methods. Experiments have played a major role in understanding the causal factors for failure, determining the fatigue life and to study the major system design parameters. A failure analysis of the fractured flank is performed. It clarified the design causal factors for failure and the mechanism of failure. Pinion being the vulnerable part is the focus of this thesis, a finite element model was developed on ANSOL HFM and the residual stresses were superposed on MSC Marc. A finite element fatigue analysis is performed on FEMFAT and the component fatigue life is determined. The calculated fatigue life is compared with physical testing results using Weibull statistical analysis in combination with probabilistic bearing life models to formulate emphatical correlation methods. The goal of this thesis is to establish a method to estimate fatigue life by taking up example of computing subsurface fatigue life of a hypoid pinion. The influence factors like the method of contact analysis, different types of residual stresses due to case hardening and shot peening, fatigue criteria, friction, material properties are studied in this thesis to develop a conscience for the methodology to computing contact fatigue life. The bulk material properties based on hardness represented fatigue properties more accurately. Scaled normal stress in critical plane fatigue criteria was found more suitable for contact analysis with pre-stresses and multi-axial non-proportional contact stress state on FEMFAT. Finite element based contact analysis method was found to be more suitable for subsurface fatigue life estimation despite the inherent advantages of the hybrid surface integral method and its accurate representation of friction. It was found that inclusion of friction in model did not change the fatigue life significantly, showing that the influence of hardness, surface topographies lubrication and contact temperature on shear stresses are too large to be neglected. Contact fatigue life increased by a factor of 4.4 times due to shot peening of gears in comparison with case hardening indicating the influence of residual stresses. For the estimation of fatigue life at the initiation of failure, a complete correlation with the fatigue test results could not be achieved and reasons for deviations were clearly identified. The area of damage indicated by this computation method correlated with the damage observed during tests. The observations and calculations indicated premature failure of pinion with explanation of mechanism of failure of pinion flank using contact conditions. / Hypoidväxlar har använts i stor utsträckning i bilar, flyg-, marin- och andra applikationer under årtionden. De speciella fördelarna med hypoidväxlar kommer med inneboende kontaktkomplexitet med varierande krökning och glidning i både profil och längdriktning. Spallingfel är katastrofala och måste hanteras med grundlig redskapsdesign. Analytiska metoder har flera begränsningar. Iterativ utveckling baserad på experiment är dyrt och tidskrävande med olika icke-linjära parametrar som är svåra att tolka. Denna avhandling syftar till att utveckla en metod för att beräkna kontaktutmattningslivslängden för initiering av spalling med finitaelementmetoden. Experiment har spelat en viktig roll för att förstå orsaksfaktorerna för fel, bestämma utmattningslivslängden och för att studera de viktigaste systemdesignparametrarna. En felanalys av den skadade kuggflanken utfördes, vilket förtydligade felens orsaksfaktorer och den underliggande felmekanismerna. Driften är fokus för denna avhandling, en finitaelementmodell utvecklades med ANSOL-HFM och restspänningarna överlagrades med FEM-verktyget MSC-Marc. En slutlig elementutmattningsanalys utfördes med FEMFAT och komponentens utmattningstid bestämdes. Den beräknade utmattningslivslängden korrelerades med fysiska provningsresultat genom att tillämpa statistisk Weibullanalys i kombination med probabilistiska livslängdsmodeller. Målet med denna avhandling är att utveckla en metod för att uppskatta utmattningslivslängden och att tillämpa metoden för att beräkna bulkmaterialets utmattningslivslängd för ett hypoidrev. Påverkningsfaktorer som metoden för kontaktanalys, olika typer av restspänningar på grund av ythärdning och kulblästring, utmattningskriterier, friktion, materialegenskaper studeras i denna avhandling för att utveckla denna metod för att prediktera kontaktutmattningslivslängden. Bulkmaterialegenskaperna för hårdhet representerade utmattningsegenskaperna mera exakt. Skalad normalspänning i kritiska planutmattningskriterier befanns vara mer lämplig för kontaktanalys med förspänningar och multi-axiell icke-proportionell kontaktspänningsstatu än andra egenskaper med FEMFAT. Metodbaserad kontaktanalysmetod visade sig vara mer lämplig för uppskattning av ytutmattningslivslängd trots de inneboende fördelarna med hybridytaintegralmetoden och dess mera exakta friktionsrepresentation. Det visade sig att inkludering av friktion i modellen inte markant förändrade livslängden, vilket visade att påverkan av hårdhet, smörjning av ytorna och kontakttemperatur på skjuvspänningarna är för stor för att försummas. Kontaktutmattningslivslängden ökade med en faktor 4,4 gånger på grund av kugghjulning jämfört med ythärdning, vilket indikerar restspänningspåverkan. För att uppskatta utmattningslivslängden vid inledningen av ytfel kunde en fullständig korrelation med utmattningstestresultaten inte uppnås och orsakerna till avvikelser identifierades tydligt. Det skadade område som indikeras av denna beräkningsmetod korrelerade väl med den skada som observerades under testerna. Observationerna och beräkningarna indikerade tidigt fel i kuggen med förklaring av mekanismen för fel hos kuggflanken med hjälp av aktuellt kontaktförhållande.