Design of an Innovative Test Rig for Industrial Bearing Monitoring with Self-Balancing Layout

The remote prognosis and diagnosis of bearings can prevent industrial system failures, but the availability of realistic experimental data, being as close as possible to those detected in industrial applications, is essential to validate the monitoring algorithms. In this paper, an innovative bearing test rig architecture is presented, based on the novel concept of “self-contained box”. The monitoring activity is applicable to a set of four middle-sized bearings simultaneously, while undergoing the independent application of radial and axial loads in order to simulate the behavior of the real industrial machinery. The impact of actions on the platform and supports is mitigated by the so-called “self-contained box” layout, leading to self-balancing of actions within the rotor system. Moreover, the high modularity of this innovative layout allows installing various sized bearings, just changing mechanical adapters. This leads to a reduction of cost as well as of system down-time required to change bearings. The test rig is equipped with suitable instrumentation to develop effective procedures and tools for in- and out-monitoring of the system. An initial characterization of the healthy system is presented.

The effect of lubricant viscosity on the performance of full ceramic ball bearings

As a new high-end bearing product, full ceramic ball bearings are favoured in a variety. However, there have been few studies on the lubrication of full ceramic ball bearings. The purpose of this study is to reveal the relationship between the vibration and temperature rise of full ceramic angular contact ball bearings and the lubricant viscosity, and to improve the service life of the bearings. In this study, the effects of lubricant viscosity on the vibration and temperature rise of silicon nitride full ceramic angular contact ball bearings under different axial loads and rotation speeds were tested. Herein, a mathematical model of oil lubrication suitable for full ceramic ball bearings is established and the relationship between the lubricant viscosity, lubricant film thickness, outer ring vibration and temperature rise of the bearing is analyzed. It was found that the vibration and temperature rise first decrease and then increase with the increase of lubricant viscosity. In this range, there is an optimal viscosity value to minimize the vibration and temperature rise of the full ceramic angular contact ball bearing. The contact surface wear of the full ceramic angular contact ball bearing varies greatly under different lubricant viscosities. There is no obvious wear on the contact surface under optimal viscosity, and the service life of the bearing is greatly improved. These results can play an important role in revealing the lubricant mechanism of full ceramic ball bearings and improving their service life under optimal lubrication.

Effect of the Distribution of Mass and Structural Member Discretization on the Seismic Response of Steel Buildings

The response of steel moment frames is estimated by first considering that the mass matrix is the concentrated type (ML) and then consistent type (MC). The effect of considering more than one element per beam is also evaluated. Low-, mid- and high-rise frames, modeled as complex-2D-MDOF systems, are used in the numerical study. Results indicate that if ML is used, depending upon the response parameter under consideration, the structural model, the seismic intensity and the structural location, the response can be significantly overestimated, precisely calculated, or significantly underestimated. Axial loads at columns, on an average basis, are significantly overestimated (up to 60%), while lateral drifts and flexural moments at beams are precisely calculated. Inter-story shears and flexural moments at columns, on average, are underestimated by up to 15% and 35%, respectively; however, underestimations of up to 60% can be seen for some individual strong motions. Similarly, if just one element per beam is used in the structural modeling, inter-story shears and axial loads on columns are overestimated, on average, by up to 21% and 95%, respectively, while the lateral drifts are precisely calculated. Flexural moments at columns and beams can be considerably underestimated (on average up to 14% and 35%, respectively), but underestimations larger than 50% can be seen for some individual cases. Hence, there is no error in terms of lateral drifts if ML or one element per beam is used, but significant errors can be introduced in the design due to the overestimation and underestimation of the design forces. It is strongly suggested to use MC and at least two elements per beam in the structural modeling.

Axial Force Analysis of the Support Bracket of Pumped Storage Unit

During operation, the support bracket is the main part to withstand the axial loads of the pumped storage unit. Moreover, the effects of axial loads including the hydraulic thrust of runner flow and the weight of runner body may cause the support bracket deformation and fatigue damage. For the safe and stable operation, the simulation of the axial force and the structural analysis of the support bracket of a pumped storage unit was carried out in this paper. The CFD simulation result has revealed the variation rule of the axial force in different operating conditions. Using ANSYS Mechanical, the static stresses and deformation of support bracket with axial loads were calculated. The results release the location and variations of maximum stress and maximum deformation caused by the axial loads. By comparing the predicted maximum axial force with the admission force calculated by the structural analysis, it is found that the axial force of the researched machine is within the safe range. This study provides the reference for the safety and stable operation of the pumped storage unit.

ANALYSIS OF THE STRESS-STRAIN STATE OF AN ASYNCHRONOUS MOTOR WITH A SHORT-CIRCUITED ROTOR UNDER AXIAL LOADS

A comparative description of the most popular and professional 3D modeling packages using the finite element method in solving problems is given. The choice of using the SolidWorks Simulation package at this stage of research is justified. Its main advantages are given. A 3D model of a real functioning asynchronous motor has been designed and modified to perform linear displacement operations. A static analysis of the strength of an asynchronous motor with linear displacement of the actuator using the plug-in module SolidWorks Simulation was performed. A direct analysis of the obtained result of the stress-strain state of the engine is carried out. Conclusions are drawn about its suitability to work with axial loads. The main directions of subsequent research of asynchronous motors with a short-circuited rotor under axial loads are determined.

Deformation and Failure Properties of High-Ni Lithium-Ion Battery under Axial Loads

To explore the failure modes of high-Ni batteries under different axial loads, quasi-static compression and dynamic impact tests were carried out. The characteristics of voltage, load, and temperature of a battery cell with different states of charge (SOCs) were investigated in quasi-static tests. The mechanical response and safety performance of lithium-ion batteries subjected to axial shock wave impact load were also investigated by using a split Hopkinson pressure bar (SHPB) system. Different failure modes of the battery were identified. Under quasi-static axial compression, the intensity of thermal runaway becomes more severe with the increase in SOC and loading speed, and the time for lithium-ion batteries to reach complete failure decreases with the increase in SOC. In comparison, under dynamic SHPB experiments, an internal short circuit occurred after impact, but no violent thermal runaway was observed.

Experimental and Numerical Investigation of Contact Parameters in a Dovetail Type of Blade Root Joints

this paper focuses on the contact characteristics of the blade root joints subjected to the dry friction damping under periodic excitation. The numerical method and experimental procedure are combined to trace the contact behavior in the nonlinear vibration conditions. In experimental procedure, a novel excitation method alongside the accurate measurements is used to determine the frequencies of the blade under different axial loads. In numerical simulations, local behavior of contact areas is investigated using the reduction method as a reliable and fast solver. Subsequently, by using both experimental measurements and numerical outcomes in a developed code, the global stiffness matrix is calculated. This leads to find the normal and tangential stiffness in the contact areas of a dovetail blade root joints. The results indicate that the proposed method can provide an accurate quantitative assessment for investigation the dynamic response of the joints with focusing the contact areas.

ASPECTS OF BRAKING EFFICIENCY CRITERIA FOR FREIGHT WAGONS UNDER THE LATEST RULES OF HOST 34434-18

The paper deals with the analysis of the braking efficiency criteria for freight trains formed with wagons that have increased axle load up to 294.3 kN (30 ts) when moving at speeds up to 120 km/h inclusive. Increasing the efficiency of freight trains by increasing the technical and economic performance of cars by increasing the axial load to 294.3 kN (30 ts) and train speeds up to 160 km/h led to the development of technical requirements and rules for braking systems set out in HOST 34434-18. According to the new rules and requirements, the following are accepted as criteria for the braking efficiency of freight wagons, that is, up to the maximum values of the braking distances of the freight train on the site in the specified intervals of speeds of axial loads; calculated coefficients of force of pressing of composite blocks on wheels at braking; the pressing force of the composite pads on the axis in terms of cast iron pads. The calculation of the maximum allowable value of the braking distance of the freight train is performed based on the actual pressing forces and the actual friction coefficients. The paper shows that the specific braking forces obtained using the actual pressing forces exceed the calculated specific braking forces using the calculated coefficients. Based on the above-mentioned, it is concluded that the braking efficiency criteria with reference to the maximum allowable values of the braking distances and the calculated coefficients of the pressing force have a significant discrepancy between each other. It is proposed to use the actual pressure force coefficients instead of the calculated coefficients to assess the braking efficiency of the freight train. The paper presents the permissible values of the actual force values of pressing the pads on the wheels for wagons with axial load (230.5 - 294.3) kN at speeds up to 120 km/h inclusive, for which the braking distance criterion of the freight train is observed. Key words: criterion, braking efficiency, freight train, axial load, braking distance, specific braking force, calculated coefficients, actual coefficient.

Unique 15kpsi Multistage Fracturing Liner System Delivers Solution to Overcome Tight Formation Challenges

Open hole Multistage Fracturing (MSF) systems have been deployed for treating open hole formations with multiple, high rate hydraulic fracturing stages while gaining efficiency during pumping operations unlike traditional plug-and-perf operations. One important challenge within the industry was availability of an open hole packer system that can overcome tough wellbore conditions during deployment and function as designed during the high rate high pressure stimulation operations. This paper will discuss the successful planning and deployment of one such system. For successful deployment of any open hole fracturing completion, one must first consider the environment that the system will be deployed into. Lateral length, open hole size, parent casing size and tubing stresses during fracturing and production all inclusively influence the need for a robust and reliable system. Other several important considerations to be deployed as a liner is the compatibility of the completion tools with the Liner deployment system, the robustness of being deployed into challenging open hole conditions where capability of high circulating rates and rotation become mandatory to get the bottom hole assembly (BHA) to its final setting depth. Last but not least, in order to achieve successful stimulation, each component of the system after overcoming all the deployment obstacles should function as designed withstanding treating differentials as high as 15kpsi, while simultaneously accommodating induced axial loads caused by these high-pressure treatments. The development and testing of individual components of the system was done keeping in mind wellbore instability and obstacles the completion will have to overcome during deployment. The field execution was planned with close collaboration with the operator and other key services that were involved for drilling the well. Real-time monitoring of the well allowed for simultaneous swift implementation of changes required on tool activation pressures, identification of hazards and mitigation plan to overcome challenges in order to execute the job successfully. It is worth mentioning that the successful deployment of this system represents the first use of additive manufacturing in high pressure, hydraulic set open hole packers. This technology allowed overcoming the barriers of challenges associated with deploying open hole completion in tight challenging formations that would otherwise have limited deployment capabilities.