Development of a simplified method for the lifetime prediction of profile rail guides under universal moment loads

开发通用力矩载荷下型材导轨寿命预测的简化方法

• 批准号: 380444129
• 负责人: Professor Dr.-Ing. Steffen Ihlenfeldt
• 金额: --
• 依托单位: Institut für mechatronischen Maschinenbau
• 依托单位国家: 德国
• 项目类别: Research Grants
• 资助国家: 德国
• 项目状态: 未结题
• 来源: https://gepris.dfg.de/gepris/projekt/380444129?language=en
• 关键词: Development; simplified; method; lifetime; prediction

Profiled rail guides (PRG) transmit forces and torques in every direction, except of the travel direction, between relatively moving assemblies. The values of these forces are important input variables for the lifespan calculation of the PRG. Pitching and yawing moments lead to different rolling contact forces within a carriage track. With the "rolling contact related life calculation" (RCRL) this fact is taken into account, that leads to lifespans that are four times higher than with the conventional lifespan calculation method. For the determination of the rolling contact forces, a mathematical method was developed, that makes FE-Calculations redundant for the user. Previous experimental investigations, which are not finished yet, with pitching torques on the PRG have shown the possible applicability of the RCRL. What is striking, however, is the large variation in the distances travelled by the PRG around the lifespan calculated with the RCRL.PRG are usually used as a composite of a carriage with four wagons and two slides. The rigidities of the surrounding parts in combination with mounting and production tolerances as well as thermal expansions lead to constraint forces in the PRG, whereby the lifespan is affected in a negative way. Furthermore, load spectra that are used for lifespan calculations cannot always be predicted because they can often change with different machining operations.Therefore, the mentioned operating conditions of PRG and the individual damage process of every single PRG ought to be taken into account in this research project. With contactless sensors, the distance between the wagon and the slide should be measured continuously and in high resolution. With that and the previously developed calculation methods, the rolling contact forces can be calculated at real operating conditions and thus the RCRL can be done. In addition, the dynamic behaviour of the PRG ought to be analysed in order to realize a condition monitoring system that predicts an impending failure of the PRG with previously developed machine learning methods and/or wear models. For the realisation of the mentioned prediction methods, control integrated measurement and analysis functions have to be developed and, furthermore, lifespan investigations with variable loads have to be conducted for validation.The full potential of the PRG should be exploited much better, whereby the risk of the usage of PRG is reduced for the user and the maintenance interval is specified.

异型导轨（PRG）在相对移动的组件之间传递除行进方向之外的各个方向上的力和扭矩。这些力的值是PRG寿命计算的重要输入变量。俯仰力矩和偏航力矩导致滑架轨道内不同的滚动接触力。“滚动接触相关寿命计算”（RCRL）考虑了这一事实，从而使寿命比传统寿命计算方法高出四倍。为了确定滚动接触力，开发了一种数学方法，使用户无需进行有限元计算。以前的实验研究，这是尚未完成的，与俯仰力矩的PRG显示可能的适用性RCRL。然而，令人惊讶的是，PRG在使用RCRL计算的寿命期间行驶的距离变化很大。PRG通常用作四节车厢和两个滑道的组合。周围部件的刚性与安装和生产公差以及热膨胀相结合导致PRG中的约束力，由此寿命受到负面影响。此外，用于寿命计算的载荷谱并不总是可以预测的，因为它们经常会随着不同的加工操作而改变。因此，在本研究项目中，应该考虑PRG的上述操作条件和每个PRG的单独损伤过程。使用非接触式传感器时，应连续、高分辨率地测量货车和滑道之间的距离。利用该方法和以前开发的计算方法，可以计算真实的运行条件下的滚动接触力，从而可以进行RCRL。此外，应该分析PRG的动态行为，以便实现状态监测系统，该状态监测系统利用先前开发的机器学习方法和/或磨损模型来预测PRG即将发生的故障。为了实现上述预测方法，必须开发控制集成测量和分析功能，此外，必须进行可变负载的寿命调查以进行验证。应更好地开发PRG的全部潜力，从而降低用户使用PRG的风险，并规定维护间隔。