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

轮廓导轨（PRG）在相对运动的组件之间传递作用力和扭矩，除了行程方向。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车厢轨道内不同的滚动接触力。使用“滚动接触相关寿命计算”（RCRL）考虑到这一事实，导致寿命比传统寿命计算方法高出四倍。为了确定滚动接触力，提出了一种数学方法，使用户不必进行有限元计算。先前的实验研究尚未完成，在PRG上使用俯仰扭矩已经显示了RCRL的可能适用性。然而，令人吃惊的是，PRG在用RCRL计算的生命周期内移动的距离变化很大。PRG通常是由四节车厢和两个滑梯组成的。周围部件的刚性与安装和生产公差以及热膨胀相结合会导致PRG中的约束力，从而对寿命产生负面影响。此外，用于寿命计算的负载谱不能总是预测，因为它们经常会随着不同的加工操作而变化。因此，在本研究项目中应考虑上述PRG的运行条件和每一个PRG的单个损伤过程。有了非接触式传感器，小车和滑梯之间的距离应该连续测量，并且分辨率高。利用该方法和已有的计算方法，可以计算出实际工况下的滚动接触力，从而实现RCRL的计算。此外，应该分析PRG的动态行为，以便实现状态监测系统，该系统可以使用先前开发的机器学习方法和/或磨损模型预测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。应该更好地利用PRG的全部潜力，从而减少用户使用PRG的风险，并指定维护间隔。

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.