SIMPACK Wind and Drivetrain Conference

SIMPACK Wind and Drivetrain Conference

SIMPACK Wind and Drivetrain Conference 

Agenda 

SIMPACK AG, S. Mulski 2010-06-17 Page 2 

Modeling Elements 

Shafts 

Bearings and Mounts 

Transmission Elements 

Gear Pair 

Flexible Bodies 

Rotorblades 

Aerodynamics 

Analysis Methods 

Resonance Analysis 

Transient Analysis 

Order Analysis 

Stress and Durability 

Scripting / Batch 

Simulink Interfaces 

Conclusions


Shafts 

Body Reference Frame (BRF) 

• Body data transferred to “To Marker” of Joint 

• Recommended: BRF on axis (easier handling of 

flexible bodies) 

BRF 


Joint “To Marker” 

BRF, Joint “To Marker” on axis 

Recommended 

BRF, Joint “To Marker” 

Not Recommended



Primitive Cylinder 02 

• For rotating shafts: Segment colour since v. 8900 

• For bearings: Inner diameter with v. 8904 

SIMPACK AG, S. Mulski 2010-06-17 Page 4


Different Force Elements 

• Linear and non-linear stiffness and damping 

• 6x6 matrices 


• User Routines 

• Integrated specialized software (Romax) 

• Complete contact model (not commonly done) 




BEARINX- SIMPACK 

• Schaeffler Technologies GmbH & Co. KG 


Romax Bearing 



• Standard element since v. 8902 

• Look up catalogue (20.000 standard elements - 

SKF, FAG, Koyo, Torrington) 

• Possible to enter outer diameter, bore and width 

• Romax calculates contact for each simulation 

step, as opposed to using look-up tables 

• Simple linear damping model 




Force Elements 41, 42 and 43 

• Evaluation of alignment for calculating moments due to cardanic stiffnesses 




• Results depend upon the order of rotation angles 

1 st alpha 

2 nd beta 

3 rd gamma 






Before v. 8903 two possible modeling techniques: 

1. Always define “From” and “To” markers of force element with z-axis aligned along rotation axis 

2. Use extra body for bearing housing with extra joint and constraint 


GBX_Housing 

� 

Shaft 

� 

� d 

BR 

FE_43



With v. 8903: 


• Choice of “From” and “To” markers of force element is arbitrary 

• Simplified modeling 

• Rotation axis defined within force element 


GBX_Housing 

Shaft 

� 

FE_43



Force Element 70, Elasto Hydro Dynamic (EHD) Bearings 

With v. 8902 

• Calculation of the oil pressure distribution taking flexible 

deformation of shaft and shell into account 

• Embedded Tower software 


“TRUE” EHD analysis (deformed bearing geometry 

considered during online EHD calculation)




With v. 8902 

• Increasing complexity requires increased computation time 


Global Elasticity 

Local Elast. 


Methods 



With v. 8902 

Impedanzce Method 

• Increasing complexity requires increased computation time 

1. Impedance Chart Method 

- Interpolation in dimensionless chart 

- Cylindrical bearing geometry 

- Constant gap in axial direction (no tilting) 

- No surface roughness contact 

2. Online FEM Method 

- Solution of Reynolds Equation in every time step 

- Arbitrary bearing geometry (Grooves, Oil supply) 

- Variable gap in axial direction (Tilting) 

- With surface roughness contact 

3. EHD Method 

- Features as Online FEM Method 

- In addition local bearing deformation 

- With surface roughness contact 


Online FEM Method 

EHD Method 

x 

y 

z 

Model Complexity 

Calculation Speed



Force Element 42, Dynamic Bushing Hydromount 

• Implemented with v. 8902 

• Suspension bushings, hydromounts, crankshaft viscodampers 

• Rotational and translational frequency and amplitude dependent elements 

rubber bushing 

hydromount 


viscodamper



Force Element 42, Dynamic Bushing Hydromount 

• Easy switching of element detail using parameterization 




Force Elements 42, Dynamic Bushing Hydromount 

• Parameter fitting in preprocessing 




Extensive library of gear elements 

• Various levels of detail for optimum solver speed and accuracy 

1-D torsional vibration model 

applied moments 

Torque converter 

applied moments 

support arm forces 


Detailed gearpair 

applied forces 

support arm forces 

bearing forces 

bending moments 

teeth meshing forces/moments 

teeth meshing excitations


Extensive element library 

• Gearboxes (FE 014, 052, 055, 056, 057, 067, 225) 

• Transmission joints (FE 053, 054, 058, 059) 

• Belt Drives (FE 240) 





Torque Convertors 

• FE 014 “Gearbox Torque to Torque” 

Application: Elastic transmission for a “black-box” gearbox 

Features: Transmission ratio, linear/non-linear 

stiffness/damping, non-uniaxial axes, flexible shafts 

• FE 057 “Planetary Gear” 

Application: Automotive & wind turbine drivetrains 

Features (see FE 014, plus): Extra sun/planet/ring bodies, 

parallel axes only 



Gear Pair 

What do Formula 1 Racing and Wind Turbines have in common? 

Detailed SIMPACK Gearwheels developed for F1 (2004) 



Gear Pair 

SIMPACK Gear Pair 

• Internal and external gears 

• Involute spur and helical gears 

• Profile shift 

• Profile and flank modification 

• Single and multiple tooth contact 

• Non-parallel axes with load distribution 

• Dynamic changing backlash and friction 

• Dynamic separation of gear wheel distance 



Gear Pair 

SIMPACK Gear Pair 

• Excitation from tooth meshing 

Courtesy of Prof. Schlecht, TU Dresden 



Gear Pair 

SIMPACK Gear Pair Primitive – New v. 8904 

1. Bevel gear rim thickness 

2. Tooth profile modification 



Gear Pair 

SIMPACK Gear Pair Primitive – New v. 8904 

1. Bevel gear rim thickness 

Before v8904 With v8904 


Rim thickness


Gear Pair 

SIMPACK Gear Pair Primitive – 

New v. 8904 

2. Tooth profile modification 

Left Flank = off Right Flank = on 

Left Flank = on Right Flank = on 


Tip Modification 

Root Modification 


Gear Pair 

Distance 

Distance 

*Perpendicular to the root circle (dedendum); modification only calculated up to base circle. 


Amount * 

Amount 

┴ 

┴ 

Exponent 

yellow=1, orange=2, red=3 

Exponent

Circular Modification 


Gear Pair 

(Pressure) Slope Modification 

Distance 

Distance 


Amount 

┴ 

�r� � angle ��r 

distance� 

�s 

� 

Angle


Gear Pair 

Left/Right Side Modification 

Distance 


┴ 

Amount 

Lead Crowning Amount 

┴ 

┴ 

┴ 

┴ 

┴ 

Exponent


Lead Angular Modification Angle 

Bias (Twist) 

Gear Pair 

Angle 



Gear Pair 

Modification by Array 



Gear Pair 

SIMPACK Gear Pair Force Element 225 – New 8904 



Gear Pair 

Gear Pair Slicing 

• Necessary for non-parallel axes and flank modifications 

• Previously done by time consuming modeling 

• Slicing now possible using single input parameter in force 

element 

to 

from 


Courtesy of Erik Pfleger, Siemens AG


Gear Pair 

Data Check – Output File for Each Gear Pair in Model 



Gear Pair 

Basic Output Values 

• On/Off using parameterisation 



Gear Pair 

Advanced Output Values 

• On/Off and type selection using 

parameterization 


z 

t


Gear Pair 





z 

y 

x


Gear Pair 




Number of 

slices = 1 


n tooth +1 

n tooth 0 

n tooth -1





LIVE DEMO 

Gear Pair 

Number of 

slices = 21 


Etc.


Flexible Tower 

Modelling of Flexible Tower 

• SIMBEAM 

• Parameterized SIMBEAM model 

• Rotorblade generator 

• Import from FE 




Modeling of Flexible Tower 

SIMBEAM parameterized 

• Known diameters and wall thicknesses 

• Easy-to-model variants 

Z +0,00001 





SIMBEAM Rotorblade Generator 

• Known cross-section stiffnesses 

• Easy to model variants 





Import from FE Model 

• Detailed FE structure 

• Stress and durability analysis 



Spec: Flexible 16717, Bodies Support for beam element with twist-bend coupling 

SIMBEAM Elements - New v. 8903 

• Independent mass and elastic properties 

• Arbitrary center of shear location 

• Center of mass and elastic center location 

• EULER-BERNOULLI and TIMOSCHENKO beam 

formulation 

• Non double-symmetric profiles 

• Profiles with eccentric loads (w.r.t. element reference 

frame) 

• Non-homogenious cross-sections 




SIMBEAM Rotorblade Generator 

• Re-ordering of columns 

• Flags for defining location of aerodynamic 

markers 

• Flags for defining orientation of stiffness and 

inertia properties 

• Flags for defining reference system for the shear, 

c.g., and elastic axes (pitch axis or element 

Reference System) 

• Options for choosing which markers to generate) 

• New naming convention for bodies and markers 

of generated rotorblade body 

• Improvements in SIMBEAM and FEMBS 

• Easy-to-model variants 

• Detailed FE model not required 

LIVE Demo 

Basic 


Advanced



SIMBEAM Rotorblade Generator – Validation 

• Eigenfrequencies identical (NASTRAN) 

• Excellent comparison results obtainable 

Important Points to Consider for Comparisons 

• Many different interpolation methods (SIMPACK Rotorblade 

Generator and FE codes) 

• SIMBEAM elements always along neutral axis 

• For twist/bend coupling a small border for “Zero Elements” 

required in FEMBS (e.g. 10.e-10) 

• A large number of modes should be considered for stability 

calculations 

Neutral 

axis 

Some FE Codes 

SIMBEAM and FE 




FE Model Example 

• FE model preparation 

• Connection node location 

• Measurement nodes location 


Courtesy NREL, GRC project

AWSM 


Aerodynamics 

Wind Turbine Aerodynamics 

• AeroDyn (NREL) 

• Bladed (Master thesis) 

• Flex5 (Company specific) 

• ECN models (BEM, AWSM) 

• CFD (Flower) 

• Etc. 



Aerodynamics 

SIMPACK – AeroDyn (NREL) 

• With 8904 – standard interface 

• Compilation of code no longer necessary 

• AeroDyn .dll for SIMPACK available on NREL 

website 

• Supported by SIMPACK AG 


M YR 

F YR 

YR 

F ZR 

ZR 

M ZR 

XR 

F XR 

XR in direction of the rotor axis 

ZR radially, orientated to rotor blade 1 

and perpendicular to XR 

YR perpendicular to XR, 

so that XR, YR, ZR rotate clockwise 

M XR


Analyses 

Eigenvalue Results in PostProcessor (v. 8903) 

• Eigenvalue amplitude 

• Phase 

• Kinetic energy 

• Drag and drop of multiple channels 

Eva file 


k 1 =1 

A 1 

phi 1 


Excitation 

Composition of Time Excitation Using Specific Order 

Components, via Fourier Series (v. 8902) 

• Analytical excitation 

• Order, amplitude and phase can be derived from measured excitation 


+ 

k 2 =2 

A 2 

phi 2 

k 3 =3 

A 3 

phi 3 

+


Analyses 

Eigenvalue Analysis 

• Parameter variation 

• Batch commands 


Run-Up FFT 


Analyses 

• Multiple quasi-static solver runs 

• Plotting FFT of each result 

velocity 

amplitude 

frequency 


velocity 

time


Analyses 


• One single run-up 


velocity 

amplitude 

frequency 


velocity 

time


Analyses 


• One single run-up 


amplitude 

amplitude 


order 

velocity 

time


Analyses 

NVH: Engine Caused Driveline Oscillations 

• Model of the entire truck including engine and driveline 

• Flexible bodies 

• Roller testrig 

•Optimization of driveline behavior 



Analyses 

NVH: Engine Caused Driveline Oscillations 

• Analysis of individual orders 

• Determination of responsible order, (e.g cause of drone) 

• Determining main path of excitation 

• Plotting of all orders, 100% plot 

• Optimization of driveline behavior 


Force 

z 

Sum 

2nd 

1st 

rpm

Frequency Sweep 

1 . 1 0 

0 . 5 5 

0 . 0 0 

- 0 . 5 5 

Aliasing 

Ω 

0 

max 


y(t) � A� 

sin(Ω 

t 

Analyses 

• Frequency sweep 

� 2. 

� � f 

� 

1[ 

s] 

- 1 . 1 0 

0 . 0 0 . 2 0 . 4 0 . 6 0 . 8 1 . 0 

0 

0 

1 

� k �t) 

�t 

2 

f � 20 [ Hz] 


0 

k �180 

[ 1/ 

s 

2 

] 

f 

max 

� 

F r e q u e n c y S w e e p 

t i m e [ s ] 

200 [ Hz]

1 .1 0 

0 .5 5 

0 .0 0 

-0 .5 5 


S a m p lin g ra te 1 0 0 [H z ] 

-1 .1 0 

0 .0 0 .2 0 .4 0 .6 0 .8 1 .0 

1 .1 0 

0 .5 5 

0 .0 0 

-0 .5 5 

tim e [s ] 


-1 .1 0 

0 .0 0 .2 0 .4 0 .6 0 .8 1 .0 

1 .1 0 

0 .5 5 

0 .0 0 

-0 .5 5 

tim e [s ] 


-1 .1 0 

0 .0 0 .2 0 .4 0 .6 0 .8 1 .0 

1 .1 0 

0 .5 5 

0 .0 0 

-0 .5 5 

Aliasing 

Analyses 

tim e [s ] 

S a m p lin g ra te 5 0 0 0 [H z ] 

-1 .1 0 

0 .0 0 .2 0 .4 0 .6 0 .8 1 .0 

tim e [s ] 



Analyses 

Stress Analysis 

• Superposition of modal stresses 

• Applied forces 


Courtesy of Komai


Analyses 

Stress and Durability Analysis 

(Integrated within SIMPACK) 

(SIMPACK export to FEMFAT) 



Qt Script for Applications (QSA) 

• QSA is an easy-to-learn, cross-platform, 

interpreted scripting language 

Typical Scripting Usage 

• Creating batch tasks 

• Automatic report generation 

• Writing macros 

• Customize GUI 

SIMPACK Scripting 

Learning Scripting 

• Use the macro recorder for easily generate your scripts 

• Example scripts available in the SIMPACK Documentation 

• Scripting Tutorial available for 8904 

Command area 

Echo area 



SIMPACK Scripting 

Examples for Scripting 

• Create a GUI for selecting a model and starting the solver 

• Create a script for applying filter chains (PostProc) 

• Create a simple ASCII exporter (batch mode) 



Why Batch Jobs? 

• Batch = Shell or script driven execution of programs or program modules 

Advantages 

SIMPACK Batch Commands 

• Easy variant calculations 

• Job execution, independent from any GUI 

(remote login without X-application) 

• Execution of several time extensive jobs 

“over night” 

• Defining a complete analysis scenario 

(PreProc-Solver-PostProc) by calling only 

one script 

• Results are standardized 


Where? 


• Execute the batch in the command shell MSYS (delivered with SIMPACK) 

Supported Functionalities 

• Time integration 

• Driven equilibrium 

• Inverse kinematics 

• Test call 

• Linear system analysis 

• Rotorblade 

• SIMAT 

• VTL 

SIMPACK Batch Commands 


# ---------------------------------------------------------------------------- 

# --- Simulation: Shell-Commands 

# ---------------------------------------------------------------------------- 

mkdir ./Eig/ ; rm ./Eig/*.eva 

# ---------------------------------------------------------------------------- 

# --- Model: 06_linear_resonance_analysis.sys 

# ---------------------------------------------------------------------------- 

model=06_linear_resonance_analysis 

Example file: MyBatch.ksh 

# ---------------------------------------------------------------------------- 

# --- Simulation: Eigenvalue 

# ---------------------------------------------------------------------------- 

# 10 = time of integration [s] at which the eigenvalues should be calculated 

simpack integ $model 

simpack linear_eig 10 none $model 

mv "./${model}.output/${model}.ev.sbr" "${wkdir}/Eig/${model}__10.ev.sbr" 

mv "./${model}.output/${model}.eva" "${wkdir}/Eig/${model}__10.eva"


SIMAT - Linear Model Export 

SIMAT - Co-simulation 

Overview of the Interfaces to MATLAB and Simulink 


MatSIM 

Code Export 


Overview of the Interfaces to MATLAB and Simulink 


MATLAB/Simulink Model 


Using “MatSIM” for the Multi-Domain Simulations 

Overview of the “MatSIM” Interface 

MatSIM creates a 

new SIMPACK Control 

Element 

Real Time 

Workshop 


Coupled Simulation in SIMPACK

SIMPACK 

U Zwischenkreis 


Using “MatSIM” for the Multi-Domain Simulations 

Simulation of an Asynchronous Motor and a Generator Short-Circuit 

(as time excitation) 

MATLAB/Simulink I 

(MatSIM-element) 

converter 

short-circuit 

functions 


uR uS �t � 

�t� uT �t� Coupled simulation in SIMPACK. SIMPACK 

Simulation of variants of the Simulink model directly in SIMPACK 

MATLAB/Simulink II 

� 

(MatSIM-element) 

Asynchronous 

motor 

(from measurements) 

parameter 

M �t� iR �t � 

iS �t � 

iT �t �


Conclusion 

New with SIMPACK 8904: 

• Profile and flank modification 

• Automatic slicing 

• Visualisation of force arrows 

• Improved SIMBEAM and Rotorblade Generator for 

flutter calculations 

• And many other improved functionalities 

Easier and faster modeling with improved 

accuracy!

SIMPACK Wind and Drivetrain Conference

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