Finite element based modeling and simulation of an elastomer gear rim

Menning, Johannes D.M.; Ewert, Arthur; Prokopchuk, Artem; Schlecht, Berthold; Henke, Markus; Wallmersperger, Thomas

doi:10.1002/pamm.202200141

Cited by 7 publications

(5 citation statements)

References 15 publications

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“…This is of importance, since based on the integration concept the force transmitted by a tooth is measured. Using a MBS-model, parameterised based on a finite element model from Menning et al [7] for elastic jaw couplings, it was shown that the displacements induct a sinusoidal fluctuation of the transmitted force. The amplitude F can reach, depending on the amount of displacement and the specific angle, up to F = 20 % of the nominal force F nomi when compared to aligned shaft hubs.…”

Section: Discussionmentioning

confidence: 99%

“…In order to determine the applied load on a tooth it is necessary to know the torsion-torque characteristic of the coupling. Few sources are available regarding this subject, Sladkowski and Opasiak [8], Bilgar et al [9], and Menning et al [7] modelled an elastomeric jaw coupling. Only Menning et al have developed a detailed finite element model for the calculation of the coupling, but the calculation times for the model are very high, due to the visco-elasticity of the material and the changing contact areas during loading.…”

Section: Methodsmentioning

confidence: 99%

“…The elastic gear rim is reduced to eight Force-Elements, each representing a tooth of the rim, which interlock with the hubs. Their stiffness is modelled based on the static torsion-torque characteristic derived from the finite element model by Menning et al [7] and considered through a lookup table in the force element. This characteristic is shown in Figure 2b.…”

Section: Methodsmentioning

confidence: 99%

“…Additionally the amplifier serves as a protective border between DES and the claws of the hubs. Furthermore, the temperature is measured, since the non-linear stiffness of the TPU is highly temperature-dependent and decreases with increasing temperature [7].…”

Section: Sensor Integrationmentioning

confidence: 99%

“…. Ewert, J. D. M. Menning, A. Prokopchuk, T. Rosenlöcher, E.-F. M. Henke, T. Wallmersperger, and B. Schlecht Definition of the misalignments K r , K w and ζ in ∆s/∆s nomi F in F/F nomi (b) Force-displacement characteristic derived from the torsion-torque characteristic by[7] …”

mentioning

confidence: 99%

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Smart Machine Elements - Sensor-Integrated Elastomer Couplings

Ewert,

Menning,

Prokopchuk

et al. 2023

10th ECCOMAS Thematic Conference on Smart Structures and Materials

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The available computational performance is steadily increasing. On this basis, digital twins become possible, but the need for data increases. In mechanical engineering, research in recent decades has focused on providing data based on external sensors, e.g. accelerometers. In contrast, in recent years, effort have been made to provide data directly from a machine element itself. The aim of this work is to outline the concept of a sensor integrated machine element (SiME), using the example of a sensor-integrated jaw coupling for "in situ" data acquisition and transmission. Elastic couplings are an integral component of the drive train and hold vast development potential. The jaw coupling will be able to measure the transferred torque. The determination of the torque is based on the measurement of capacity changes resulting from the deformation of the elastic teeth of the gear rim. Based on the high deformations of the tooth, a soft strain sensor made of dielectric elastomer material (DES) is integrated. Furthermore, it can be shown that the rotational speed and shaft misalignments can be evaluated based on the same data. In order to evaluate the sensor-integrated coupling both a static and a dynamic test bench are described. Therefore, different load cases are defined to evaluate the performance of the jaw coupling. They are focused on the visco-elastic behaviour of the materials used for the elastic gear rim.

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Section: Discussionmentioning

confidence: 99%

Section: Methodsmentioning

confidence: 99%

Section: Methodsmentioning

confidence: 99%

Section: Sensor Integrationmentioning

confidence: 99%

mentioning

confidence: 99%

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Smart Machine Elements - Sensor-Integrated Elastomer Couplings

Ewert,

Menning,

Prokopchuk

et al. 2023

10th ECCOMAS Thematic Conference on Smart Structures and Materials

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A Review on Sensor‐Integrating Machine Elements

Kirchner,

Wallmersperger,

Gwosch

et al. 2024

Advanced Sensor Research

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This contribution summarizes the current state of research regarding so‐called sensor‐integrating machine elements as an enabler of digitalization in mechanical engineering and——if available—their application in industry. The focus is on the methodical aspects of the development of these machine elements in general as well as specific sensor‐integrating machine elements that are either already in use or currently under development. Developmental aspects include the robust design of initially evaluated concepts for sensor‐integrating machine elements as well as their modularization. Smart materials with sensory functions are included in the analysis as well as the differentiation with regard to add‐on sensors. The aim of the authors interlinked by a special research program funded by the German Research Foundation (DFG) is to facilitate the exchange with other researchers with the help of the comprehensive overview given in this contribution. The contribution concludes with a brief discussion of open challenges, such as the energy supply and data transfer in rotating systems and also data security.

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Numerical detection of shaft misalignments using a sensor‐integrating jaw coupling

Menning,

Ewert,

Prokopchuk

et al. 2024

Proc Appl Math and Mech

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Shaft misalignments are one of the main causes of damage to couplings in machines. If they are not detected in time, they can lead to machine downtimes. When assembling a machine, however, it is not always possible to align the shafts perfectly. Elastic couplings are able to compensate for such misalignments up to a certain degree. To detect the present radial misalignment, the concept of a sensor‐integrating jaw coupling, developed to determine the transmitted torque, is used. In the teeth of the gear rim, boreholes are drilled and dielectric elastomer sensors (DES) are inserted. If the teeth deform during use of the coupling the DES will deform as well, leading to a change in capacitance, which can be detected. If the two shafts, which the coupling connects, are perfectly aligned to each other, each of the loaded teeth will deform uniformly. However, if there is a radial or angular misalignment, the deformation is different for each tooth, which can be determined with the help of the DES. To demonstrate this effect, a finite element model of the sensor‐integrating jaw coupling with misalignments is created, and numerical simulations are conducted. In this model, the hyper‐viscoelastic material behavior of (i) the gear rim of the jaw coupling and (ii) the DES is taken into account. From the mechanical simulation, the deformed state of the DES is obtained, which is used to compute the capacitance of the sensor. With the results of the numerical simulations, a symbolic regression is performed. The result is an analytical formula that makes the accurate detection of the present radial misalignment possible. The developed framework can later be easily programmed on a microcontroller which is integrated in the sensor‐integrating jaw coupling.

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Finite element based modeling and simulation of an elastomer gear rim

Cited by 7 publications

References 15 publications

Smart Machine Elements - Sensor-Integrated Elastomer Couplings

Smart Machine Elements - Sensor-Integrated Elastomer Couplings

A Review on Sensor‐Integrating Machine Elements

Numerical detection of shaft misalignments using a sensor‐integrating jaw coupling

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