Dynamic Simulation and Fatigue Analysis of an Automated ... · • MBS-Simulation: – Flux of inner and outer forces of the complete veh icle – Analysis of the dynamic behavior

Doppelmayr Cable Car Presentation 116 June 2014

Dynamic Simulation and Fatigue Analysis of an Automated People Mover (APM)

Dipl.-Ing. Patrick Casagrande1, Dr. Stefan Waser2;Dipl.-Ing. Klaus Puchner2

1) Doppelmayr Cable Car GmbH & Co KG, Wolfurt (A)2) Magna Powertrain, Engineering Center Steyr GmbH & CoKG,

St. Valentin (A)


Content

• Description of a Doppelmayr Cable Car• Target of the Simulation• Description Bogie• Description Train• MBS-model• Results of the MBS-Simulation• FEM-Model• Fatigue-Software FEMFAT• Results Fatigue Analysis• Summary


Doppelmayr Cable Car GmbH & Co KG

• Belongs to the Doppelmayr/Garaventa Gruppe• Since 15 years in the APM business;

– Projects: Birmingham Airport UK, Toronto Pearson Airport, Airport Mexiko City, Venedig, Caracas, 2 systems in Las Vegas, 2 more projects (Doha International Airport und Oakland Airport Connector) are in the commissioning phase


What is a Cable Car?

• Rope propelled, driverless system for public transport

• Fully automated operation; personal in the central control room react if necessary

• Closed rope loop – vehicle is connected to the rope via grips

• No drive machinery in the vehicle (noise level very low, mass of the vehicle is lower…)

• Acceleration and deceleration via drive machinery in a soundproofed room

• Friction between tires and guideway is not a driving parameter in the design


Guiding of the Vehicle• Vertical via tires• Lateral via guiding wheels• Longitudinal via closed rope loop


Target of the simulation

• MBS-Simulation:– Flux of inner and outer forces of the complete vehicle– Analysis of the dynamic behavior of the complete vehicle– Resulting accelerations in the vehicle based on the speed profile – Acting forces in the system as base for the fatigue analysis– Determination of the clearance profile

• FEM und fatigue analysis:– Calculation of the stiffness of the vehicle– Structural analysis of the bogie frame and the car body– Fatigue analysis of the weld seams


Description Bogie

traverse 1 traverse 2

Longitudinal bar

2 dampers

Stabilizing system

Bogie frame

Air spring

2 dampers

Stabilizing system

4 guiding wheels

4 tires


Description Train

Flux of force in the train:• rope – grip – bogie• Car body – traverse 1 – traverse 2 – car body

4 car bodies connected to each other via bogie frames in Jacobs arrangement


MBS-Model• bogie:

– Rigid body– Air spring: stiffness in axial and radial direction– Stablization system and dampers– Contact elements between traverse and bogie frame– guiding: contact elements between wheel and guideway and the correct degrees of freedom

• Car body:– Separated in 2 independent parts connected via a spring element that represents the correct

translational and rotatory stiffness– Dependent on the loading condition the correct mass and inertia of the car body is considered

• Over all model:– Consists of 4 car bodies and 5 bogie frames– Rope between the bogie frames is considered via a unilateral

force with constant stiffness– Lateral forces of the rope are considered via an a priori

Simulation

• Overall model has 450 degrees of freedom


Animation


Rope forces at the bogie frame

arc

slope

slope


• Lateral forces are transmitted via the guiding wheels

• Pre tension in nominal state

• Pre tension is reduced in curved section

Guiding wheels


Accelerations in the Vehicle

• The resulting acceleration in vertical direction is neglectable

• The resulting accelerations in longitudinal and lateral direction are within the allowable limits according to the ASCE 21

ASCE max. acceleration

standing sitting

Long. ±0.16g ±0.35g

Lat. ±0.10g ±0.25g

Vertikal ±0.05g ±0.25g

Long. Notfall ±0.32g ±0.60g


FE-Model end caraluminum profile

steel

glas

„help structure“ with very low stiffness

Al-bearing structurewelded

Non structural mass considered as mass points:• front nose• HVAC unit• doors + door drives• seat boxes• seated passengers Glued windows:

Stiffness of the glue considered


FEMFAT Weld

MAT 207MAT 207 MAT 209MAT 209

C 100C 100

TOPTOP TOPTOP

TO

PT

OP

MA

T 2

11M

AT

211

Modelling GuidelineModelling Guideline

MAT 207 MAT 209

C 100

TOP TOP

TO

P

MA

T 2

11

Modelling Guideline

• damage• safety factors• analysis report

WELD DatabaseWELD DatabaseWELD Database

• FE-Modell• Spannungsergebnisse• Last-Zeit-Verläufe

EUROCODE 3EUROCODE 9DIN 15018British Standard 7608IIW GuidelineFKM GuidelineDVS 1612DVS 1608

Doppelmayr Cable Car Presentation 1616 June 2014 16

Utilization [-]

Utilization caused by tranient loading

End car bearing structure


Utilization [-] 1 2

12 3

34

4

view

Window corners

F4

window F4

Utilization caused by transient loading


Utilization [-] Bogie frame


Utilization [-]

identification of the high loaded weld seams by using FEMFAT Weld

Improvement of the utilization due to changed weld types


Summary

• Creating the model of a Doppelmayr Cable Car• Analysis of the transient behavior of the complete system• Determination of the resulting acceleration in the vehicle• Determination of the inner forces as base of the fatigue analysis• Easy method to analyze the fatigue behavior of weld seams• Improving the fatigue behavior of weld seams due to detailed analysis

Thank you for your attention!


Back up



Standards in FEMFAT WELD• Following standards and guidelines has already been used in conjunction with

FEMFAT WELD:

EUROCODE 3EUROCODE 9DIN 15018British Standard 7608IIW GuidelineFKM GuidelineDVS 1612DVS 1608

by Habenbacher / Stadler Rail


guideway


Documents

Dynamic Simulation and Fatigue Analysis of an Automated ... · • MBS-Simulation: – Flux of inner and outer forces of the complete veh icle – Analysis of the dynamic behavior