Dynamic Simulation and Fatigue Analysis of an Automated People Mover (APM)
Dipl.-Ing. Patrick Casagrande 1, Dr. Stefan Waser 2;Dipl.-Ing. Klaus Puchner 2
1) Doppelmayr Cable Car GmbH & Co KG, Wolfurt (A) 2) Magna Powertrain, Engineering Center Steyr GmbH & CoKG, St. Valentin (A)
16 June 2014 Doppelmayr Cable Car Presentation 1 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
16 June 2014 Doppelmayr Cable Car Presentation 2 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
16 June 2014 Doppelmayr Cable Car Presentation 3 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
16 June 2014 Doppelmayr Cable Car Presentation 4 Guiding of the Vehicle • Vertical via tires • Lateral via guiding wheels • Longitudinal via closed rope loop
16 June 2014 Doppelmayr Cable Car Presentation 5 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
16 June 2014 Doppelmayr Cable Car Presentation 6 Description Bogie
traverse 1 traverse 2
2 dampers 2 dampers
Longitudinal Air spring Stabilizing bar Stabilizing system system
Bogie frame
4 guiding 4 tires wheels
16 June 2014 Doppelmayr Cable Car Presentation 7 Description Train 4 car bodies connected to each other via bogie frames in Jacobs arrangement
Flux of force in the train: • rope – grip – bogie • Car body – traverse 1 – traverse 2 – car body
16 June 2014 Doppelmayr Cable Car Presentation 8 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
16 June 2014 Doppelmayr Cable Car Presentation 9 Animation
16 June 2014 Doppelmayr Cable Car Presentation 10 Rope forces at the bogie frame
arc slope slope
16 June 2014 Doppelmayr Cable Car Presentation 11 Guiding wheels
• Lateral forces are transmitted via the guiding wheels • Pre tension in nominal state • Pre tension is reduced in curved section
16 June 2014 Doppelmayr Cable Car Presentation 12 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
16 June 2014 Doppelmayr Cable Car Presentation 13 FE-Model end car „help structure“ with very low stiffness aluminum profile glas
Al-bearing structure welded
steel 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
16 June 2014 Doppelmayr Cable Car Presentation 14 FEMFAT Weld • FE-Modell • Spannungsergebnisse • Last-Zeit-Verläufe Modelling Guideline TOPTOP TOP
C 100 MATMATMAT 211 211 211
TOPTOPTOP TOPTOPTOP MAT 207 MAT 209
• damage • safety factors EUROCODE 3 • analysis report WELD Database EUROCODE 9 DIN 15018 British Standard 7608 IIW Guideline FKM Guideline DVS 1612 DVS 1608
16 June 2014 Doppelmayr Cable Car Presentation 15 Utilization [-] End car bearing structure
Utilization caused by tranient loading
16 June 2014 Doppelmayr Cable Car Presentation 16 16 Utilization [-] 1 2 Window corners
F4 view window F4
2 3 4 1 3
4
Utilization caused by transient loading
16 June 2014 Doppelmayr Cable Car Presentation 17 Utilization [-] Bogie frame
16 June 2014 Doppelmayr Cable Car Presentation 18 Utilization [-] Improvement of the utilization due to changed weld types
identification of the high loaded weld seams by using FEMFAT Weld
16 June 2014 Doppelmayr Cable Car Presentation 19 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!
16 June 2014 Doppelmayr Cable Car Presentation 20 Back up
16 June 2014 Doppelmayr Cable Car Presentation 21 16 June 2014 Doppelmayr Cable Car Presentation 22 Standards in FEMFAT WELD • Following standards and guidelines has already been used in conjunction with FEMFAT WELD:
EUROCODE 3 EUROCODE 9 DIN 15018 British Standard 7608 IIW Guideline FKM Guideline DVS 1612 DVS 1608
by Habenbacher / Stadler Rail
16 June 2014 Doppelmayr Cable Car Presentation 23 guideway
16 June 2014 Doppelmayr Cable Car Presentation 24 16 June 2014 Doppelmayr Cable Car Presentation 25