Modeling and experimental characterization of belt drive systems in micro-hybrid vehicles

Belt Drive Systems (BDS) constitute the traditional automotive mechanism used to power the main internal accessories (such as the alternator, water pump and air conditioning pump) taking power from the engine's crankshaft rotational motion. BDS usually work in the severe ambient conditions of the engine compartment and are subject to highly dynamic excitations coming from the crankshaft harmonics. The substitution of the traditional alternator with an electric machine, namely Belt Starter Generator (BSG), is the most promising micro-hybrid technology towards a quick and effective satisfaction of the current regulations of fuel consumption and pollutant emissions reduction. The use of a BSG leads to increased stresses in the already complex front end accessory drive. As a matter of fact, a BSG is an electrical machine able to work both as motor and as generator and defines two distinct functioning modes of the drive, namely motor and alternator modes. The relative alternation of tight and slack spans profoundly changes the functionality of the overall drive and affects its transmissions capability and efficiency, furthermore resulting in NVH (noise vibration harshness) effects that need to be carefully addressed. Traditional automatic tensioners acting on the slack span of the alternator mode application are not capable of facing the irregular stresses of a BSG-based BDS which requires the use of a tensioning device capable of keeping the belt tension inside a safe range and of preventing slippage during all the operating conditions of the drive. With this goal many solutions are currently being investigated, such as the cooperation of two tensioners one for each span, active tensioners, double arm tensioners or hydraulic tensioners. The critical issues due to the involvement of BSG in BDS require a deep study focused on the tension conditions of the belt and its influence on the overall efficiency of the system. The aim of the research described in this thesis is to obtain a defined modelling approach of belt drive systems for micro-hybrid vehicles and to validate it through extensive experimental analysis. To obtain a reliable testing environment, a dedicated full-electric test rig was designed and realized. The test rig presented in this work is capable of assuring the repeatability and accuracy of the measurements leaving aside the uncertainties deriving from the irregularities of the ICE behaviour that usually affect the experimental activities conducted on front engine accessory drives. After providing both the modelling and testing environment as assets for the analysis, several experimental activities are carried out with the goal of assessing the dynamic behaviour of belt drive systems and their efficiency, comparing the performances of different tensioning solutions, understanding the behaviour in static and dynamic conditions of a traditional automatic tensioner and one example of an omega twin arm tensioner, which is the tensioning solution most explored by the manufacturers at present. The ultimate goal of gaining a complete understanding of belt drive systems in the special case of micro-hybrid vehicles is eventually fulfilled by an experimental validation of the static and dynamic models proposed

Experimental analysis of v-belt tensile loads

An experimental investigation was conducted to determine the magnitude of v-belt stresses in automotive drive situations. A constant tension belt test apparatus was designed and fabricated using a variable speed cradled D.C. motor for power and two automotive alternators for absorption. Free span stresses on the dynamic torque loaded belt drive were determined from the equations governing a pivoted drive system. Centrifugal stress was determined by a theoretical analysis of belt motion. Bending stresses were obtained from a static test employing strain gages mounted on the top of belts with exposed cord layers. The variation in load stress around the pulleys in a dynamic torque loaded drive was to be determined by taking time synchronized photographs of a marked belt section and measuring strain from enlarged photographic negatives. The time synchronization of high speed close-up photography was accomplished during this study, but the capability of making measurements from photographic data was not perfected. Insight gained from this work led to the advancement of ideas which may allow photographic determination of belt strain in a future study. A magnetic pickoff and timer system also failed to indicate the magnitude of dynamic belt strains. In order to complete the present analysis, the Hornung analytical solution for tensions around torque loaded pulleys was employed in a digital simulation program. A matrix of computer runs was made for the range of drive parameters studied. Finally, power losses in belt drives were experimentally obtained in order to determine the design acceptability of the drive situations tested. Superposition of bending, centrifugal and load tensions led to the conclusion that bending stress is by far the largest stress factor to be considered in automotive v-belt drives. The fact that small changes in load stress cause noticeable changes in belt fatigue life must be attributed to the creep, slip, and heat generation phenomena which accompany torque transmission --Abstract, pages ii-iii

Design of an affordable anthropomorphic mechanical prosthetic hand

Includes bibliographical references.This dissertation outlines the conceptualisation, design, manufacture, assembly and experimental testing of an affordable anthropomorphic mechanical hand prosthesis. In many countries, upper-limb amputees lack access to prosthetic hand devices. Furthermore, currently available mechanical devices require a large amount of effort to actuate; fatiguing and frustrating patients who have no other alternative but to use them. Consequently, a need has arisen to provide a mechanical device that is affordable enough to be accessible to low and middle-income patients, is functional enough to allow users to easily perform their Activities of Daily Living (ADLs), and is aesthetically appealing enough to ensure that patients feel comfortable and confident when wearing it. Concept solutions of several mechanisms were identified and evaluated from which the final design was selected. Analytical force analysis was used to generate a mathematical model to analyse the response of each dynamic member in the hand. A linear relationship between the input-force and applied grasp-forces of the hand was identified. Finite Element Analysis (FEA) used to investigate the lateral and hyperextensive loading limits of the phalanges, generated results that corresponded well to the experimental outcomes. Amongst the utilised actuation mechanisms (levers, pulleys, tendon-wires, bearings and springs), the tendon-wires were of concern due to their repetitive tensile loading and relative movement with the phalanges. Tensile testing of various tendon-wires and endurance testing of the phalangeal tendon-channels, yielded a combination which surpassed the infinite life requirement of 1,200,000 loading cycles; with carbon-nylon contact wearing at the lowest rate as confirmed by gravimetric tests in accordance with ASTM F2025 (2000). Manufacture of the hand used rapid prototyping in combination with traditional machining methods and standard components, enabling a fully-assembled cost of R 11,628.37; below the required R 18,000 limit. Various power and precision grasping configurations were achieved and the contact forces satisfactorily maintained, using the hand’s built-in locking mechanism. Feedback gathered from the prosthetist and patients suggested making slight alterations to the hand’s aesthetics and to address minor functional challenges, such as the control of the closing trajectory for precision grasps

Design and analysis of a modified power-split continuously variable transmission

The CVT has advantages over the conventional stepped ratio transmission because of its smooth, stepless shifting, simplified design, and a potential for reduced fuel consumption and tailpipe emissions. The power split CVPST has a potentially higher mechanical efficiency than a conventional shaft-to-shaft CVT, but it is unknown whether that efficiency can be improved. For the CVPST, the branch control circuit that contains the CVT can be disengaged at the ring gear for a 1:1 overall transmission ratio, which will interrupt the power flow through the CVT. This could increase overall efficiency because the branch control circuit is no longer transmitting any power. This system is compared to a conventional CVPST, a direct-drive CVPST, and a shaft-to-shaft CVT. A computer program is produced to study the mechanical losses for each system over the entire operating range of a representative simulation model. From this analysis, the value of disengaging the branch control circuit at the ring gear can be determined

ReHand - a portable assistive rehabilitation hand exoskeleton

This dissertation presents a synthesis of a novel underactuated exoskeleton (namely ReHand2) thought and designed for a task-oriented rehabilitation and/or for empower the human hand. The first part of this dissertation shows the current context about the robotic rehabilitation with a focus on hand pathologies, which influence the hand capability. The chapter is concluded with the presentation of ReHand2. The second chapter describes the human hand biomechanics. Starting from the definition of human hand anatomy, passing through anthropometric data, to taxonomy on hand grasps and finger constraints, both from static and dynamic point of view. In addition, some information about the hand capability are given. The third chapter analyze the current state of the art in hand exoskeleton for rehabilitation and empower tasks. In particular, the chapter presents exoskeleton technologies, from mechanisms to sensors, passing though transmission and actuators. Finally, the current state of the art in terms of prototype and commercial products is presented. The fourth chapter introduces the concepts of underactuation with the basic explanation and the classical notation used typically in the prosthetic field. In addition, the chapter describe also the most used differential elements in the prosthetic, follow by a statical analysis. Moreover typical transmission tree at inter-finger level as well as the intra- finger underactuation are explained . The fifth chapter presents the prototype called ReHand summarizing the device description and explanation of the working principle. It describes also the kinetostatic analysis for both, inter- and the intra-finger modules. in the last section preliminary results obtained with the exoskeleton are shown and discussed, attention is pointed out on prototype’s problems that have carry out at the second version of the device. The sixth chapter describes the evolution of ReHand, describing the kinematics and dynamics behaviors. In particular, for the mathematical description is introduced the notation used in order to analyze and optimize the geometry of the entire device. The introduced model is also implemented in Matlab Simulink environment. Finally, the chapter presents the new features. The seventh chapter describes the test bench and the methodologies used to evaluate the device statical, and dynamical performances. The chapter presents and discuss the experimental results and compare them with simulated one. Finally in the last chapter the conclusion about the ReHand project are proposed as well as the future development. In particular, the idea to test de device in relevant environments. In addition some preliminary considerations about the thumb and the wrist are introduced, exploiting the possibility to modify the entire layout of the device, for instance changing the actuator location

Modeling of A Continuously Variable Transmission and Clutching of A Snowmobile

This thesis describes the conceptual operation of a continuously variable transmission (CVT) and develops a model of a CVT system. The purpose is to form a framework for understanding how CVTs work, what factors go into their design, why they are used on almost all modern snowmobiles, and how they can be tuned for better performance. By developing a model using rigid body analysis, computer modeling, and a list of structured equations, a CVT can be tuned more efficiently. The model is used to calculate values difficult or tedious to evaluate by hand with visual aide for clearer understanding of the motion. By combing the model results with a series of equations, that prescribe the dynamics of the CVT a methodological framework is developed that can be used to tune a snowmobile to save time, money, and tune more efficiently

Conceptual design study of an improved automotive gas turbine powertrain

Automotive gas turbine concepts with significant technological advantages over the spark ignition (SI) engine were assessed. Possible design concepts were rated with respect to fuel economy and near-term application. A program plan which outlines the development of the improved gas turbine (IGT) concept that best met the goals and objectives of the study identifies the research and development work needed to meet the goal of entering a production engineering phase by 1983. The fuel economy goal is to show at least a 20% improvement over a conventional 1976 SI engine/vehicle system. On the basis of achieving the fuel economy goal, of overall suitability to mechanical design, and of automotive mass production cost, the powertrain selected was a single-shaft engine with a radial turbine and a continuously variable transmission (CVT). Design turbine inlet temperature was 1150 C. Reflecting near-term technology, the turbine rotor would be made of an advanced superalloy, and the transmission would be a hydromechanical CVT. With successful progress in long-lead R&D in ceramic technology and the belt-drive CVT, the turbine inlet temperature would be 1350 C to achieve near-maximum fuel economy

Low-Cost Throttle-By-Wire-System Architecture For Two-Wheeler Vehicles

This paper investigates the performance of a low-cost Throttle-by-Wire-System (TbWS) for two-wheeler applications. Its consisting of an AMR throttle position sensor and a position controlled stepper motor driven throttle valve actuator. The decentralized throttle position sensor is operating contactless and acquires redundant data. Throttle valve actuation is realized through a position controlled stepper motor, sensing its position feedback by Hall effect. Using a PI-controller the stepper motors position is precisely set. Sensor and actuator units are transceiving data by a CAN bus. Furthermore, failsafe functions, plausibility checks, calibration algorithms and energy saving modes have been implemented. Both modules have been evaluated within a Hardware-in-the-Loop test environment in terms of reliability and measurement/positioning performance before the TbWS was integrated in a Peugeot Kisbee 50 4T (Euro 5/injected). Finally, the sensor unit comes with a measurement deviation of less then 0.16% whereas the actuator unit can approach throttle valve positions with a deviation of less then 0.37%. The actuators settling time does not exceed 0.13s while stable, step-loss free and noiseless operation

An investigation of controlled tethering in space

Astronaut tethering and retrieval operations - systems analysis and design, and motion equations for connected bodies in orbi