Systemanalyse und -synthese für die Auslegung varianter Leichtbaustrukturen unter dynamischen Lasten

Die vorliegende Arbeit stellt einen neuen methodischen Ansatz zur Unterstützung der Ausle-gung von varianten Leichtbaustrukturen unter stationären dynamischen Lasten vor. Dieser unterstützt die Leichtbauauslegung mit einer simulationsbasierten Vorhersage des Schwingverhaltens bei einer hohen Anzahl an Produktvarianten durch die Kopplung von mehreren dynamischen Substrukturen entsprechend einer modularen Produktstruktur. Das hierzu genutzte hybride Modell kann sowohl Simulationsdaten wie auch reale Testdaten im Frequenzbereich verwenden. Für valide Modelle und Modellparameter wurden umfangreiche Versuche von Sandwichpanels bis hin zu voll beladenen Flugzeugbordküchen durchgeführt.This thesis presents a newly developed methodical approach to support the dimensioning of variant lightweight structures under stationary dynamic loads. The approach supports the lightweight optimization with a simulation based prediction of the vibration behaviour for many product variants by coupling various dynamic substructures according to a modular product structure. The hybrid model used for this can consist of combined real test data with simulation models in the frequency domain. To obtain valid models for simulation based lightweight optimization of cabin interior various system identification tests have been per-formed of specimens ranging from sandwich panels to fully loaded galleys

Consideration of damaging frequency ranges of structural excitation for testing large battery packs in Battery Electric Vehicles (BEV)

Realistic vibration testing of large floor mounted Battery Pack, sometimes called Rechargeable Energy Storage Systems (RESS), for Batterie Electric Vehicles (BEV) is important for developing safe new battery structures. On the other hand, the requirements for realistic replications of worst-case environments in a lab usually demand costly and complex infrastructure. A key factor to the quality of environment replication and an important cost driver due to the increasing complexity is the needed frequency range the equipment must be able to replicate. The contribution analyzes data from a first pre-test campaign to demonstrate a feasible process of deriving frequency band requirements for the test equipment. The key method used here is the Fatigue Damage Spectrum (FDS) to analyze the potential damage a vibration could cause in certain failure mechanism of interest, particularly “weighted” by the corresponding double-logarithmic dependance of stress magnitude over occurring load cycles. This enables a good assessment of how much damage could be induced in certain frequency ranges for a well justified and cost-effective choice on the needed test equipment.PeerReviewe

Towards realistic vibration testing of large floor batteries for battery electric vehicles (BEV)

This contribution shows an analysis of vibration measurement on large floor-mounted traction batteries of Battery Electric Vehicles (BEV). The focus lies on the requirements for a realistic replication of the mechanical environments in a testing laboratory. Especially the analysis on global bending transfer functions and local corner bending coherence indicate that neither a fully stiff fixation of the battery nor a completely independent movement on the four corners yields a realistic and conservative test scenario. The contribution will further show what implication these findings have on future vibration & shock testing equipment for large traction batteries. Additionally, it will cover an outlook on how vibration behavior of highly integrated approaches (cell2car) changes the mechanical loads on the cells.Hochschule für Angewandte Wissenschaften HamburgPeerReviewe

Requirements for vibration testing of large floor mounted batteries of Battery Electric Vehicles (BEV)

This contribution shows an analysis of vibration measurement on large floor-mounted traction batteries of Battery Electric Vehicles (BEV) from some pre-study measurements for a larger test campaign plan. The focus lies on the requirements for a realistic replication of the mechanical environments in a testing laboratory. Especially the analysis on global bending transfer functions and local corner bending coherence indicate that neither a fully stiff fixation of the battery nor a completely independent movement on the four corners yields a realistic and conservative test scenario. The contribution will further show what implication these findings have on future vibration & shock testing equipment for large traction batteries. Additionally, it will cover a look on the needed frequency range regarding potential fatigue damage. For this a Fatigue Damage Spectrum (FDS) on the measured signals is used with respect to potential faults of the batteries

Flying vibrations for driving success

NonPeerReviewe