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) 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 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 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 Doppelmayr Cable Car Presentation 4
Guiding of the Vehicle Vertical via tires Lateral via guiding wheels Longitudinal via closed rope loop 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 Doppelmayr Cable Car Presentation 6
Description Bogie traverse 1 traverse 2 2 dampers 2 dampers Stabilizing system Longitudinal bar Air spring Stabilizing system Bogie frame 4 guiding wheels 4 tires 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 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 Doppelmayr Cable Car Presentation 9
Animation Doppelmayr Cable Car Presentation 10
Rope forces at the bogie frame arc slope slope 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 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 Doppelmayr Cable Car Presentation 13
FE-Model end car aluminum profile help structure with very low stiffness 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 Doppelmayr Cable Car Presentation 14
FEMFAT Weld Modelling Guideline FE-Modell Spannungsergebnisse Last-Zeit-Verläufe C 100 MAT 211 TOP TOP TOP MAT 207 MAT 209 WELD Database EUROCODE 3 EUROCODE 9 DIN 15018 British Standard 7608 IIW Guideline FKM Guideline DVS 1612 DVS 1608 damage safety factors analysis report Doppelmayr Cable Car Presentation 15
Utilization [-] End car bearing structure Utilization caused by tranient loading Doppelmayr Cable Car Presentation 16 16
Utilization [-] 1 2 F4 view Window corners window F4 1 2 3 3 4 4 Utilization caused by transient loading Doppelmayr Cable Car Presentation 17
Utilization [-] Bogie frame 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 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! Doppelmayr Cable Car Presentation 20
Back up Doppelmayr Cable Car Presentation 21
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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 Doppelmayr Cable Car Presentation 23
guideway Doppelmayr Cable Car Presentation 24
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