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Romax engineering solutions extensive professional services from experienced specialists

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Originally presented in October 2013 at the Romax European Summit 2013

Originally presented in October 2013 at the Romax European Summit 2013

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  • 1. Romax Engineering Solutions: Extensive professional services from experienced specialists An Illustration Through Case Studies Barry James CTO
  • 2. Drivetrain Case Studies across industries Case study 1 – Excavator Gearbox Static Analysis Case study 2 - Gear whine noise reduction Case study 3 - Gear whine optimisation including manufacturing tolerances Case study 4 – Automatic gear box NVH Process Improvement Case study 5 – Fork Lift Truck NVH Analysis Case study 6 – Gear Rattle Test Rig Development Case study 7 – Transient Shock Load Analysis Case study 8 – Gear Failure Investigation Case study 9 – Contra-rotating gearbox design Case study 10 – Highly integrated off-shore wind turbine drivetrain design Slide 2 CONFIDENTIAL © Copyright 2013
  • 3. Case Studies: Industries Covered • Automotive (3) • Wind (1) • Rail (3) • Marine (1) • Off-Highway (2) Slide 3 CONFIDENTIAL © Copyright 2013
  • 4. Case Study 1: Excavator Gearbox Static Analysis Project activities: • Modelled the excavator gearbox using data and drawings provided by the customer, • Calculated the stress at the planetary carrier, ring gear, and housing stress using static finite element analysis. Project achievements: • Results for the planetary carrier and housing were validated against test measurements with excellent correlation. Slide 4 CONFIDENTIAL © Copyright 2013 No Distribution
  • 5. Case Study 2: Gear Whine – Noise Reduction Project background: • Reduce the radiated noise (sound pressure level) from a locomotive traction motor & cannonbox assembly Objectives: • With application of gear box error (TE), model the vibration response of the system and predict the radiated noise (sound pressure level) • How does the gear geometry affect radiated noise? • How does the housing design affect radiated noise? • What are the most effective design changes to reduce noise? Slide 5 No Distribution CONFIDENTIAL © Copyright 2013
  • 6. Case Study 2: Gear Whine – Noise Reduction Drivetrain radiated noise reduced by up to 4.5dB(A)  Complete system model in RomaxDesigner to predict the effect of design changes on radiated noise.  Romax improved the gear design  Customer testing verified the Romax simulation Slide 6 CONFIDENTIAL © Copyright 2013 No Distribution
  • 7. Case Study 3: Gear Whine Optimisation including Manufacturing Tolerances Project activities: • Created a full dynamic model of the 7-speed automated manual transmission • Analysis of casing and shaft stiffness to identify component misalignment • Analysis of gearbox mode shapes to identify housing vibration • Gear micro-geometry optimisation Project achievements: • Romax generated a robust gear microgeometry design to minimise gear whine excitation for a range of operating conditions, and considering manufacturing variations. Monte Carlo TE Sensitivity 3rd Gear Drive Slide 7 CONFIDENTIAL © Copyright 2013 No Distribution
  • 8. Case Study 4: Automatic Transmission NVH Process Improvement Project aim & activities: One of the top 5 vehicle manufacturers • Improve the side band & overall noise for automatic gearboxes (6 & 8 speed) • Specified improved gear geometry to avoid side band noise and reduce overall noise • Specified improved heat treatment process to reduce ring gear distortion • Specified design improvement to improve the location of ring gear to housing Project achievements: • Design improvements suggested by Romax were tested and verified by the customer. • Planetary side band noise was reduced by more than 10 dB. End of line test rejection rate improved from 60% failure to 90% pass = Huge savings for our customer! Slide 8 CONFIDENTIAL © Copyright 2013 No Distribution
  • 9. Case Study 4: Automatic Transmission NVH Process Improvement Client Challenges: o Build up a world class design process using a combination of the best practice experienced based engineering and powerful simulation tools; Romax Scope: o Use a real pilot project to assess the client process and resolve their specific issues (i.e. the gear whine / sideband noise performance of client’s automatic gear boxes) o Develop a process which can be used by the client independently, and train the engineering team Achievements: o Successful pilot project lead to 10 week time saving compared to existing process o Implementation of process to the complete gear box engineering team Cost reduction of $1.2Million over 2 years! Slide 9 CONFIDENTIAL © Copyright 2013
  • 10. Case Study 5: Fork Lift Drive Axle NVH Analysis Project activities: • Virtual modelling of the complete axle, • Static and dynamic analysis of the axle system, • Analysis of gear mesh misalignment and planetary gear contact, • Comparison of the dynamic analysis results with the customer’s analysis tools and measured test data. Project achievements: • Full body structure required to define the boundary condition for the drive axle Slide 10 CONFIDENTIAL © Copyright 2013 No Distribution
  • 11. Case Study 6: Gear Rattle Test Rig Development Romax developed a test rig to investigate the onset of gear rattle in manual transmissions for a customer. Project activities: • Design of the test rig, using an electric motor to drive the gearbox via a universal joint • Development of a system to monitor and control both the gearbox oil temperature and fill level • Correlation of drag torque between simulation and test results for different oil fill levels Project achievements: • A good correlation of housing acceleration levels between Romax and customer tests was achieved. • The design of the test rig was the subject of a 2009 SAE technical paper. Slide 11 CONFIDENTIAL © Copyright 2013 Distribution Allowed
  • 12. Case Study 7: Transient Events Study Project background: • Short circuit events are infrequent and generally milliseconds in duration but generate torque levels many times the rated value Objectives: • To investigate the effect on the axle system of motor short circuit events • Determine loading level and influence on structural components Value to our customer: • Safety critical item - confirmed existing design was suitable • Testing and evaluation time significantly reduced Slide 12 No Distribution CONFIDENTIAL © Copyright 2013
  • 13. Case Study 8: Gear Failure Investigation Project background: On going issue of final drive pinion gear failures on a metro train fleet Project objectives: • Identify the root causes • Provide a solution Slide 13 CONFIDENTIAL © Copyright 2013 No Distribution
  • 14. Case Study 8: Gear Failure Investigation Project activities: • Conducted a detailed practical inspection of the gear box in the train depot • Created models of the gear box in RomaxDesigner • Validated the gear contact pattern with the virtual model and actual practical gear box testing • Conducted durability analysis using measured load data • Analysed the impact of bearing end-float and gear micro-geometry. Slide 14 CONFIDENTIAL © Copyright 2013 No Distribution
  • 15. Motor Side Motor Side Powerflow Counter Clockwise Wheel Side Powerflow Clockwise Wheel Side Case Study 8: Gear Failure Investigation Excellent correlation! Slide 15 CONFIDENTIAL © Copyright 2013
  • 16. Case Study 8: Gear Failure Investigation Practical investigation and system simulation Gear mesh misalignment and tooth contact are sensitive to bearing end-float Problem understood Problem contained Lubrication survey of fleet Problem solved Specified reduced end float Design improved Specified improved gear microgeometry Slide 16 CONFIDENTIAL © Copyright 2013 No Distribution
  • 17. Case study 9 – Contra-rotating gearbox design Project background: Fuel saving of $2.5Million per ship per year! Design of a 10MW drivetrain for a contra-rotating propeller system Project activities: • Feasibility studies for parallel, planetary and perpendicular gear types, • Concept design selection, system packaging & comparison of different bearing concepts, • Detailed design • Prototype test & manufacturing support Project achievements: • Romax identified a number of designs that met the customer’s requirements, and that would fit inside the existing vessel hull. • Romax are now developing the detailed design ready for prototype testing Slide 17 CONFIDENTIAL © Copyright 2013 No Distribution
  • 18. Case Study 10: Highly integrated off-shore wind turbine drivetrain design Project background • Winflo project – Consortium of companies in France developing floating turbine technology Romax activities • Identification, review & ranking of multiple drivetrain concepts • Initial CAD design of 3 shortlisted concepts • Extensive RomaxDesigner drivetrain modelling of 3 concepts (gearbox & generator) • Feasibility assessment & identification of the preferred concept for detailed design Slide 18 CONFIDENTIAL © Copyright 2013
  • 19. Case Study 10: Highly integrated off-shore wind turbine drivetrain design Concept down selection Electro-mechanical RomaxWIND model Value to our customer Gearbox Generator • Complex relationship between generator air gap & planetary load sharing uncovered “Very satisfied with the • Extensive data provided to enable selection of optimum concept • Reduced development time & cost by highlighting critical areas to focus on in the detailed design phase Slide 19 service brought by ROMAX - Good reactivity and initiatives - Quality of the provided documents” Customer feedback (90% satisfaction rating) CONFIDENTIAL © Copyright 2013
  • 20. Summary Across many industries similar challenges are being faced …… Romax have the tools, expertise and engineering experience to solve them Slide 20 CONFIDENTIAL © Copyright 2013