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1. INTRODUCTION
The increasing demands of safety and reliability on mechanical systems have
improved the scientific understanding of dynamic properties of structure. All real
physical structures behave dynamically when subjected to loads or displacements
which varies with time. In such cases, a dynamic analysis is applied to reflect both the
varying load and response, where the vibrations of a structure is of interest. Vibrations
can be destructive and should be avoided, or they can be extremely useful and desired.
If the loads or displacements are applied very slowly (the frequency of loading is less
than one third of the lowest natural frequency of the structure), the inertia forces can
be neglected and a static load analysis can be justified.
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Dynamical Analysis of Silo Surface Cleaning Robot Using Finite Element Method
Cleaning robot with two platforms - in retracted form on Fig.1(a) and in opened form
on Fig.1(b). Each platform consists of central body and three telescopic arms;
support unit consisting of: control unit for all functions of the system; lifting arm for
positioning the cleaning robot at the silo central axis and spools unit contains spool of
steel cables with respective driving motors used for robot suspension and motion;
Cleaning tools attached to the centre of the platform which rotate around the platform
centre, i.e. around the silo vertical axis.
In operation, the cleaning tool removes the build up materials from the inside silo
surface by blowing a pressurised air on a stripe while rotating around the silo vertical
axis, and the robot fully covers the inner surface of the silo through successive
crawling movements of its two platforms. During these two essential process
(cleaning and crawling), the system is subjected to different types of loads, hence a
dynamic analysis for system is required to predict its response.
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The main purpose of this study is to calculate the dynamic characteristic of the
robot i.e. the natural frequency and the mode shapes by using modal analysis method.
The dynamic characteristics are computed by the finite element analysis software
(ANSYS). The information provided by modal analysis is used to understand the
behaviour of the structure under general excitation. Thus verifying whether or not the
robot will successfully overcome resonance, fatigue, and other harmful effects of
forced vibrations.[3, 4].
The paper is organized as follows: Section 2 describes the finite element model of
SIRO. Then, in Section 3 the static structure analysis is presented. Section 4 discusses
the dynamic analysis of SIRO through applying the most common types of analyses:
modal, harmonic frequency response, and transient dynamic analysis. Finally section
5 provides some conclusions of this work.
After the model is imported, the type of material is assigned for each part. Three
materials are defined for the model: the silo and its roof are concrete, the cable and
the three linear shafts are steel and the platforms with the arms are aluminium alloy.
the material proprieties are well defined in the ANSYS.
ANSYS Workbench automatically recognizes the contacts existing between each
part. The contact conditions for corresponding contact surfaces and the joints between
parts are defined. Frictionless contact type was chosen as contact condition for contact
surfaces between the arms and the platforms shoulders. The contact surfaces armssilo have friction contact type with friction coefficient value of 0.6. The rest of contact
surfaces have a completely bonded contact type. Rotation joints are defined between
the arms and the platforms.
The model is meshed automatically with suitable meshing elements, the default
element size is determined based on a number of factors including the overall model
size, the proximity of other topologies, body curvature, and the complexity of the
feature. The model parts are meshed using higher order 3D solid elements; SOLID186
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Dynamical Analysis of Silo Surface Cleaning Robot Using Finite Element Method
(a )
(b)
Figure 3 Pressure on contact surfaces when there are a) internal forces. b) no internal forces
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(a )
Figure 4 The total deformation when there are a) internal forces. b) no internal forces
Therefore comparing the deformation of the robot with(fig 4(a)) / without (fig
4(b)) the effect of applying the internal forces shows that in the first situation the
telescopic arms of the robot bend on the level of the second segments of the arms
indicating that the arms have fix points on silo surface. While in the second situation
the arms have the maximum deflection at the distal end of the arm which indicate that
the arms have a free end. The maximum deformation of the robot with/without
internal forces is placed on the distal ends of the cleaning tool and it is in the range of
16 mm, which is an acceptable deformation regarding to the length of the cleaning
tools (3.5m for each arm).
The equivalent Von Mises stress analysis of the system (fig. 5) shows that the
maximum stress (with Finternal ) is located on the contact surface arms-silo ( 58 MPa ).
It is less than the yield point value of the arm material. In the other case (without
Finternal) the maximum value of stress is at the connection arm-platform and it is in the
safety range too (22 MPa). So the design is statically safe.
( a)
( b) No internal force
Figure 5 The equivalent stress (Von Mises) when there are a) internal forces. b) no internal
forces
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Dynamical Analysis of Silo Surface Cleaning Robot Using Finite Element Method
4. DYNAMIC ANALYSIS
The dynamic analysis attempts to solve the motion equations (1) of every node point
in the structure, which are determined in matrix form as
(1)
where the eigenvalue is w2, and {A} is the eigenvector associated with each value
of w2. The total number of eigenvalues or natural frequencies is equal to the total
number of degrees of freedom in the model. Since each of the eigenvectors cannot be
null vectors, the equation which must be solved, let = w2, is
([K] [M]) = {0}
(3)
Necessary and sufficient condition for the equation (3) to have non-zero solution
is that determinant of ([K] [M]) is zero.
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By modal analysis techniques, a large and complex system can be divided into
several subsystems which can be independently analysed, thus the dynamic
characteristics of the overall system can be determined from the subsystem
information, and the design of a complex system can be carried out by designing and
developing its subsystems separately [7]. Our system can be decomposed to three
subsystems: two platforms with cables and the cleaning tool. In this paper, only the
dynamic analysis of the platform with the cable is studied.
Two modal analysis are studied to the platform with cable: first when the arms of
the platform have fixed supports (the internal forces through the arms produce friction
force in the contact surface arms-silo). The second when the arms have free ends (the
complete model has no internal forces through the arms). In the two studies the free
end of the cable is supposed fix support.
Table 1 compare the first thirty natural frequencies fw of the system with internal
forces and those fwout when there are no forces. It is clearly noticed that there are
difference in the natural frequencies. There is only one identical frequency (58.103
Hz), and the mode shapes (Fig.6) corresponding this frequency show an oscillation to
the cable in both when the arms are free and fixed.
Table 1 The first thirty natural frequency of the system with/without internal forces through
the telescopic arms
mode
1
2
3
4
5
6
7
8
9
10
fwout Hz
0.18686
0.38422
0.38429
1.4572
1.4604
10.074
10.1
10.105
10.914
10.919
fw Hz
10.229
10.246
11.128
11.138
11.766
22.137
22.179
22.403
29.622
29.636
mode
11
12
13
14
15
16
17
18
19
20
fwout Hz
22.224
22.312
24.603
29.723
29.736
31.665
36.804
36.865
58.078
58.103
fw Hz
49.294
51.398
51.64
58.103
58.127
60.3
64.922
65.001
95.831
95.873
mode
21
22
23
24
25
26
27
28
29
30
fwout Hz
64.225
67.221
67.488
73.525
81.202
81.427
95.986
96.028
102.58
123.13
fw Hz
105.31
112.29
112.38
113.8
141.13
141.15
146.07
146.14
163.51
168.41
Figure 6 Mode shape of identical natural frequency of the platform; free arms (left), fixed
arms (right)
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Dynamical Analysis of Silo Surface Cleaning Robot Using Finite Element Method
Figure 7 Mode shape of the first natural frequency for the platform; free arms (left), fixed
arms ( right )
Figure 7 shows the mode shape of the model at the first natural frequency when
the distal ends of arms are free and fixed. The first mode with free arms shows a
rotation to the platform on the axis Z. While when the arms have fixed ends, there is a
torsion of the platform and two arms around the axis of the third arm.
Figures 8and 9 present different mode shapes of the platform when the distal ends
of arms are free and fixed respectively. Mode 27 (free arms)and mode 19 (fixed arms)
have the same behaviour due to having almost the same natural frequencies.
Figure 8 Mode shape of different natural frequencies for the platform (free arms)
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Figure 9 Mode shape of different natural frequencies for the platform (fixed arms)
(4)
(5)
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Dynamical Analysis of Silo Surface Cleaning Robot Using Finite Element Method
Figures 10,11 and 12 present the frequency response of the platform , the second
segment of the arm and the distal end of the arm respectively, when the arms are fixed
and free. The harmonic force is applied on the platform in Z direction where the
frequency range is between 0 to 200 Hz and the the peak force amplitude F0 = 1000N.
From the previous figures we can notice that the model start responding when f =
10Hz for free arms and 22.5Hz for fixed arms. Also it is noticed that when the arms
have fixed ends the dominant frequency is 163.5Hz, while it is 73.5Hz when the arms
have free ends.
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From this analysis, we can conclude that the frequency of the harmonic excitation
should be less than 10 Hz to not have any significant response of the platform. In
another words, the rotation of the cleaning tool should not be bigger than 600 rpm.
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Dynamical Analysis of Silo Surface Cleaning Robot Using Finite Element Method
Figure 13 Stress transient response of 2nd arms segment when applying shock force in the Z
direction
Figures 13 and 14 show the stress and deformation of the second segment of the
arm on the Z direction respectively, when the arms have free / fixed ends. Von Mises
stresses obtained from finite element analyses are utilized in fatigue life calculations.
All fatigue analyses are performed according to infinite life criteria (i.e., N = 109
cycles). Comparing the safety factor of the second segment of the arm in static (Sfactor
= 15) and dynamic analysis (S factor = 9.7) indicates that the arm predicted to be safe
against fatigue under static and dynamic loadings.
Figure 14 Deformation transient response of 2nd arms segment when applying shock force
in the Z direction
5. CONCLUSION
The aim of this study was to determine the static and dynamic finite element analysis
of SIRO by using ANSYS. The static structural analysis is implemented to SIRO with
silo model in two different boundary conditions: first when there is a friction contact
on the contact surface arms-silo, thus the arms are considered having fixed contact
with silo, second when there is no friction contact therefore the arms have free ends.
The dynamic analysis is conducted by applying modal analysis, harmonic frequency
response and transient response. Depending on the properties of modal analysis, the
dynamic analysis in this study is implemented on the subsystem of SIRO, which
consists of platform, three arms and cable. Using the eigenvalues and eigenvectors
from the modal analysis, a harmonic response and a transient response to the
subsystem is carried out indicating that the subsystem is safe under the dynamic
loading.
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Future work: The limitations of the FEM approach lie in the increasing model size
required to properly describe complex structures with appropriate detail (models with
over 1 million degrees of freedom are used today in the car and aircraft industry). This
leads to higher model construction and calculation times, but even more important,
there remain inherent modelling accuracy limitations, related to the modelling of
structural junctions, non-homogeneous elements, complex materials etc. [8] To
address these limitations, an experimental approach to modal analysis must developed
yielding results which can be used either as a model by itself, or to validate and
improve the FE models.
REFERENCES
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
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