2015 HBM nCode Products User Group Meeting · • Harley-Davidson Motor Company produces cruiser...

2015 HBM nCode Products User Group Meeting

March 4-5, 2015 2015 HBM nCode Products User Group Meeting Livonia, MI (USA)

www.ncode.com

GlyphWorks Accelerated Testing: Not Just for Developing PSD Based Shaker Profiles

Presented By Phil KorthTechnical Staff EngineerHarley-Davidson


www.ncode.com

2015

HB

M n

Cod

e P

rodu

cts

Use

r Gro

up M

eetin

g

3

• Harley-Davidson Motor Company produces cruiser and touring motorcycles and offers a complete line of Harley-Davidson motorcycle parts, accessories, riding gear and apparel, and general merchandise. For more information, visit Harley-Davidson's Web site at www.harley-davidson.com.

Intro to Harley-Davidson


www.ncode.com

2015

HB

M n

Cod

e P

rodu

cts

Use

r Gro

up M

eetin

g

4

• GlyphWorks Accelerated Test tool is recognized for developing PSD based vibration profiles but often overlooked for other uses

• Turning an invalid test into useful information• Comparing alternate supplier test qualifications• Duty Cycle/Time History Damage Editing• Determination of a non-Gaussian damage factor

Challenge/project scope


www.ncode.com

2015

HB

M n

Cod

e P

rodu

cts

Use

r Gro

up M

eetin

g

5

• Provides a documented repeatable process for developing vibration profiles

• Test profiles can be generated from time histories, PSD’s or a mix of both

• Calculates fatigue based on accelerometer measurement• Provides damage correlation• Doesn’t Require Component Response Measurement – Test

Profiles can be created prior to the existence of parts• Test specification can be used for FEA based virtual test and real

physical test (allows FEA to lab correlation)• Provides a method to accelerate tests without extensive data

editing• Provides a method to verify that loads are not excessive• One PSD represents the equivalent Damage of an entire Duty

Cycle

Why We Use GlyphWorks Accelerated Test


www.ncode.com

2015

HB

M n

Cod

e P

rodu

cts

Use

r Gro

up M

eetin

g

6

• Accelerated Test Glyph is a canned process for producing a PSD or Sine Sweep

• People are familiar with what data goes into the glyph• Time Histories• PSD’s

• People are familiar with what data comes out of the glyph• PSD’s• Sine Sweeps

• People not as familiar with properties inside of the glyph• Frequency Damage Spectrum (FDS)• Shock Response Spectrum (SRS )

• To most people the FDS & SRS are a data check• With increased knowledge the FDS & SRS can be used for so

much more• For this presentation we will only focus our attention on the

Frequency Damage Spectrum (FDS)

Why Other Uses Are Overlooked


www.ncode.com

2015

HB

M n

Cod

e P

rodu

cts

Use

r Gro

up M

eetin

g

• FDS results are often unclear• Not sure how to interpret data • Is damage cumulative?• Does more damage occur at low frequencies?• How much damage difference exists?

Why Other Uses Are Overlooked


www.ncode.com

2015

HB

M n

Cod

e P

rodu

cts

Use

r Gro

up M

eetin

g

8

• Better Method to Compare FDS• Divide Results• Produce Damage Factor Plot

Divide & Conquer Method


www.ncode.com

2015

HB

M n

Cod

e P

rodu

cts

Use

r Gro

up M

eetin

g

9

• Overlay FRF or Response PSD• Compare Damage Factor at Damaging Frequency

Improved FDS Interpretation When Comparing Data Sets


www.ncode.com

2015

HB

M n

Cod

e P

rodu

cts

Use

r Gro

up M

eetin

g

10

• Test Scenario • Previous Profile Used to Run Test• Parts failing at 8 hr. duration need to last 30 hrs.• Test profile suspected of being wrong • Prove validity of test profile• If wrong what do results mean?

• Available Information• PSD data from ED Shaker • Newly acquired valid test data from vehicle

• Process• Create PSD test from new data• Generate FDS from each PSD and compare

Case Study 1: Turning an Invalid Test Into Useful Information


www.ncode.com

2015

HB

M n

Cod

e P

rodu

cts

Use

r Gro

up M

eetin

g

11

• PSD Generation for Engine Excitation – Step 1 - FDS & SRS Generation

Turning an Invalid Test Into Useful Information


www.ncode.com

2015

HB

M n

Cod

e P

rodu

cts

Use

r Gro

up M

eetin

g

12

• PSD Generation for Engine Excitation – Step 2 – PSD Generation from FDS



www.ncode.com

2015

HB

M n

Cod

e P

rodu

cts

Use

r Gro

up M

eetin

g

13

• From plot over test is obvious• Was 8 hours enough at over test to validate the part?• Minimum acceleration factor is 30, 8*30 = 240 hours• PSD of response provides better confirmation of acceleration factor



www.ncode.com

2015

HB

M n

Cod

e P

rodu

cts

Use

r Gro

up M

eetin

g

14

• Test Scenario • Vendor A part validated to motorcycle specification• Proposed Vendor B part validated to automotive specification • Does Vendor B part require validation?

• Available Information• PSD data from Vendor A & B tests

• Process• Generate FDS from each PSD and compare

Case Study 2: Comparing Alternate Supplier Test Qualifications


www.ncode.com

2015

HB

M n

Cod

e P

rodu

cts

Use

r Gro

up M

eetin

g

15

Comparing Alternate Supplier Test Qualifications

• PSD Vendor A vs PSD Vendor B – Based on PSD overlay should be o.k.

• How much different is it?• How much more damaging is it?


www.ncode.com

2015

HB

M n

Cod

e P

rodu

cts

Use

r Gro

up M

eetin

g

16

• Convert PSD’s to FDS’s



www.ncode.com

2015

HB

M n

Cod

e P

rodu

cts

Use

r Gro

up M

eetin

g

17

• FDS & Damage Factor FDS – Worst case 2.5 X damage factor



www.ncode.com

2015

HB

M n

Cod

e P

rodu

cts

Use

r Gro

up M

eetin

g

18

• Test Scenario • Need to create a time history based test profile• Data collected on a vehicle for various courses making up a duty cycle • Only accelerometer data was collected. • What can be done to edit the data to create a reasonable test time?

• Available Information• Input and response time history accelerometer data

• Process• Generate FDS from inputs and overlay FRF’s to determine damage

factors. Eliminate non damaging time histories• Use visual amplitude editing of response acceleration and verify by

comparing FDS’s

Case Study 3: Duty Cycle/Time History Damage Editing


www.ncode.com

2015

HB

M n

Cod

e P

rodu

cts

Use

r Gro

up M

eetin

g

19

• Calculate FDS• 6 Road Courses• Unedited – 444 hours of test time

Duty Cycle/Time History Damage Editing

Test NameTime

DurationDC

Repeats DC Time % TimeRC1 290.4 1738 5.05E+05 31.57%RC2 152 2319 3.52E+05 22.05%RC3 102.8 1738 1.79E+05 11.17%RC4 104 3478 3.62E+05 22.62%RC5 135.6 695 9.42E+04 5.89%RC6 154 695 1.07E+05 6.69%

1.60E+06444 Hours


www.ncode.com

2015

HB

M n

Cod

e P

rodu

cts

Use

r Gro

up M

eetin

g

20

• Does FDS give ability to edit out non-damaging road content?• Road course 2 appears to have overall least amount of damage



www.ncode.com

2015

HB

M n

Cod

e P

rodu

cts

Use

r Gro

up M

eetin

g

21

• FDS damage factor compared to RC2• Can you easily edit out non-damaging road content?



www.ncode.com

2015

HB

M n

Cod

e P

rodu

cts

Use

r Gro

up M

eetin

g

22

• FRF vs Response PSD• Why is the FRF better?



www.ncode.com

2015

HB

M n

Cod

e P

rodu

cts

Use

r Gro

up M

eetin

g

23

• Pick damage at frequency of interest from FDS• Keep most damaging events• Eliminating non-damaging events reduced test time to 170 hours


Test NameEvent

DamageDC

RepeatsDC

Damage%

DamageRC1 5.15E+01 1738 8.95E+04 24.75%RC2 1.00E+00 2319 2.32E+03 0.64%RC3 1.65E+01 1738 2.87E+04 7.93%RC4 4.10E+00 3478 1.43E+04 3.94%RC5 7.90E+00 695 5.49E+03 1.52%RC6 3.11E+02 695 2.16E+05 59.79%

Total Damage 3.57E+05

Test NameTime

DurationDC

Repeats DC Time % TimeRC1 290.4 1738 5.05E+05 82.50%RC2 0 2319 0.00E+00 0.00%RC3 0 1738 0.00E+00 0.00%RC4 0 3478 0.00E+00 0.00%RC5 0 695 0.00E+00 0.00%RC6 154 695 1.07E+05 17.50%

6.12E+05170 Hours


www.ncode.com

2015

HB

M n

Cod

e P

rodu

cts

Use

r Gro

up M

eetin

g

24

• Utilize Visual Editing Limit Detection Tool for further editing of individual time histories



www.ncode.com

2015

HB

M n

Cod

e P

rodu

cts

Use

r Gro

up M

eetin

g

25

• Compare FDS of edited vs non-edited time history• Verify that damage content is acceptable• Test time now reduced to 80.5 hours


Test NameTime

DurationDC

Repeats DC Time % TimeRC1 105 1738 1.82E+05 63.03%RC2 0 2319 0.00E+00 0.00%RC3 0 1738 0.00E+00 0.00%RC4 0 3478 0.00E+00 0.00%RC5 0 695 0.00E+00 0.00%RC6 154 695 1.07E+05 36.97%

2.90E+0580.5 Hours


www.ncode.com

2015

HB

M n

Cod

e P

rodu

cts

Use

r Gro

up M

eetin

g

26

• How Does The Method Compare To Strain Based Damage?


Test Name

Event Damage

DC Repeats

DC Damage

% Damage

RC1 3.05E-01 1738 5.30E+02 16.61%RC2 4.95E-02 2319 1.15E+02 3.59%RC3 1.98E-01 1738 3.44E+02 10.77%RC4 8.99E-02 3478 3.13E+02 9.80%RC5 5.44E-02 695 3.78E+01 1.18%RC6 2.67E+00 695 1.85E+03 58.04%

Test NameEvent

DamageDC

RepeatsDC

Damage%

DamageRC1 5.15E+01 1738 8.95E+04 24.75%RC2 1.00E+00 2319 2.32E+03 0.64%RC3 1.65E+01 1738 2.87E+04 7.93%RC4 4.10E+00 3478 1.43E+04 3.94%RC5 7.90E+00 695 5.49E+03 1.52%RC6 3.11E+02 695 2.16E+05 59.79%

Strain Based Damage Accelerated Test Based Damage


www.ncode.com

2015

HB

M n

Cod

e P

rodu

cts

Use

r Gro

up M

eetin

g

27

• Test Scenario • Using an Electro-Dynamic shaker to reproduce a non-Gaussian based

vibration profile• GlyphWorks Accelerated Test produces equivalent Gaussian based

PSD test profile• How much more damaging is the test if its run in a non-Gaussian mode

with different Kurtosis?

• Available Information• Time History Data from Shaker• GlyphWorks Accelerated Test

• Process• Collect a minimum of 3 minutes of accelerometer time history data

from the Gaussian & non-Gaussian profiles on the shaker • Compare FDS’s to determine increased damage factor

Case Study 4: Determination Of A Non-Gaussian Damage Factor


www.ncode.com

2015

HB

M n

Cod

e P

rodu

cts

Use

r Gro

up M

eetin

g

28

• Compare 4 profiles• 50 hour Gaussian• 100 hour Gaussian• 100 hour non-Gaussian Kurtosis 4.64• 100 hour non Gaussian Kurtosis 8.48

Determination Of A Non-Gaussian Damage Factor


www.ncode.com

2015

HB

M n

Cod

e P

rodu

cts

Use

r Gro

up M

eetin

g

29

• Calculate & Compare FDS• What can you determine from this plot?



www.ncode.com

2015

HB

M n

Cod

e P

rodu

cts

Use

r Gro

up M

eetin

g

30

• Divide FDS’s by 100 hour Gaussian FDS• Compare Scale Factors – Determine Damage Factor



www.ncode.com

2015

HB

M n

Cod

e P

rodu

cts

Use

r Gro

up M

eetin

g

31

• How does strain response compare?



www.ncode.com

2015

HB

M n

Cod

e P

rodu

cts

Use

r Gro

up M

eetin

g

32

• Calculate PSD of Strain to understand frequency content of damage



www.ncode.com

2015

HB

M n

Cod

e P

rodu

cts

Use

r Gro

up M

eetin

g

33

• Calculate Strain Damage • Compare Strain Damage with FDS Damage Factor at Damaging

Frequencies


TestName Damage Damage Factordc_50hr_gaussian_mi 2.84E‐02 2.26dc_100hr_gaussian_mi 1.26E‐02 1.00dc_100hr_kurt4pt64_mi 1.62E‐02 1.29dc_100hr_kurt8pt48_mi 2.06E‐02 1.64


www.ncode.com

2015

HB

M n

Cod

e P

rodu

cts

Use

r Gro

up M

eetin

g

34

• FDS provides a valid method to observe and calculate increased damage due to Kurtosis

• Knowledge of resonance frequency and bandwidth can provide a very accurate prediction of damage factor

• The calculated damage factor can be used to adjust original test time

• Though not demonstrated in this presentation it has been observed that not all vendors Kurtosis based vibration controllers produce the same damage factor across the frequency band

• Statistically they all produce the same Kurtosis when analyzing the time history

• Variations exists in damage factor and uniformity across the bandwidth• The damage factor variation makes it difficult to create a canned

process based on Kurtosis that can be used across all vibration controllers

FDS Non-Gaussian (Kurtosis) Damage Factor Conclusions


www.ncode.com

2015

HB

M n

Cod

e P

rodu

cts

Use

r Gro

up M

eetin

g

35

• GlyphWorks Accelerated Test tools were successfully utilized for the following:

• Turning an invalid test into useful information• Comparing alternate supplier test qualifications• Duty Cycle/Time History Damage Editing• Determination of a non-Gaussian damage factor

• A picture may be worth a thousand words, but sometimes to be worthwhile you have to look at the right picture

• Remember when comparing FDS’s to divide and conquer

Summary


www.ncode.com

2015 HBM nCode Products User Group Meeting

Thank you!

Phil [email protected]


www.ncode.com

2015 HBM nCode Products User Group Meeting · • Harley-Davidson Motor Company produces cruiser...

Documents

Transcript of 2015 HBM nCode Products User Group Meeting · • Harley-Davidson Motor Company produces cruiser...