Nampally, Sneha Rupa (2024)
Development of Active Vibration Control System for Gearbox Housings.
Technische Universität Darmstadt
doi: 10.26083/tuprints-00028797
Ph.D. Thesis, Primary publication, Publisher's Version
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Item Type: | Ph.D. Thesis | ||||
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Type of entry: | Primary publication | ||||
Title: | Development of Active Vibration Control System for Gearbox Housings | ||||
Language: | English | ||||
Referees: | Rinderknecht, Prof. Dr. Stephan ; Melz, Prof. Dr. Tobias | ||||
Date: | 23 December 2024 | ||||
Place of Publication: | Darmstadt | ||||
Collation: | xvi, 158 Seiten | ||||
Date of oral examination: | 22 October 2024 | ||||
DOI: | 10.26083/tuprints-00028797 | ||||
Abstract: | This thesis presents a systematic approach to developing an active vibration control system for lightweight transmissions by placing piezoelectric inertial mass actuators on the gearbox housing. The main objective is to minimise the structure-borne vibrations caused by gear whine at the mounting points of the gearbox where it is connected to the car body. These vibrations, particularly in the frequency range of 1000 - 5000Hz, can be amplified into audible noise in the passenger compartment, reducing comfort. The development process begins with studying the system’s dynamics through two gearbox housing models. The first model is a simplified version of a dual-clutch transmission with a non-rotating load, analysed using ANSYS to determine actuator requirements. The second model is a hybridized version of a fully operational dual-clutch gearbox, modelled with Romax to simulate dynamic behaviour under realistic excitation, helping establish actuator force requirements, placement, and control strategies. Macro-Fibre Composites (MFCs) are chosen as sensors for their low cost and wide operating bandwidth in the desired frequency range. They are calibrated for use in place of piezoelectric accelerometers. A real-time system is constructed with a microcontroller development board for high-speed data acquisition from the MFCs and closed-loop control implementation with the actuators. Optimal actuator placement is determined using Frequency Response Functions (FRFs) from an experimentally correlated model of the gearbox and actuator. The optimization considers spatial and modal controllability in the frequency domain. The thesis discusses single and paired actuator positioning. Multi-point control approaches based on the FxLMS algorithm are developed to minimize vibrations at the mounting points within the computational constraints of a microcontroller. Three variations—single input multi-output, mixed error, and switched error algorithms—are studied and compared. Mixed and switched error algorithms reduced the computational time of multi-point control by almost half compared to single input multi-output approach. The active vibration control system is demonstrated on an operational gearbox, achieving vibration attenuation of 4 - 14dB can be achieved with both switched and mixed error approaches at 2500Hz. The mixed error algorithm proved to be most feasible to implement given its comparable performance in achieving vibration reduction across all points and computational simplicity. The thesis also discusses the cost and weight implications of the add-on system. |
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Uncontrolled Keywords: | Active Vibration Control, Gearbox housing, Actuator, Macro-fiber Composites, Control algorithms, Automotive transmissions | ||||
Status: | Publisher's Version | ||||
URN: | urn:nbn:de:tuda-tuprints-287979 | ||||
Classification DDC: | 600 Technology, medicine, applied sciences > 620 Engineering and machine engineering | ||||
Divisions: | 16 Department of Mechanical Engineering > Institute for Mechatronic Systems in Mechanical Engineering (IMS) 16 Department of Mechanical Engineering > Institute for Mechatronic Systems in Mechanical Engineering (IMS) > Aircraft Engines and Rotating Machinery |
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TU-Projects: | EC/H2020|860243|LIVE-I | ||||
Date Deposited: | 23 Dec 2024 10:02 | ||||
Last Modified: | 23 Dec 2024 10:02 | ||||
URI: | https://tuprints.ulb.tu-darmstadt.de/id/eprint/28797 | ||||
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