Vekatech Engineering

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Finite Element Analysis

Finite Element Analysis (FEA) is a powerful computational tool used to simulate and analyze the physical behavior of complex structures and systems under various conditions. By breaking down a design into small, manageable elements, FEA allows engineers to predict how materials and components will respond to real-world forces such as stress, vibration, heat, and fluid dynamics.

 

At Vekatech Engineering, I use FEA to optimize product designs, improve structural integrity, and ensure safety and reliability. Whether it’s assessing mechanical stresses, evaluating dynamic behavior, or simulating thermal effects, FEA provides critical insights that help reduce costly physical prototyping and shorten development time. From initial concept to final product validation, our FEA capabilities are key in delivering innovative, robust solutions for our clients.

Case study: Stiffnnes behavior wind turbine generator

Wind turbine generators using the permanent magnet direct drive principle operate with a very small air gap between the rotor and stator. To prevent the risk of the air gap closing during operation, a detailed study was conducted to calculate the minimum air gap that could occur under various load conditions. A comprehensive ANSYS simulation model was developed to assess the generator’s stiffness, accounting for the complex magnetic interactions between the rotor and stator. The model included specialized non-linear components to accurately simulate the generator’s real-world performance and ensure operational reliability.

Magnetic interaction:

The model simulated the non-linear behavior of magnetic forces between the rotor and stator using custom spring elements. These elements, programmed with ANSYS Parametric Design Language (APDL), accurately replicated the changes in magnetic pulling force as the air gap between the rotor and stator varied during operation.

Main bearing:

The non-linear stiffness behavior of the double roller bearing was integrated into the ANSYS model by simulating the stiffness interactions between the roller elements and the raceways. This interaction was based on Hertzian contact pressure and accounted for shape changes in each individual roller under varying loads.

The model was subjected to wind and thermal loads to evaluate air gap deformations. These deformations were extracted with APDL and processed using Python scripts, which combined the deformation data with probability density functions derived from wind and thermal load measurements.

 

A Monte Carlo analysis was conducted using this statistical data to assess the likelihood of minimum air gap conditions occurring throughout the turbine’s lifespan. This analysis provided detailed insights into the probability of air gap variations under different load scenarios, offering valuable predictions for the long-term reliability and performance of the wind turbine.

Acoustics in Product Development

Acoustics in product development is a complex interplay between a product’s functionality and its noise production. Often, these two aspects are closely intertwined, meaning that adjustments to the acoustic behavior can impact the product’s primary functions. Vekatech Engineering can support you throughout the design process by providing deeper insights into the acoustic behavior of a (new) product and its relationship to its core functions.

To achieve this, Vekatech Engineering utilizes a range of advanced tools to perform complex acoustic and dynamic analyses and calculations, ensuring that your product meets both performance and noise requirements.

Case study: Acoustic analysis for Philips Coffee Machine

A noise analysis was conducted on a Philips coffee machine to determine which noise mechanism was most dominant. Generally, two types of noise mechanisms can be distinguished:

  • Structure-borne sound: Noise produced by vibrating components of the machine or device.
  • Airborne sound: Noise produced directly as sound waves.

In the coffee machine, noise is generated by the water pump, a solenoid pump that presses hot water through the boiler and coffee pod. This pump generates both vibrations (structure-borne sound) and direct pump noise (airborne sound).

In the coffee machine, noise is generated by the water pump, a solenoid pump that presses hot water through the boiler and coffee pod. This pump generates both vibrations (structure-borne sound) and direct pump noise (airborne sound).

 

To separate these two types of noise, a computational model was developed using the Python programming language to calculate the airborne sound. The model uses the following inputs:

  • Pump noise: The sound power level of the pump during operation. During sound measurements, the backpressure on the pump was varied by placing different restrictions in the pump’s outlet.
  • Pressure profile: The measured backpressure over time that the pump experiences during the coffee-making process.
  • Sound insulation: The measured sound insulation for each frequency band (spectral).

The results of the sound measurements show the relationship between pump noise and backpressure. By multiplying this relationship by the pressure profile during coffee making, the airborne sound of the pump was calculated. Then, the sound insulation of the machine’s housing was subtracted from this result, isolating the sound power level due only to the airborne sound of the pump, excluding the structure-borne sound component. All calculations were performed across different frequency bands (spectral analysis).

 

The results revealed that the airborne sound component was approximately 8 dB lower than the total measured sound power level of the coffee machine (structure-borne sound plus airborne sound). This indicates that the structure-borne sound is the dominant noise source in this machine.

Based on these findings, further research was conducted to develop an improved pump suspension system.

Data Processing & Automation

Material fatigue is a failure mechanism caused by fluctuating loads, where the stresses leading to fatigue damage can be significantly lower than the material’s tensile strength. Vekatech Engineering has the expertise to perform (complex) fatigue calculations using international standards such as Eurocode 3, VDI 2230, DNV-GL, and others.

 

These fatigue analyses are conducted using the Python programming language, allowing for the integration of product-specific loading conditions and material properties into the calculations. For more complex geometries, finite element simulations (FEA) are employed, where the simulation results serve as input for the fatigue analyses. Depending on the complexity of the loading conditions, various methodologies can be applied, such as Maximum Absolute Principal Stress (MAPS) or Critical Plane analysis.

Case study: Material Fatigue Software Development

Vekatech Engineering developed custom software for a wind turbine manufacturer to calculate material fatigue damage in wind turbine components. The software uses the following inputs:

  • Load-Stress Relationship: This is obtained through ANSYS simulations, where material stresses are calculated under different unit loads.
  • Dynamic Loads: The dynamic loads exerted on the turbine over its entire 20-year lifespan are derived from wind load simulations.
  • S-N Curve: The fatigue life is calculated according to several guidelines and standards.

Vekatech Engineering implemented the advanced “Critical Plane” methodology to handle complex multiaxial stress conditions, where both the amplitude and direction of principal stresses vary over time. This approach enables precise prediction of material fatigue in scenarios such as doubly curved surfaces or non-proportional loading.

 

To manage these complex calculations, Vekatech developed a high-performance computing cluster using Python. The cluster, capable of load balancing and optimization, runs on both Windows and Linux platforms and performs fatigue analyses on finite element meshes of around 80,000 mesh-elements within 48 hours.

 

A unique feature of the software is its ability to compute fatigue damage across a full ANSYS mesh, providing clear identification of high-damage areas (“hot spots”). This software has been used in certifying three wind turbine platforms, offering accurate fatigue assessments for castings, welds, bolts, and other structural components.

Have any questions? I’m always open to talk about your business, new projects, creative opportunities and how I can help you.