Energy efficiency in materials testing by reactive power – part 1: power recirculating method in wear testing

Dietmar Findeisen; Dirk Schröpfer

doi:10.1515/mt-2023-0136

Article

Energy efficiency in materials testing by reactive power – part 1: power recirculating method in wear testing

Dietmar Findeisen
Prof. Dr.-Ing. habil.

Dietmar Findeisen, born in 1935, studied Mechanical Engineering at TH Hannover and obtained his doctor degree in 1974. In 1984, he habilitated in the field of vibration machines. In 1989, he was appointed an apl. professorship at the TU Berlin. Until March 2000, he was head of the division “Scientific Instrumentation” at the Federal Institute for Materials Research and Testing (BAM) in Berlin. His research areas include systems theory and vibration engineering, complex power theory, and hydrostatic power transmission (oil hydraulics). From 1976 to 2002, he taught at the TU Berlin in “Elements of Vibration Control” and “Hydraulics and Pneumatics”. Dietmar Findeisen passed away in 2024.
and Dirk Schröpfer
Dr.-Ing.

Dirk Schröpfer, born in 1981, studied materials engineering at TU Ilmenau and achieved his final qualification of Dipl.-Ing. in 2007. He subsequently worked as R&D-engineer at QSIL AG in Ilmenau and from 2012 as research assistant at Federal Institute for Materials Research and Testing (BAM). In 2017, he obtained his doctor degree in the field of integrity of welded joints. Since then, he worked as a postdoctoral researcher at BAM in the area of innovative manufacturing processes and component safety. In 2022, he became head of the division “Testing Devices and Equipment” at BAM.

Published/Copyright: December 16, 2024

Published by

Become an author with De Gruyter Brill

Submit Manuscript Author Information

From the journal Materials Testing Volume 67 Issue 1

Abstract

Reactive power is related to the type of power that does not consume energy but stores it. In the design of test machines, the utilization of this physical phenomenon would be very beneficial. Reactive power allows for the combination of power amplification with energy savings, making it an ideal principle for conducting long-term tests that involve high loads and prolonged energy consumption. This concept is illustrated in this work focusing test machines used in rotary testing procedures. Drive element pairs, which serve as component test objects, are primarily exposed to wear stress. These stressed element pairs are consequently integral parts of a tribological system. The underlying principles of power amplification and power feedback are explained from the perspectives of drive technology, systematic design, methodical design, and mechatronics.

Keywords: reactive power; power amplification; power feedback; wear testing; strained element pairs

Corresponding author: Dirk Schröpfer, Bundesanstalt für Materialforschung und -prüfung (BAM), Berlin, Germany, E-mail: dirk.schroepfer@bam.de

In memory of Dietmar Findeisen.

About the authors

Dietmar Findeisen

Prof. Dr.-Ing. habil.

Dietmar Findeisen, born in 1935, studied Mechanical Engineering at TH Hannover and obtained his doctor degree in 1974. In 1984, he habilitated in the field of vibration machines. In 1989, he was appointed an apl. professorship at the TU Berlin. Until March 2000, he was head of the division “Scientific Instrumentation” at the Federal Institute for Materials Research and Testing (BAM) in Berlin. His research areas include systems theory and vibration engineering, complex power theory, and hydrostatic power transmission (oil hydraulics). From 1976 to 2002, he taught at the TU Berlin in “Elements of Vibration Control” and “Hydraulics and Pneumatics”. Dietmar Findeisen passed away in 2024.

Dirk Schröpfer

Dr.-Ing.

Dirk Schröpfer, born in 1981, studied materials engineering at TU Ilmenau and achieved his final qualification of Dipl.-Ing. in 2007. He subsequently worked as R&D-engineer at QSIL AG in Ilmenau and from 2012 as research assistant at Federal Institute for Materials Research and Testing (BAM). In 2017, he obtained his doctor degree in the field of integrity of welded joints. Since then, he worked as a postdoctoral researcher at BAM in the area of innovative manufacturing processes and component safety. In 2022, he became head of the division “Testing Devices and Equipment” at BAM.

Research ethics: Not applicable.
Informed consent: Not applicable.
Author contributions: The authors have accepted responsibility for the entire content of this manuscript and approved its submission.
Use of Large Language Models, AI and Machine Learning Tools: DeepL to improve English language.
Conflict of interest: The authors state no conflict of interest.
Research funding: None declared.
Data availability: Not applicable.

References

[1] Technical Principles of mechanisms – Terminology of mechanisms, VDI 2127, 1993 [Online]. Available at: https://www.dinmedia.de/de/technische-regel/vdi-2127/954759.Search in Google Scholar

[2] G. Niemann and H. Winter, Maschinenelemente – Band 2: Getriebe allgemein, Zahnradgetriebe – Grundlagen, Stirnradgetriebe, Berlin, Germany, Springer, 2003.10.1007/978-3-662-11873-3_2Search in Google Scholar

[3] H. Czichos and K.-H. Habig, Tribologie-Handbuch – Tribometrie, Tribomaterialien, Tribotechnik, Berlin, Germany, Springer, 2020.10.1007/978-3-658-29484-7Search in Google Scholar

[4] H. Czichos, “Tribologie – 50 Jahre interdisziplinäre Reibungs- und Verschleißforschung,” Mater. Test., vol. 58, nos. 11–12, pp. 921–926, 2016, https://doi.org/10.3139/120.110943.Search in Google Scholar

[5] Gears – Wear and Damage to Gear Teeth – Part 1: Nomenclature and Characteristics, ISO 10825-1, May 2022 [Online]. Available at: https://www.dinmedia.de/de/norm/iso-10825-1/355735018.Search in Google Scholar

[6] G. Niemann and H. Rettig, “Der FZG-Zahnrad-Kurztest zur Prüfung von Getriebeölen,” Erdöl und Kohle, vol. 07, no. 10, pp. 640–642, 1954.Search in Google Scholar

[7] H. Winter, K. Michaelis, Fresstragfähigkeit von Stirnradgetrieben, Antriebstechnik, vol. 14, Part 1: no. 07, pp. 405 – 409 /Part 2: no. 08, pp. 461 – 465, 1975.Search in Google Scholar

[8] B.R. Höhn, P. Oster, K. Michaelis, Zahnfuß-betriebsfestigkeitsuntersuchungen an einsatzgehärteten zahnrädern, Antriebstechnik, vol. 40, Part 1: no. 08, pp. 37 – 39 /Part 2: no. 09, pp. 65 – 69, 2001.Search in Google Scholar

[9] A. Sitzmann, Th. Tobie, K. Stahl, and S. Schurer, “Influence of the case properties after nitriding on the load carrying capacity of highly loaded gears,”in ASME 2019 International Power Transmission and Gearing Conference, Proceedings, Anaheim, CA, USA, 2019, pp. 1–9.10.1115/DETC2019-97405Search in Google Scholar

[10] Gears – FZG Test Procedures – Part 1: FZG Test Method A/8,3/90 for Relative Scuffing Load-Carrying Capacity of Oils, 2006 ISO 14635-1 [Online]. Available at: https://www.din.de/de/mitwirken/normenausschuesse/nam/veroeffentlichungen/wdc-beuth:din21:87430709.Search in Google Scholar

[11] Planetary gear drives – definitions, symbols, designs, calculations, 2012 VDI 2157 [Online]. Available at: https://www.din.de/de/wdc-beuth:din21:138169923.Search in Google Scholar

[12] H. W. Müller, Die Umlaufgetriebe: Auslegung und vielseitige Anwendungen, Berlin, Germany, Springer, 1998.10.1007/978-3-642-58725-2Search in Google Scholar

[13] B. Bender, and K. Gericke, Eds., Pahl/Beitz Konstruktionslehre, 9th ed. Berlin, Germany, Springer, 2020.10.1007/978-3-662-57303-7Search in Google Scholar

[14] K. Roth and R. Simonek, “Mechanische verstärker,” Konstruktion, vol. 23, no. 3, pp. 90–98, 1971.Search in Google Scholar

[15] K. Roth, Konstruieren mit Konstruktionskatalogen – Band 2: Kataloge, Berlin, Germany, Springer, 2000.10.1007/978-3-642-17466-7Search in Google Scholar

[16] Design Methodology for Mechatronic Systems, VDI 2206, June 2004 [Online]. Available at: https://www.dinmedia.de/de/technische-regel/vdi-2206/73296956.Search in Google Scholar

[17] R. Isermann, Mechatronische Systeme – Grundlagen, 2nd ed., Berlin, Germany, Springer, 2007.Search in Google Scholar

[18] S. Rinderknecht, R. Nordmann, and H. Birkhofer, Einführung in die Mechatronik für den Maschinenbau, 2nd ed., Shaker, Ed., Aachen, Germany, 2018.Search in Google Scholar

[19] L. Zhihong, H. Ping, and S. Rinderknecht, “A combined theoretical and experimental Investigation of the overall energy consumption in a wet dual clutch system during a driving profile,”ASME 2021 International Mechanical Engineering Congress and Exposition, Proceedings, 2021, pp. 1–9. online.Search in Google Scholar

[20] Fluid Power Systems and Components – Graphic Symbols and Circuit Diagrams – Part 1: Graphic Symbols for Conventional use and Data-Processing Applications, ISO 1219-1, June 2016 [Online]. Available at: https://www.din.de/de/mitwirken/normenausschuesse/nam/veroeffentlichungen/wdc-beuth:din21:297840234.Search in Google Scholar

[21] K. V. Schaller, Betriebsfestigkeitsuntersuchungen zur Grübchenbildung an einsatzgehärteten Stirnflanken, Ph.D. dissertation, FZG – Department of Design Components, Technical University of Munich (TUM), Munich, Germany, 1990.Search in Google Scholar

[22] C. Eberspächer, Reihenfolgeeffekte bei der Grübchen-Betriebsfestigkeit einsatzgehärteter Zahnräder, Ph.D. dissertation, FZG – Department of Design Components, Technical University of Munich (TUM), Munich, Germany, 1995.Search in Google Scholar

[23] C. Lohmann, Zusammenhang von Ermüdung, Rissbildung, Verschleiß und Graufleckentragfähigkeit an Stirnrädern, Ph.D. dissertation, Chair of Industrial and Automotive Drivetrains (LIFA), Ruhr-University Bochum (RUB), Bochum, Germany, 2016.Search in Google Scholar

[24] A. Kretschmer, “Eine Leistungsprüfanlage für Triebelemente,” Mater. Test., vol. 01, no. 04, pp. 132–141, 1959, https://doi.org/10.1515/mt-1959-010402.Search in Google Scholar

[25] K.-H. Bußmann, H. Lösche, Winkelmessungen an gummi-keilriemen, Kautschuk und Gummi, vol. 11, Part 1: no. 10, pp. 238 – 242 /Part 2: no. 11, pp. 266 – 276, 1958.Search in Google Scholar

[26] P. Schrimmer and H. Lösche, “Treibriemen, Riementriebe und Treibriemenprüfung,” Klepzig Fachberichte, vol. 72, no. 01, pp. 4–12, 1964.Search in Google Scholar

[27] P. Schrimmer, “Profilverformung und Betriebsverhalten von Keilriemen,” Ph.D. dissertation, Department of mechanical and electrical engineering, Technical University Brunswick, Brunswick, Germany, 1971.Search in Google Scholar

[28] E. Jarchow, K. Langenbeck, H. Benthake, “Planeten- und Überlagerungsgetriebe,” Antriebstechnik, vol. 06, Part 1: no. 11, pp. 402 – 406 /Part 2: no. 12, pp. 432 – 440, 1967.Search in Google Scholar

[29] E. Jarchow, “Stufenlose hydrostatische Umlauf- und Koppelgetriebe,” VDI-Berichte, vol. 167, pp. 5–20, 1971.Search in Google Scholar

[30] D. Findeisen, “Gleichförmig übersetzende Getriebe stufenloser Übersetzungsänderung, Gegenüberstellung von mechanischer und fluidtechnischer Energieübertragung,” Part 2, Konstruktion, vol. 33, no. 01, pp. 15–24, 1981.Search in Google Scholar

[31] S. Helduser, Grundlagen elektrohydraulischer Antriebe und Steuerungen, Mainz, Germany, Vereinigte Fachverlage, 2013.Search in Google Scholar

[32] D. Findeisen and S. Helduser, Ölhydraulik – Handbuch der hydraulischen Antriebe und Steuerungen, 6th ed., Berlin, Germany, Springer, 2015.10.1007/978-3-642-54909-0Search in Google Scholar

[33] D. Findeisen, Durchführung des Prüfverfahrens Schwingfestigkeitsversuch – Anforderungen an die Schwingprüfmaschine aus systemtheoretischer Sicht, Teil 1 und 2, Mater. Test., vol. 17, no. 4, pp. 96–104, https://doi.org/10.1515/mt-1975-170204.Search in Google Scholar

Published Online: 2024-12-16

Published in Print: 2025-01-29

You are currently not able to access this content.

Articles in the same Issue

https://doi.org/10.1515/mt-2023-0136

Keywords for this article

reactive power; power amplification; power feedback; wear testing; strained element pairs