Prediction of Failure Rate of Rotary Machine Using Computer Simulations

[+] Author and Article Information
Jie Chen, Gang Bai, Xiaofeng Li, Andrew Hsu

Department of Mechanical Engineering, IUPUI, 723 W. Michigan Street, Indianapolis, IN 46202

Zhongmin Shen

Department of Mathematics, IUPUI, Indianapolis, IN 46202

David Fulton

 Delco Remy America, Indiana

J. Manuf. Sci. Eng 127(4), 768-772 (Mar 14, 2005) (5 pages) doi:10.1115/1.2037088 History: Received June 07, 2004; Revised March 14, 2005

Failures can occur in brushless alternators due to interferences between the moving and stationary parts, called “rub.” Improper design of component target dimensions and tolerances can result in interferences. A method was developed to evaluate the component tolerances that can create interference in a brushless alternator. Mathematic models were created to relate target dimensions to the interferences. Monte Carlo simulation was utilized to statistically evaluate the effects of tolerances on failure rate. This method allows a designer to avoid potential rub failures while still in the design phase. It can also be used to analyze rotary machines of similar designs.

Copyright © 2005 by American Society of Mechanical Engineers
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Figure 1

A brushless alternator made by Delco Remy America. The five potential interference points are indicated.

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Figure 2

Schematics showing the definition of the scale factor

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Figure 3

The definitions of the two vectors, RSBLF and RSBLR

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Figure 4

Schematics describing the coordinate transformation. P1Pa″ is on the rotor’s centerline, P0P1, described in the stator’s coordinate frame

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Figure 5

Schematics describing the second algorithm

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Figure 6

Schematics describing the third algorithm

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Figure 7

The distributions of RSBLR as a function of the angle θ. (Normal distribution is used for individual dimension variation).

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Figure 8

The power densities of RSBLR



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