Vertical Stand

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Description

Figure 1: CAD Geometry

The vertical stand (see xx--CrossReference--dft--fig:cad--xx) represents a structural part of a machine tool. On one of its surfaces a pair of guide rails is located. Caused by a machining process a tool slide is moving on these rails. The machining process produces a certain amount of heat which is transported through the structure into the vertical stand. This heat source is considered to be a temperature input at the guide rails. The induced temperature field, denoted by $T$ is modeled by the heat equation

$c_p\rho \frac{\partial T}{\partial t}=\mathrm{\nabla }.(\lambda \mathrm{\nabla }T)=0$

with the boundary conditions

$\lambda \frac{\partial T}{\partial n}=f$ on ${\mathrm{\Gamma }}_{slide}$ (surface where the tool slide is moving on the guide rails),

describing the heat transfer between the tool slide and the vertical stand. The heat transfer to the ambiance is given by the fixed Robin-type boundary condition

$\lambda \frac{\partial T}{\partial n}=g_i={\kappa }_i(T-T_i^{ext})$ on ${\mathrm{\Gamma }}_{surf}$ (remaining boundaries).

The motion driven temperature input and the associated change in the temperature field $T$ lead to deformations $u$ within the stand structure. Since the mechanical behavior of the machine stand is assumed to be much faster than the propagation of the thermal field, it is sufficient to consider the stationary linear elasticity equations

$\begin{array}{rlr}-\mathrm{div}(\sigma (u))& =f& \text{ on }\mathrm{\Omega },\\ \epsilon (u)& ={\mathbf{𝐂}}^{-1}:\sigma (u)+\beta (T-T_{ref})I_d& \text{ on }\mathrm{\Omega },\\ {\mathbf{𝐂}}^{-1}\sigma (u)& =\frac{1+\nu }{E_u}\sigma (u)-\frac{\nu }{E_u}\text{tr}(\sigma (u))I_d& \text{ on }\mathrm{\Omega },\\ \epsilon (u)& =\frac{1}{2}(\mathrm{\nabla }u+\mathrm{\nabla }{u}^T)& \text{on }\mathrm{\Omega }.\end{array}$

Geometrical dimensions:

Stand: Width ($x$ direction): $519mm$, Height ($y$ direction): $2010mm$, Depth ($z$ direction): $480mm$

Guide rails: $y\in [519,2004]mm$

Slide: Height $500mm$

Discretized Model

The solid model has been generated and meshed in ANSYS. For the spatial discretization the finite element method with linear Lagrange elements has been used and is implemented in FEniCS. The resulting system of ordinary differential equations (ODE), representing the thermal behavior of the stand, reads

$\begin{array}{rl}E\frac{\partial }{\partial t}T(t)& =A(t)T(t)+B(t)z(t),\\ T(0)& =T_0,\end{array}$

with $t>0$ and a system dimension of $n=16626$ degrees of freedom and $m=6$ inputs. Note that $A(.)\in {\mathbb{ℝ}}^{n\times n}$ and $B\in {\mathbb{ℝ}}^{n\times m}$ are time-dependent matrix-valued functions. More precisely, here the time dependence origins from the change of the boundary condition on ${\mathrm{\Gamma }}_{slide}$ due to the motion of the tool slide. The system input is, according to the boundary conditions, given by

$z_i=\{\begin{array}{l}f,i=1,\\ g_i,i=2,\dots ,6\end{array}.$

The discretized stationary elasticity model becomes

$Mu(t)=KT(t).$

For the observation of the displacements in single points/regions of interest an output equation of the form

$y(t)=Cu(t)$

is given.

Exploiting the one-sided coupling of the temperature and deformation fields, and reorganizing the elasticity equation in the form $u(t)=M^{-1}KT(t)$, the heat equation and the elasticity model can easily be combined via the output equation. Finally, the thermo-elastic control system is of the form

$\begin{array}{rl}E\frac{\partial }{\partial t}T(t)& =A(t)T(t)+B(t)z(t),\\ y(t)& =\tilde{C}T(t),\\ T(0)& =T_0,\end{array}$

where the modified output matrix $\tilde{C}=C{M}^{-1}KT(t)$ includes the entire elasticity information.

The motion of the tool slide and the associated variation of the affected input boundary are modeled by two different system representations. The following specific model representations have been developed and investigated in , .

Switched linear system

Figure 2: Schematic segmentation

For the model description as a switched linear system, the guide rails of the machine stand are modeled as 15 equally distributed horizontal segments with a height of $99mm$ (see a schematic depiction in xx--CrossReference--dft--fig:segm--xx). Any of these segments is assumed to be completely covered by the tool slide if its midpoint (in y-direction) lies within the height of the slide. On the other hand, each segment whose midpoint is not covered is treated as not in contact and therefore the slide always 5 to 6 segments at each time. Still, the covering of 6 segments only will occur for high movement resolutions and further do not have a significant effect on the behavior of the temperature and displacement fields. Due to that and in order to keep the number of subsystems small, this scenario will be neglected. Than, in fact 11 distinct, discrete boundary condition configurations for the stand model that are prescribed by the geometrical dimensions of the segmentation and the tool slide are defined. These distinguishable setups define the subsystems

$\begin{array}{rl}{E}_{th}\dot{T}& =A_{th}^{\alpha }T+B_{th}^{\alpha }z,\\ y& =\overline{C}T,\end{array}$

of the switched linear system , where $\alpha$ is a piecewise constant function of time, which takes its value from the index set ${𝒥}=\{1,\dots ,11\}$. To be more precise, the switching signal $\alpha$ implicitly maps the slide position to the number of the currently active subsystem.

Acknowledgement & Origin

The base model was developed , in the Collaborative Research Centre Transregio 96 Thermo-Energetic Design of Machine Tools funded by the Deutsche Forschungsgemeinschaft .

Data

Switched System Data

The data file VertStand_SLS.tar.gz contains the matrices

$\begin{array}{r}E\in {\mathbb{ℝ}}^{n\times n},\tilde{C}\in {\mathbb{ℝ}}^{q\times n},A^{\alpha }\in {\mathbb{ℝ}}^{n\times n},B^{\alpha }\in {\mathbb{ℝ}}^{n\times m},\alpha =1,\dots ,11.\end{array}$

defining the subsystems of the switched linear system. The matrices $A^{\alpha }$ and $B^{\alpha }$ are numbered according to the slide position in descending order (1 - uppermost slide position / 11 - lowest slide position).

System dimensions:

$n=16626,m=6,q=27$

Parametric System Data

in preparation

Citation

To cite this benchmark, use the following references:

• For the benchmark itself and its data:

The MORwiki Community. Vertical Stand. MORwiki - Model Order Reduction Wiki, 2018. http://modelreduction.org/index.php/Vertical_Stand

   @MISC{morwiki_vertstand,
    author = {The {MORwiki} Community},
    title = {Vertical Stand},
    howpublished = {{MORwiki} -- Model Order Reduction Wiki},
    url = {http://modelreduction.org/index.php/Vertical_Stand},
    year = {2014}
   }

• For the background on the benchmark:

   @Article{morLanSB14,
     author =       {Lang, Norman and Saak, Jens and Benner, Peter},
     title =        {Model Order Reduction for Systems with Moving Loads},
     journal =      {at-Automatisierungstechnik},
     year =         2014,
     volume =       62,
     number =       7,
     pages =        {512--522},
     month =        {June},
     publisher =    {deGruyter},
     doi =          {10.1515/auto-2014-1095}
   } 

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