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PACS Housing: Structure Analysis

This document details the structural analysis of the PACS Housing, focusing on strength evaluation under various loading scenarios. Conducted by Dr. G. Wanderer at CASE GmbH, it encompasses dynamic and static load assessments of housing components, including pins and bolts. The analysis explores notching impacts under sine and random vibration loads, with specifications for material properties (AW 6061T6, A4-70 steel) and compliance with MIL Handbook standards. Insights include vibration response, interface load monitoring, and detailed stress calculations provided for critical load paths in suspension systems.

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PACS Housing: Structure Analysis

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  1. PACS Housing: Structure Analysis • Dr. G. Wanderer • CASE GmbH

  2. Loads • Strength Analysis of Housing Parts • Housing • Pins and Bolts • Notching of Sine- and Random Qualification Loads • Suspension Analysis • Brackets • Pins and Bolts

  3. Dynamic and Static Loads • Quasistatic: • LC1 longitudinal 20g, lateral 2g • LC2 lateral 14 g • Sine Vibration • longitudinal 5- 40 Hz 20g • 40-100 Hz 10g • lateral 5-100 Hz 14g • Random Vibration • 20 - 100 Hz +6 dB/Oct • 100 - 300 Hz 0,05 g2/Hz • 300 - 2000 Hz -6 dB/Oct

  4. Material • The PACS Housing is build of AW 6061T6, • Bolts and Pins are of Typ A4-70 (i. e. Steel AISI 316) • Ref: MIL HDBK-5H, ESACRACK user´s manual

  5. Spectrometer Housing • Spectrometer Housing is the highest loaded part except Suspension • Stresses in Spectrometer Housing:

  6. Spectrometer Housing

  7. Pins And Bolts

  8. Notching of Vibration Loads Accelerometer- Positions with good correlation to I/F Forces

  9. Monitoring of I/F Loads Reference Grid 13136 I/F Loads for constant 1g Sine

  10. Notch Procedure • an accelerometer is located on the FPU at a place that the measured values correspond to the interface loads • the notch calculation is based on the FE results scaled to the measured damping values for the major natural modes. • random vibration: • the equivalent force is calculated for each major natural mode by integrating the Force Power Spectral Density (PSD) around the mode • The 4-sigma response is limited to the static load level for each major natural mode. • The notch width shall be smaller than 1/3 octave around the natural frequency. • The slope of the notch shall be as steep as possible (more than 24dB/Oct, typical 50dB/Oct). • sine vibration: • the output is limited to the calculated static interface force in the frequency range 50 to 100 Hz

  11. 1-Axis Suspension

  12. Forces in Suspensions

  13. 1 axis Suspension • critical load path through pin of diameter 10mm (shear) • t = F/(2*A) = 7975N/(2*78mm2) = 50,8N/mm2 • s = F*l/8W = 7975N*6mm / (8*98mm3) = 60,9 N/mm2 • sMises = 107 MPa

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