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Dynamic Stress Distribution in Composite Leaf

Springs for Electromagnetic Vibratory Feeder

Conference Paper · May 2015

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Milica Vujovic Dr Zeljko V Despotovic

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 Dynamic Stress Distribution in Composite Leaf
Springs for Electromagnetic Vibratory Feeder
Milica M.Vujović
Department of Robotics
Mihajlo Pupin Institute, University of Belgrade
Belgrade, Serbia
milica.vujovic@pupin.rs
Abstract—Vibratory feeders having electromagnetic drive i.e.
electromagnetic vibratory feeders (EVF’s) are widely used for
performing gravimetric flow of particulate and granular
materials in processing industry. EVF’s are compact, robust,
reliable in operation and easy for maintenance. However, their
performance is highly sensitive to different kind of disturbances.
In addition, elastic elements of vibratory feeders are very
dynamic strained, given that the frequency of oscillation of such a
mechanical system is relatively high. For example, if one such
EVF unit operates about 10 hours on a day, at the frequency of
50Hz (50 oscillations per second), it will generate about 1.8
million oscillations in the one day, or about 650 million cycles of
during the year. In fact, elastic elements of EVF, usually
performed as composite leaf springs, are the most critical element
of the device from the standpoint of reliability and flexibility of
whole vibratory drive. The paper discusses the dynamic stress
distribution in composite leaf springs for one characteristic type
of resonant EVF. The dynamic analysis and simulations are done
in ANSYS Workbench software on a model that has been
imported from Solid Works software package. In ANSYS is used
Transient Structural module. Modelling and simulation were
conducted in a computer classroom at the Faculty of Mechanical
Engineering, University of Belgrade. In this module was done
setting the excitation force and as results were obtained
intensities of stress in composite springs, as well as their
oscillatory displacements. The motivation for this study was to
show the behaviour of composite elastic elements in a given
system of EVF and create a basis for further research in the area
of their fatigue and determine their lifetime.
Keywords—vibrations; vibratory feeder; composite springs;
resonance; electromagnetic drive
I. INTRODUCTION
The vibratory feeder having electromagnetic drive i.e.
electromagnetic vibratory feeder (EVF) are widely used for
performing gravimetric flow of particulate and granular
materials in processing industry. Vibratory motions represent
the most efficient way of granular and particulate materials
conveying. Conveying process is based on a sequential throw
movement of particles. The vibrations of load-carrying
element (LCE), in which the material is placed, induce the
movement of material particles, so that they resemble a highly
viscous liquid, and the material becomes easier to transport
Željko V. Despotović
Department of Robotics
Mihajlo Pupin Institute, University of Belgrade
Belgrade, Serbia
zeljko.despotovic@pupin.rs
and to dose. The conveying material flow directly depends on
the average value of particles throw movements, being on a
certain operating frequency of LCE. This average value, on
the other hand, depends on vibratory width i.e. doubled
amplitude oscillation, of the LCE. Optimal conveying of
material is determinate by the drive frequency and vibratory
width. There are the frequency range 5Hz-120Hz and
vibratory width range 0.1mm-10mm, for the most of
particulate and granular materials [1-4].
Different drive types can achieve mechanical vibrations of
the LCE. The very first drives were originally mechanical
(pneumatics, hydraulics and inertial). Nowadays, most of the
common drives are electrical. When a reciprocating motion
has to be electrically produced, the use of a rotary electric
motor with a suitable transmission is really a rather
roundabout way of solving the problem. It is generally a better
solution to look for an incremental-motion system with
magnetic coupling, so-called “electromagnetic vibratory
actuator” (EVA), which produces a direct “to-and-from”
movement [5]. Electromagnetic drives offer easy and simple
control of the gravimetric flow of conveying materials. In
comparison to all previously mentioned drives, these have a
more simple construction and they are compact, robust and
reliable in operation. The absence of wearing mechanical part,
such as gears, cams belts, bearings, eccentrics or motors,
makes vibratory conveyors and vibratory feeders most
economical equipment [6-10].
Application of EVA drive in combination with power
converter provides flexibility of EVF during operation. It is
possible to provide operation of the EVF in the region of the
mechanical resonance. Resonance is highly efficient, because
large output displacement is provided by small input power.
Operation in this region is favourable from the energy point of
view, since it requires minimal energy consumption. In this
way, the whole vibratory conveying system has behaviour of
the controllable mechanical oscillator [11-13].
EVF’s are compact, robust, reliable in operation and easy
for maintenance. However, their performance is highly
sensitive to different kind of disturbances. For example, as the
feeder vibrations occurred at its resonance frequency,
vibration amplitude is highly dependent on a damping factor.
On the other hand, damping factor depends on the mass of
material on the LCE, type of material, and the vibration
amplitude [1],[5],[8],[11]. These disturbances can reduce
drastically (up to 10 times) the vibration amplitude, thus
reducing the performance of EVF.
In addition, elastic elements of vibratory feeders are very
dynamic strained, given that the frequency of oscillation of
such a system is relatively high from a mechanical standpoint.
For example, if one such unit operates about 10 hours on a
day, at the frequency of 50Hz (50 oscillations per second), it
will generate about 1.8 million oscillations in the course of a
day, or about 650 million cycles of during the year. In fact,
these elastic elements are the most critical element of the
device from the standpoint of reliability [14-15].
In many papers, the dynamic characteristics and optimal
design of the composite leaf springs are analyzed. These
papers are mainly related to composites that are used by in the
automotive industry [16-20].
The problems related to analysis of the dynamic stress of
the EVF leaf springs are represented in key references [20-23].
It is a fact that a very few number of published papers and
research in fields.
Previously mentioned facts were motivation for analyzing
and study the dynamic stress distribution in composite leaf
springs for one characteristic type of resonant EVF used in
packaging machine for dosing particulate material (sugar) in
processing food industry.
II. DESCRIPTION OF MECHANICAL
CONSTRUCTION OF EVF
A typical mechanical construction of one real resonant
EVF and its 3D arrangement are presented in Fig.1 and Fig.2,
respectively. There are three main components: the load carry
element (LCE) (1), EVA as source of excitation force f and
supporting flexible elements (2). Flexible elements are made
of composite leaf springs. These elements are rigidly
connected with the LCE on their one side, while, on the other
side, they are fitted to the base (3) of the device and sloped
down under certain angle.
Fig. 1. Typical mechanical construction of EVF
The base of EMF is resting on rubber pads (4) to the
foundation. EVA consists of a magnetic core (5), covered by
continuous windings coils (6).
As the ferromagnetic material has a very high
permeability, all energy of the magnetic field is stored in air
gap. Created magnetic field producing the electromagnetic
force f acts on armature (7) attached to the LCE. This element
carries the vibratory trough (8) along with conveying
particulate material. The granular material comes to the trough
from storage hopper (10). Input flow can be braked off by
closing the movable shutter (11).
The vibratory displacement is measured by non-contact
inductive sensor (9), with analogue output providing voltage
signal proportional to the target’s distance located on movable
LCE. Output voltage linearly depends on the distance of the
target over the entire sensing range.
Fig. 2. 3D arrangement of EVF
This presented construction is base for generating model in
SolidWorks software package. The dynamic analysis and
simulations can be done in ANSYS Workbench software on
an EVF model that has been imported from Solid Works.
Transient Structural module will be used in ANSYS software.
In this module the setting of the excitation force was done and
as results were obtained intensities of stress in composite
springs, as well as their oscillatory displacements. Modelling
of EVF and simulation of dynamic loading were conducted in
a computer classroom at the Faculty of Mechanical
Engineering, University of Belgrade.
III. ANSYS SIMULATION MODEL OF EVF
In this section the simulation model of EVF is described
presented in Fig.1. The goal of the dynamic analysis and
simulations is to examine the composite springs that will be
used during the experiment on a EVF in real terms.
Investigation focuses on the analysis of deformation and
stresses that occur in elastic springs, considering their number
oscillation cycles a dynamic stress.
Excitation force that occurs in magnetic circuit of EVF
acts in direction as shown in Fig.1. The frequency of the
excitation force is 50 Hz, and the amplitude of 100N. The
force acting on the LCE, also on the vibratory through, in
which the particulate material is placed. The connection of
LCE and the base of the EVF structure that relies on the
substrate were achieved through elastic springs made of
composite material, namely Fiberglass S-Ply® leaf springs.
The technical data i.e. fiberglass constants, orthotropic
elasticity and alternating stress/mean stress are given in Tables
I, II and III, respectively.
The simulation was done in ANSYS Workbench software
package, where excitation force is represented as concentrated
with cyclic loading. The material itself is defined according to
characteristics of a material built into the existing EVF.

TABLE I. FIBERGLASS - CONSTANTS

Material Density Fig. 3.Connection of EVF elastic elements to LCE; (а) side view of the
Fiberglass 2.65e-006kg/m³ springs, (b) detailed view

TABLE II. FIBERGLASS –ORTHOTROPIC ELASTICITY In the considered case, there are two springs whose
dimensions are pre-defined in terms of length and width is
Young’s modulus X direction shown in Fig.2 (a) and on detailed view on Fig.2 (b). The
3.7e+008
[Pa]
Young’s modulus Y direction thickness of the spring is 2.75mm, and consists of
8.8e+009 approximately 11 layers thickness of 0.25 mm.
[Pa]
Young’s modulus Z direction
8.8e+009 The modulus of elasticity of the spring, which directly
[Pa] affects the fatigue and the life time, depends on the way of
Poisson’s Ratio XY 0.285 sorting the layers and their total number. The simulation aims
Poisson’s Ratio YZ 0.285 to show how much deflection and stresses occurred in the
Poisson’s Ratio XY 0.285 spring due to the effects of mentioned forces. Input
simulations are based on the existing springs that are built in
Shear Modulus XY [Pa] 3.3e+009
as well as the manufacturer's recommendations for newer
Shear Modulus YZ [Pa] 7.5e+008 models of springs designed for this type of system. Based on
3.3e+009 data on mechanical and physical characteristics of the
Shear Modulus XZ [Pa]
fiberglass springs that are available and provided by the
manufacturer of S-Ply, it is possible to define simulation
TABLE III. FIBERGLASS – ALTERNATING STRESS MEAN STRESS
precisely.
Alternating Stress
Cycles
Mean Stress To perform a correct simulation that corresponds as close
[Pa] [Pa]
to real case was given a series pulses of the excitation force.
3.6e + 008 100 1.5e + 008 These pulses have been square-sine, duration about 5ms, and
3.15e + 008 1000 1.5e + 008 the amplitude of 100 N. Otherwise, this waveform of
2.55e + 008 10000 1.5e + 008
excitation force is relate to a sinusoidal waveform of EVA
excitation current, which is obtained in the case of EVA
2.e + 008 1.e + 005 1.5e + 008
excitation the thyristor i.e. phase control SCR converter [5],
1.6e + 008 1.e + 006 1.5e + 008 [7], [11], [13].
1.3e + 008 1.e + 007 1.5e + 008 The goal was to conduct an analysis in ANSYS
Workbench software package, because based on the model of
1.25e + 008 1.e + 008 1.5e + 008
the overall system in Solid Works software package, it turned
out to be that the greatest stresses occur at the end of the
In the simulation of elastic springs the goal is to determine spring, or in a place where it is attached to the support.
the most unfavourable effect behaviour springs, its Stresses in this place affect the life time of the product, which
deformation and dynamic stress distribution. Also, goal is to is needed to verify the solution.
determine how springs react to the load. This investigation ANSYS Workbench software suite enables creation of
focuses on the analysis of deformation and stresses that occur models for springs just the way it is necessary to examine the
in springs. material, and that is by giving the exact material
The connection of elastic elements (composite leaf characteristics. To explain the process, analysis will be briefly
springs) and direction of the exciting force are shown in Fig.3. explained, in the software package applied to the observed
Elastic springs are made of fiberglass in different ways. example. ANSYS Workbench software package consists of
Depending on the method of sorting the layers, and the modules designed for the type of analysis that can be
provision of the grain in the layers, as well as the total conducted.
thickness of the layers that make up a spring, the spring itself In the specific case Transient Structural module was used.
will affect on the behaviour of the monitored system. The model in which the simulation is performed can be
imported from other software packages, such as Solid Works
as was the case here. Setting the material takes place in the
sector of Engineering Data, which also includes the materials
that are defined by manufacturer. Characteristics of springs
that are built into the EVF were entered as the input data for
the simulation. The next step relates to the geometry and
physical characteristics of the model, where it checks that the
appropriate model is imported, and where each component
gets the material that has been defined as explained. The
sector Setup defines supports and loads. After the set of input
parameters, the simulation runs and we can read the results.
IV. SIMULATION RESULTS
On the basis of the entered parameters, the results are
observed in terms of deflection of the springs in relation to the
initial position and the location and intensity of the stress
occurs in the spring.
The Fig. 4 shows the model EVF where the red colour
indicates the spring’s largest deflection (view is exaggerated
to make it clear where is the greatest displacement). This is
followed by graphic representation of the displacement in Fig.
5, with a maximum deviation of about 2 mm. Graph represents
time wave shape of displacement where maximum value of
displacement is displayed with its corresponding time
reference and where we can see rising trend of deformation
which is crucial for further conclusion about life span in
regard to fatigue.
Fig. 4. Displacement of the spring in relation to the initial position
Fig. 5. . Time wave shape of initial displacement of the spring
The simulation showed that the highest stresses occur in
the lower part of the spring that is trapped. Simulation enables
reading of stress values at each point of the model. Shades of
blue show the change in stress intensity and light blue
signifies a greater stress. The points in zones of greatest stress,
which in this case refers to the part of the spring which is
close to support element show approximately the same values
in the upper and lower part of stresses, and it is around 20MP,
which is shown in Fig. 6.
The location of greatest stress indicates a potential for
damage due to prolonged use EVF. It is important to
determine this parameter in order to establish the basis for
further study.
Fig. 6. Stress in selected points
V. CONCLUSION
In the simulation of EVF, the greatest strain occurs in the
upper and lower part of the springs as can be seen from the
graph that is the result of simulation in ANSYS software
package.
The springs are in this part at the greatest stress on the
basis of which we can assume a place for a potential fracture
of the spring.
The observed simulations did not show sufficient stress
due to which the elastic spring would be broken, but it can be
assumed that the places that suffer the greatest stress can be
most critical in terms of cracking, for longer periods of EVF
operation.
The upper zone of the spring suffers slightly higher
stresses than the lower zone which would, for the analysis of
fatigue, due to long hours of working, be an important figure.
Based on the obtained results, guidelines are set for further
research of fatigue of elastic springs and their life span at the
EVF operation.
VI. ACKNOWLEDGMENTS
This investigation has been carried out with the financial
support of the Serbian Ministry of Science- Project No:
TR33022, time period 2011-2015.
The authors are grateful to the anonymous reviewers
whose helpful suggestions contributed to improving the
quality of this paper.
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