Archive

Selected project examples  (extract )

High- performance camshaft phasing

• high adjustment speed  by reducing leakage
• application of a central valve with integrated holding valve
• high utilization –degree of camshaft alteration moments

Development high-pressure oil pump for axle transmission of passenger car

• application in passenger vehicle – sport segment
• low starting  torque
• high pressure level

Elastomer bearing design

• structure analysis of the subframe and  analysis of  the structure-borne noise transmission
• designing of optimal bearing-charcteristic  per spatial direction with respect to support
• function, isolation and life-span
• realization into a real design up to the manufacturing of prototypes

Powerpack

• compact construction
• modular assembly   
• high degree of efficiency
• flexible design
• economic design
• low weight

 
Development valve technique

• on/off valves, pilot valves, direction control valves, pressure  regulating valves
• in  Cartridge construction,
• without Cartridge, operating directly 

Motorcycle transmission concept

• design of 2  types (sliding collar, sliding wheel)
• 3D design
• life-time calculation of gearings, axles, bearings

Bowden cable buzz

• measurement analysis of noise problems  in the shift- and  select-cable of a gearshift in the time – and frequency- domain  with the additional help of a virtual camera
• assembly of a simulation model and alignment with performance data
• sensitivity analysis on the components test bench and in the simulation as well as
• the planning of a solution regarding the serial application

 Concept-comparison  of  Torque  Vectoring systems

•  simulation models of various Torque Vectoring concepts
• virtual assessment with respect  to regulating  dynamics, controllability and temperature behaviour
• development of controllability strategies by means of a critical course

Shifting strategy for a automated gearbox  (AMT)

• measurement and analysis gearshift AMT
• construction of a simulation model of the entire powertrain
• planning of new gearshift strategies and alternative synchronization concepts for
  the cycle time of AMT´s

Optimization of pumps

• simulation of pumps in the conceptual phase on the basis of AMESim (LMS)
• pre-optimization of hardware prototypes
• verification on the pump test bench

Coupling – temperature model

• thermal calculation of wet and dry gearshift- and starting – elements
• fast and simple diagnozing of temperatures under varying parameters and
  operating conditions
• display of temporal- and spatial  - temperature characteristics of all clutch components
• simulation of critical repetitive gearshifting

Hydrostatic Torque Vectoring

• shorter  reaction time than those systems already available  on the market
• exact control of the vector moment, independent of the temperature
• for system-inherit reasons a very low wear and tear due to hydrodynamic lubrication
• compact mode of construction by through integrated actuating elements
• maximum utilization of the availabe heat capacity
• application possible as inter-axle and inter-wheel differential lock

Steering – NVH optimization

• measuring analysis of air-and structure-borne sound during the steering with EPS
• development of improvements of the E-motor controls for a reduced  acoustic noise generation
• development of measurements for a reduced structure-borne transmittance

Fatigue failure at auxillury equipment

• Stress analysis in the area of the failure by combination of multi-body-simulation (equipment in its elastic mountings) and FEM (metal geometry) 
• Design of elastic mountings for reduced vibration of the equipment and optimization of the metal geometry
• Calculation of damage accumulation with respect to known load profile and durability estimation

Hybrid demo-vehicles

• development, construction and adaption of complete hybrid powertrains
  (front-crosswise AND rear- lengthwise) inclusive design of passenger compartment
• development, construction and integration of belt transmission concepts for  hybrid vehicle
• concepts for torque converter connections for hybrid vehicles

Variable valve lifting devices - market survey

• introduction of projects and description of system-properties
• comparison and assessment of systems

• Development of wheelset, dual clutch, hydraulic control, electronics (HW+SW)
• Free of traction interruption due to overlay of hydrostat/planetary transmission
• Application for off-road vehicles in the performance range up to 240 HP

• Development of A & B sample, industrialization
• Testing of function and durability
• Modular control concept
• High degree of efficiency, good actuator controllability
• Actuation technology integration option
• Cost-optimized design and low weight

• High pressure level (>2200bar)
• Long lasting >4000h
• High degree of efficiency, cost-optimized design, low weight
• Good controllability of delivery volume and rail pressure

• Optimal dynamic parameter of elastomer decoupling in powertrain, while taking entire powertrain into consideration
• Design of new elastomer component and hardware implementation thereof
• Function verification and durability testing on special test bench

• Construction of new series shift transmission housing
• FEM calculation for durability and acoustics
• Weight reduction >2kg equals savings of >1.8 million Euros p.a.

• Planning of mechanical production, assembly, final checking
• Logistics concepts and quality assurance
• Supplier development

• Establishment of function requirements and simulation of process sequences
• Concept variants in close agreement with component developer
• Development, production and start-up of plant

• Analysis of powertrain resonance, shift shock, load change behaviour and rattling transmission as a basis for series development of a new motorcycle
• Measurement of rpm and torque (DMS with telemetry) in transmission and at rear wheel
• Comparison of road, roll, simulation model

• Measurement analysis with the aid of the automated shift-comfort evaluation programme ProGear® and shift-comfort diagrams
• Construction of a simulation model for the specific shift-comfort problem
• Sensitivity examination and solution-finding with simulation
• Hardware implementation and verification – improvement of synchronization force, of the 2nd pressure point and the unlocking force by means of an alternative synchronization

• Measurement analysis of several NVH phenomena in a powertrain 
• Elaboration of a virtual toolbox for clutch and DMF/TD development
• Comparison road, roller test bench measurements and simulation models

• Analysis of juddery-start problem with automatic transmission and construction of relevant simulation model
• Parametrical influence study and development of an active anti-judder algorithm in the simulation, including rigidity testing
• Implementation in series

• Optimization of surface coating of all affected components
• Constructive elimination of axial bearing wear in the pump
• Optimization of pressure limitation valve / suction throttle valve
• High-speed images of feed pump in operation (proof and removal of cavitation)
• Set-up of prototype pumps for precise measurement of torque and bends in the pump (telemetry)

• Testing of individual functions
• Testing of overall functioning
• Influences of changes can be rapidly checked

• Torque at motorcycle rear wheel
• Common rail pump
• Clutch

• Component-independent modelling strategy
• Shorter development times due to resource-optimized model distribution
• Shorter calculation times

• Construction of a dual-clutch transmission plant model with vehicle model for SIL and HIL
• Development of a control algorithm with Matlab Stateflow
• Virtual test of control unit software (SIL) before the hardware prototypes

• Set-up of simulation model of a camshaft phaser based on drawings
• Prediction of adjustment dynamics and adjustability
• Optimization before the hardware

• Set-up of a hybrid powertrain model as a plant model with vehicle model for SIL (Software in the loop)
• Development of a control algorithm for optimal comfort and consumption with Matlab Stateflow

Software application with rapid prototyping control unit in demonstrator vehicle and proof of consumption and comfort