Design

Researchers in the competence group for design work closely together with the teams for simulation and testing to find technical solutions for challenges arising in the various competence areas of the Project Group. Here CATIA V5 is used together with a PDM system and an extensive material database. To guarantee optimal collaboration with our industrial partners, an MML design methodology is used, which generates a clear and uniform component structure. This facilitates the exchange of information within the team and with project partners.

Clean sheet design

The Project Group NAS develops completely new and complex assemblies. Developments include prototypes for the validation of new operating principles and layout concepts for thermal energy converters such as turbines or piston engines. The team carries out all the necessary steps from developing ideas and concepts and preparing the first designs through to detail design and process-oriented drawings. Validation is then performed by the testing team in close cooperation with the research teams for simulation and measurement technology.

 

Redesign and optimization

Extensive analyses are conducted in order to detect weak points in existing systems, and the resulting optimization approaches are developed to the production stage. Some subsystems can also be developed on the basis of existing products. Throughout the entire process, the researchers work closely together with the simulation teamRedesign and optimization.

 

New processes and materials

Development work is often centered on new materials and manufacturing processes. One research project involves the substitution of metal alloys by high performance composite materials in combustion engines; in another, the application of selective laser melting (SLM) to manufacture raw parts allows for more creativity in the design, and thus for optimized components.

Packaging of components and entire systems

In the research area of design, emphasis is placed on the packaging of electronic components developed in-house for electric power trains. Various projects also include packaging concepts for entire conventional or electrified vehicle power trains.

 

Collaboration with the testing team

In order to ensure the comparability of different samples, safe installations and simple assembly, all test stands and their peripherals are developed and documented virtually in the CAD system.

 

Collaboration with the simulation team

In direct collaboration with the research team for simulation, component models are created which can be used for both in-house projects and for the flow, FEM, heat transfer and dynamic simulations of our industrial partners.