Gearbox Demonstrator Development

Transcription

1 Dynamik für Ihre Entwicklung Gearbox Demonstrator Development Hervé MOTTE ARRK Shapers R&D / Innovation Manager

2 AGENDA ARRK Company overview Phase 1 Motivation and general feasibility Phase 2 Engineering Phase 2 Manufacturing Next steps & perspectives 2

3 AGENDA ARRK Company overview Phase 1 Motivation and general feasibility Phase 2 Engineering Phase 2 Manufacturing Next steps & perspectives 3

4 ARRK AT A GLANCE Who are ARRK Capabilities International technology group Engineering Founded 1948 Your One global of the product world s development largest product specialist development specialists Turnover 418 M (2015/16) Prototyping Worldwide > employees 20 ARRK companies in 15 countries Listed on the Tokyo Stock Exchange (TSE) Tooling Low Volume Production (LVP) 4 4

5 PRODUCT DEVELOPMENT COMPETENCE Engineering Prototyping Tooling Low Volume Production (LVP) Design Rapid Prototyping SLA, SLS & 3D Printing Simulation, Moldflow Analysis, Stress Analysis Injection Moulded Parts CAE & Simulation Vacuum Castings Project Management Composite Components Test & Validation Block Modelling Prototype & Rapid Tooling Low Volume Production Intent Components Electrical & Electronics Rapid CNC Machining Innovative Production Tooling Low Volume Complex Assemblies 7 Centres of Competence Prototyping Project Management Tooling Maintenance, Modification & Refurbishment Batch Production Runs : s Full Integrated Service Engineering, Prototyping, Tooling & Low Volume Production Industries we serve: Automotive, Aerospace, Special and Commercial Vehicles, Transportation and Medical Industry 5

6 AGENDA ARRK Company overview Phase 1 Motivation and general feasibility Phase 2 Engineering Phase 2 Manufacturing Next steps & perspectives 6

7 MOTIVATION MARKET Light weight design is taken into account mainly for CO2 reduction but electric car autonomy increase is also a critical point. Existing demonstrators with low mechanical strenght, or structural parts for car body but not for engine or transmission. ARRK Knowhow & skills improvement Design and manufacturing (product and process) based on TP composites technologies. Decision for gearbox housing demonstrator as a good compromise between complexity and feasibility Targets Produce a working demonstrator with an overmolded organo sheet based on an existing part with a conventional material concept (e.g. aluminum) Keep manufacturing costs of existing part in low volume production 7

8 PHASE 1 GENERAL FEASIBILITY Simulation model Smart gearbox Comparison of conventional and composite gearbox results Smart gearbox Simulation model Composite gearbox (non-optimized) Reengineering of an existing aluminum gearbox determination of target values Estimation of general feasibility with composite housing Feasibility confirmed 8

9 AGENDA ARRK Company overview Phase 1 Motivation and general feasibility Phase 2 Engineering Phase 2 Manufacturing Next steps & perspectives 9

10 PHASE 2 1ST DRAFT 1st concept Functional specification Function list Searching for solutions Creating different concepts Economical and technical evaluation Concept decision 1st draft Design 1st draft (design space) Topology optimization for load path and divisional plane Design revised draft Reduced FE-model and layer optimization Economical and technical evaluation Material decision Detailed draft and evaluation Approval detailed draft Detailed design Creating detailed design Approval design Creating design documents Approval manufacturing documents 10

11 1ST CONCEPT Functional specification Morphological analysis Concept evaluation Category Description Value/Info A B Function Solution 1 Solution 2 Solution 3 Solution 4 Current gearing New gearing Modification of current gearing Power transmission + costs 1 + compensation of different gearbox behavior + compensation of different gearbox behavior - no correction possible costs 4 - costs Currents bearings New bearings New bearing material + Connecting to carbon fibre material if stainless steel Bearing + costs + higher stiffness possible bearing rings - inserts needed when in contact with carbon fibre - costs + Stiffer bearings - costs injection molded bearing seat metal insert bearing seat connected bearing seat screwed inserts Dimensions Design space Geometry Tolerances bearing positions Bearing positions ± 20µm Tolerances flange mounting surfaces CAD Mass without interior parts less than 5,826kg Input torque 130 Nm at 4000 min -1 Loads Crash loads 10g for x,y,z Impact loads Mounting, stone chip Thermal heating 100 C Power transmission According to smart gearbox Torque support Mounting gearbox to environment Deflection bearings due to loads According to smart gearbox defined Functional Acoustics According to smart gearbox Disassembly Housing and cover disassemblable Oil proof Flanges sealing, input/output sealing Oil level Measuring defined oil level Temperature -30 to 100 C Corrosion Contact corrosion Fluid resistance Environmental Transmission oil Fluid resistance H Oil-proof input/output I Mounting electrical machine Creating different concepts Engine oil, petrol, rim cleaner, antifreeze, brake cleaner, aceton, brake fluid, batterie acid, cooling fluid, wash chemicals Costs Manufacturing According to smart gearbox costs Oil drain plug Air drain petcock Maintenance Oil refill plug Measuring temperature C D E J K L M N O P Q R S Axle distance due to mechanical load Axle distance due to thermal expansion Connection housing to cover Deriving functions F Screws Searching and evaluating of G Centering cover to housing several solutions ensure compansation overpressure, avoid oil loss Seperate or combined with air drain petcock Oilsump, bearings, gearbox surface Centering housing to electrical machine Resistance fluids Air drain petcock Air drain petcock oil proof Measuring temperature oil sump Measuring temperature bearings Measuring temperature surface Lubrication gears, bearings Oil (re)fill Oil level + mass + precision + costs + precision + stiffness - precision - costs - mass - stiffness - costs carbon fibre organo sheet glass fibre organo sheet steel/aluminum bearing connector insert - collision of gears due to thermal heating possible + better than alu+steel (regular) combination + comparable to current gearbox/gearing glued flanges screwed flanges+sealing clip connection + disassemblable + no inserts needed for screws + disassemblable + no inserts + compensation of manufacturing inaccuracy, - inserts (mass, corrosion), sealing - milling necessary, sealing - not disamssemblable - Resistance against axial force 2 inserts 1 insert no inserts + no creeping and pretension force loss - costs dowel pin, centering screw/sleeve + high accuracy due to milling afterwards - inserts necessary - without inserts destruction of transition fit current sealing concept + costs glued flanges see connection cover to hosuing dowel pin, centering screw/sleeve + high accuracy due to milling afterwards - inserts necessary - without inserts destruction of transition fit material selection Shapers' next meeting simple air drain petcock tube Oil drain plug + costs + no additional insert, mass reduction + costs - creeping centering surfaces + no inserts needed - effort for reaching accuracy new sealing concept - costs - technical effort screwed flanges see connection cover to hosuing centering surfaces + no inserts needed - effort for reaching accuracy coating surface coating with fluid resitance air drain petcock with labyrinth sealing designed barrier Interior sensor - costs - separate seraling or wireless data transmission bore for sensors at bearing positions Interior sensor - costs - additional process - separate seraling or wireless data transmission Direct Optical Laser Infrared sensor + costs + more detailed results + more detailed results - limited resolution - costs - costs splash lubrication (according to smart) dry sump circulating lubrication + lubrication precision + lubrication precision + costs + less oil contact of composite material - costs oil pump - additional lubrication sheets + no churning losses - high technical effort - churning losses - costs (2 oil pumps) + reservoir - churning losses - high technical effort separate oil fill plug air drain petcock for refilling oil + mass + independent of possible air drain plug geometries + 1 part 2 functions - design space - geometry constraints removable sight glass defined oil volume oil dipstick oil fill plug at maximum oil level + costs + oil level directly measurable + robust method + oil level directly measurable + no design modifications - costs + using for oil drain possible + direct measurable - oil level not directly measurable - design space - design space - costs - seperate oil drain plug necessary - seperate oil drain plug necessary - tilt housing for oil drain or seperate oil drain plug + costs - creeping + precision - mass Feasibility study Concept rating Concept decision Further investigation only for appropriate concepts Concept 1 Concept 3 11

12 1ST CONCEPT Concept Description Low cost concept Cage insert concept Seperate bearing insert concpet Highest precision concept Details - current gears, bearings, sealing - thermoplastic bearing seat - glass fiber organosheet - glued flanges (housing/cover) - no inserts at screws - center surface housing to cover - engine screwed to housing, centering by surface - simple air drain petcock with tube to avoid oil loss - air drain petcock also used for oil (re)fill - defined oil volume - smart lubrication concept - measuring oil temperature at oil drain plug - measuring bearing temperature at drilled holes - direct surface temperature measuring - current gears, bearings, sealing - connected insert for bearing seat - glass fiber or carbon fiber organosheet - screwed flanges (hosuing/cover) - 2 inserts for each screw - dowel pin for housing/cover centering - engine screwed to housing, centering by surface - simple air drain petcock with tube to avoid oil loss - oil fill plug at maximaum oil level - smart lubrication concept - measuring oil temperature at oil drain plug - measuring bearing temperature at drilled holes - direct surface temperature measuring - current gears, bearings, sealing - metal insert for bearing seat - glass fiber - screwed flanges (hosuing/cover) - 2 inserts for each screw - dowel pin for housing/cover centering - engine screwed to housing, centering by surface - simple air drain petcock with tube to avoid oil loss - air drain petcock also used for oil (re)fill - smart lubrication concept - measuring oil temperature at oil drain plug - measuring bearing temperature at drilled holes - direct surface temperature measuring - current sealing - new gear design, new bearings - connected insert for bearing seat - glass fiber or carbon fiber organosheet - screwed flanges (hosuing/cover) - 2 inserts for each screw - dowel pin for housing/cover centering - engine screwed to housing, centering by dowel pin - air drain petcock with labyrinth sealing and geometrical barrier to avoid oil loss - sight glass for oil level inspection - dry sump lubrication - measuring oil temperature with interior sensor - measuring bearing temperature with interior sensor - optical surface temperature measuring Pros Cons - lowest costs - lowest mass - no milling at flanges necessary (compensation with glue) - low stiffnes and strength at bearing seats - only glass fiber organo sheet possible (thermal expansion) - no inspection possible due to glued flanges - no direct oil level measurable - high stiffness and strength at bearing seats - high position and centering precision due to connected bearing inserts - glas fiber or carbon fiber organosheet possible - inspection of gear mesh possible - further cost reduction for series possible - high costs - high mass - adequate stiffness - adequate precision - inspection of gear mesh possible - high costs - high mass - high stiffness and strength at bearing seats - high position and centering precision due to connected bearing inserts - compensation of bearing deflection possible by adjusted gear design - glas fiber or carbon fiber organosheet possible - inspection of gear mesh possible - bearing with higher stiffness possible - further cost reduction for series possible - direct oil measuring - evaluation of detailed temperature distribution - very high costs - high mass Not suitable to show capability of composite Inappropriate costs 12

13 1ST CONCEPT Concept decision FE-Analysis Basic Deriving Composite FE- Model for feasibility analysis Deriving Variants Considering Basic simulation results Stiffness evaluation Concept desicion Concept 3 with CF organo sheet feasible FE-Analysis Concept 3 with GF organo sheet probably feasible Deriving counter measurements (ribs,ud) Comparing with stiffness target (reference housing) Concept 1 not feasible 13

14 PHASE 2 1ST DRAFT 1st concept Functional specification Function list Searching for solutions Creating different concepts Economical and technical evaluation Concept decision 1st draft Design 1st draft (design space) Topology optimization for load path and divisional plane Design revised draft Reduced FE-model and layer optimization Economical and technical evaluation Material decision Detailed draft and evaluation Approval detailed draft Detailed design Creating detailed design Approval design Creating design documents Approval manufacturing documents 14

15 1ST DRAFT Topology optimization Optimization process Optimization results Deriving shape Topology optimization Deriving revised draft Setup Minimization of strain energy Mass constraint Stiffness constraints Strength constraints 15

16 1ST DRAFT Layer optimization Shell model for layer optimization Optimization result Derived results Setup 0/90/45/-45/-45/45/90/0 Optimization for CF Laminate thickness 0.6 to 6 mm Balanced 45 /-45 plys Considering stiffness results Optimizing thickness of several layers Evaluation Results Higher thickness for 45 /-45 plys Using especially 45 /-45 plys to further improve stiffness Reduction of laminate thickness by mainly using 45 plys Further local reinforcement measurements by using UD-Tapes 16

17 1ST DRAFT Further stiffness optimization Deriving variants based on FE-Optimizations Stiffness, evaluation Deriving optimized UD, flange, TP matrix and rib design Detailed draft 17

18 1ST DRAFT Feasibility analyses of manufacturing Injection molding simulation Stamping simulation 18

19 STAMPING SIMULATION PAM-FORM Composites Forming Simulation Software Validation of preformed stamping process : shear angles Feasibility confirmed 19

20 STAMPING SIMULATION PAM-FORM Composites Forming Simulation Software Validation of preformed stamping process : net-shape profile Ply 0 stamping simulation Ply 0 outer profile Ply 45 stamping simulation Feasibility denied Ply 45 outer profile Cutting required after stamping 20

21 STAMPING SIMULATION PAM-FORM Composites Forming Simulation Software Validation of preformed stamping process : UD tapes UD Tapes behaviour during stamping Tooling design Process optimization Tool design optimization Feasibility confirmed 21

22 PHASE 2 DETAILED DESIGN 1st concept Functional specification Function list Searching for solutions Creating different concepts Economical and technical evaluation Concept decision 1st draft Design 1st draft (design space) Topology optimization for load path and divisional plane Design revised draft Reduced FE-model and layer optimization Economical and technical evaluation Material decision Detailed draft and evaluation Approval detailed draft Detailed design Creating detailed design Approval design Creating design documents Approval manufacturing documents 22

23 DETAILED DESIGN Detailed design with CF organo sheet GF reinforced TP injection molding material Aluminum inserts for bearing position Metal inserts for screws 23

24 AGENDA ARRK Company overview Phase 1 Motivation and general feasibility Phase 2 Engineering Phase 2 Manufacturing Next steps & perspectives 24

25 MANUFACTURING Organo sheet hot stamping process 25

26 MANUFACTURING Overmolding process 26

27 DEMONSTRATOR Assembly Weight saving 30% (cover only) Demonstrator visible on Auto Planet Booth N80 / Hall6 27

28 AGENDA ARRK Company overview Phase 1 Motivation and general feasibility Phase 2 Engineering Phase 2 Manufacturing Next steps & perspectives 28

29 FURTHER STEPS First test of prototype cover to validate FE simulations Mapping of stamping results to consider in FE simulations Take into account fibers orientation after stamping Looking for new materials opportunities To reduce thickness To reduce cost material (glass instead of carbon fabrics, removing of UD tapes) To reduce processing costs (netshape preform to remove cutting phase) Design Optimization of prototype cover Design Optimization of 2 nd part of gearbox Manufacturing of 2 nd part of gearbox Testing with complete gearbox assembly 29

30 QUESTIONS / ANSWERS THANKS YOU FOR YOUR ATTENTION Contact : Hervé MOTTE R&D / Innovation Manager herve.motte@arrkeurope.com Tel Mob

31 Contact us ARRK Europe Ltd Caldwell Road, Nuneaton Warwickshire, CV11 4NG, United Kingdom SPG Pre-Series Tooling & Prototyping B.V. Celsiusstraat DG, Weert Netherlands P+Z Engineering GmbH Shapers Group ARRK LCO Protomoule Frankfurter Ring Munich Germany Z.I de la Bergerie Rue Gutenberg La Séguinière, France rue des champs de la Pierre ALBY sur CHERAN France Engineering Prototyping Tooling Low Volume Production