Gain an impression
We have almost 20 years of experience in a wide range of more than 40 projects. The following selection in the field of product development shows you our diverse and comprehensive application possibilities in the areas: Automotive, Energy Systems, Facility Technology, Household Appliances, Medical Technology, ... Please understand that we cannot disclose all details for reasons of customer protection.
Power plant filter
Task
We were asked to find the cause of vibrations within a gas pressure control and measuring system. After investigating the flow behaviour, these could be attributed to the asymmetrical and swirling outflow from the filter. The filter is used to separate solids (e.g. rust particles) and liquids from the gas.
Solution
By adapting the internal components (while retaining the original filter cartridges), it was possible to achieve a uniform filter outflow. The separation efficiency was increased, the required installation space reduced and the pressure loss halved. The halved pressure loss leads to a (hydraulic) power saving of approx. 15,000 W (corresponds to 2.5 MWh per week when operating 24/7).
Film drying
Task
In a "wetgate" film scanner, the film leaves the apparatus too wet, it drips. The nozzles (called Air-Knifes) used for drying do not manage to blow the tetrachloroethylene (PER) off the film to a sufficient extent. The optimised nozzles should be plug'n'play interchangeable.
Solution
The redesigned nozzles convert the available compressed air into kinetic energy much more efficiently. So efficient that the inlet pressure can be reduced by approx. 20 %. Now the film is wound up without dripping. Shown are the velocity fields in the middle of the film.
Intake pipe
Task
We were asked to design an intake distribution pipe for the adaptation of a larger throttle. The aim is to de-throttle the intake for the purpose of increasing performance.
Solution
Our flow-optimised design can be used plug'n'play without restrictions as a functional prototype (or as small series production). Manufactured via 3D printing (MJFMulti Jet Fusion).
Radial fan
Task
As a component of a household appliance, a radial fan is to be optimised so that the overall appliance achieves a better EEIEnergy Efficiency Index. The spiral housing must not be changed in order to keep the injection moulding tool costs low. An acoustic improvement is also desirable.
Solution
Our design does increase the (static) efficiency of the fan by approx. 50 %. This corresponds to a (hydraulic) power saving of 11 W. Calculated per 100,000 units, this amounts to 1.1 MW, „just“ with a smarter fan design. The operating noise could be reduced by approx. 3 db. (all velocity scales are identical)
Ultrasonic water meter
Task
The flow behavior of a water meter shall be investigated, since it issues too high measuring uncertainties in some operating points. This is supposed to be usable for a very large dynamic rangeMaximum to minimum flow ratio (240 in this case). The currently used sensors (transducer) are to be retained.
Solution
Our designed variant fulfils all requirements. The flow in the measuring area is much more even which leads to lower measuring uncertainties over the hole operating range. In addition, the pressure loss is approx. 30 % lower.
Dust trap
Task
The currently used dust trap filters dust, largely consisting of iron oxide, by means of a glass fibre filter mat. It is to be investigated whether this mat can be substituted by a "smart" flow guidance.
Solution
Our final design meets all requirements and does not need an additional filter mat. The standard test regarding the filter rate has been passed. Compared to the reference, the pressure loss could be reduced by approx. 20 %.
Fluid mechanics laboratory
Task
Selection of measurement technology, project planning and construction supervision. The available space must be used optimally. Research and teaching shall be possible in the same way.
Solution
The laboratory is now (among other things) equipped with: soundproofed room, acoustic camera (beamforming), chamber test rig, 3D PIVParticle Image Velocimetry system, small wind tunnel. The floor planning also allows the combination of different test benches, e.g. chamber test rig and soundproofed room.
Room ventilation
Task
Design of a retrofittable (with little effort) ventilation system for classrooms. The room air should be "exchanged" at least three times per hour without causing discomfort (due to draughts) to the people. The natural convection occurring in this room due to human waste heat should be effectively supported.
Solution
Our presented concept fulfils all requirements. The air exchange takes place four times per hour and can be supported by a HEPAHigh Efficiency-Particulate Airfilter filter. The maximum air velocity is (still) below 15 cm/s and is therefore uncritical according to the german workplace directive ASR A 3.6. The distribution of aerosols in the room is effectively reduced.
Heater
Task
The existing heating system shall be optimised with regard to its heat distribution. The aim is to increase the heat output without increasing the fire hazard due to hot spots. Trials with different heating coil arrangements did not bring the desired success.
Solution
Due to the optimised inflow conditions, the heat power can easily be increased by 20 %. The temperature distribution is now much more even. At the same time, the maximum temperature at the outlet can be reduced by 100 °C.
Exhaust system
Task
The exhaust system of a sports car is to be optimised for the purpose of increasing performance. Sufficient distance to heat-sensitive components (e.g. ignition coils) must be ensured. No parts may protrude from the underbody. In order to optimally use the available installation space while retaining the catalytic converters, we have digitally captured the underbody / engine with our 3D scanner.
Solution
Our design fulfils all requirements. The primary tubes are larger in diameter, equal long (their lengths differ only ± 2 mm or << 1 %) and designed symmetrically left / right. Due to identical (large) bending radii, the primary tubes can be produced efficiently using a CNC bending machine. The titanium muffler (from another model) features a X-pipe, which further improves the gas exchange.
Axial wheel meter
Task
The existing axial wheel gas meter is to be investigated for its operating behaviour at different, disturbed inflows. Based on these findings, the rectifier element in front of the impeller shall be optimised.
Solution
Numerical simulations were used to identify the key areas. By making small changes to the rectifier, the operating behaviour is now constant over all (disturbed) inflow conditions.
Aerodynamics
Task
A sports car is to be equipped with "plug'n'play" add-on parts to improve aerodynamics. The available rear wing is being investigated in different heights, angles of attack (AOA) and with and without Gurney. The add-on parts are intended to reduce lift or convert it into downforce while increasing drag as little as possible.
Solution
In the variant shown, the lift of the reference model (approx. 600 N) is in combination with the canards transformed into double downforce. At the same time the drag coefficient increases relatively low by 0.024 points. (Calculations base on a modified DrivAer model, pictures show results at 250 km/h).
Intra okular lenses
Task
A test bench is to be developed for the in-vitro testing of the next generations of intraocular lenses. This will be used to stretch / compress / tilt the lenses and analyse the influence on the optical properties / refraction of light. The test bench shall be equipped with actuators and sensors to determine the force-displacement characteristics. The use of OCToptical coherence tomography must be made feasible. The investigation of real eyes should also be possible.
Solution
Our test bench fulfils all requirements and includes an additional preparation station. During the analysis and concept phase, several possible implementation approaches were identified. The most promising concept was produced in advance as a 1:1 model using 3D printing in order to be able to understand the handling and individual work steps. The final test bench was manufactured using high-precision CNC machines and uses eight force sensors and actuators.
Impeller optimization
Task
A turbomachine shall be optimized without changing the periphery. This also includes impeller diameter, width, shaft position and drive speed, leaving the blade profile as the only remaining parameter. CFD can be used to evaluate the velocity fields within the blade channels. Experimentally, e.g. using PIV, this is only possible at great expense.
Solution
The evaluation of the relative velocities, i.e. from a “co-moving Lagrangian view”, shows the separation and recirculation zones. A suitable blade profile from the NACA series is placed in these zones, here 35145-42. The static pressure build-up increases here by 8 % and the efficiency by 5 %. This is due to the significantly more uniform flow.
Electric motor
Task
A CAD script is required for the interdisciplinary simulation workflow of an electric motor. In addition to structural mechanics, this workflow shall also include power electronics, electromagnetics as well as fluid mechanics and be carried out within the Ansys Workbench.
Solution
The Ansys Spaceclaim script contains 32 parameters. The permanently energized electric motor is rebuilt with every parameter change to ensure consistent data. In combination with DOE, suitable motor configurations can be determined automatically and application-specifically.
Gas meter
Task
A modular gas meter concept is to be developed. The concept shall be suitable for different markets, connection pipe distances and flow ranges. Subsequently, a functional prototype is to be created that can be tested in the climate chamber, among other things.
Solution
The functional prototype is divided into three segments. Using three different connection piece segments, six connection piece distances can be realized in U or S configuration. The middle module can be adapted to the desired measuring range using different sensing element configurations.
Lightweight rims
Task
The driving dynamics of a sports car shall be improved by lightweight rims. This reduces the unsprung masses and improves the power-to-weight ratio. The weight shall be reduced by 10 kg compared to the already relatively light, forged OEM aluminum wheel set. The rims shall also be suitable for motorsport activities.
Solution
The AZ80 magnesium alloy is used to achieve the weight specification. FEM detail optimizations enable the rims to be fatigue-resistant even under double the ECE R124 load without violating the design specification. The first set of prototypes did not reach the target weight. 3D scans show that the supplier deviated from the specification during CNC production.
Intercooler
Task
An optimized intercooler is to be designed for the purpose of boosting performance. It should fit plug'n'play into the existing installation space. Installation shall be possible using the OEM mounting options and connections.
Solution
By changing the throughflow, the pressure loss can be halved. As a result, performance can be increased without having to increase the turbocharger pressure. The response time improves and the so-called turbo lag is reduced.
Volute casing optimization
Task
A concept for optimizing volute casings of radial turbomachines is to be developed. The concept shall be adaptable to specifications regarding installation space as well as inlet and outlet flow constraints. The usability is to be proven by means of CFD simulations.
Solution
An iterative "sedimentation script" is created in Ansys CFX. The script leads to a geometry proposal after a few generations. In the example shown, the total pressure loss is lower by a factor of three, while the static pressure conversion is higher by a factor of 5.
Projects Overview by Industry
engineering office, CFD, computaional fluid dynamics, fluid mechanics, FEM, structural mechanics, simulation, topology optimisation, bionik, evolution strategy, CIP, Six Sigma, Lean Management, quality, innovation, efficiency, aerodynamic, air flow, fan, blower, pump