Projects

We have more than ten years of experience in a wide range of projects. The following selection shows you our diverse and comprehensive application possibilities in the areas: Automotive, Energy technology, Household appliances, Medical technology, ... Please understand that we cannot disclose all details for reasons of customer protection.
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gas filter compressed air drying intake pipe fan optimisation ultrasonic water meter dust trap fluid dynamics laboratory room ventilation wire coil heating exhaust optimisation axial gas meter aerodynamics
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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).

gas filter

Film drying

Task

In a "wetgate" film scanner, the film leaves the apparatus too wet, it drips. The nozzles 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.

compressed air drying

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).

intake pipe

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)

fan optimisation

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.

ultrasonic water meter

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 %.

dust trap

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.

fluid dynamics laboratory

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.

room ventilation

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.

wire coil heating

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 original catalytic converter position, we have digitally captured the underbody / engine with our 3D scanner.

Solution

Our design fulfils all requirements. The primary tubes are larger in diameter, extra 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 tailpipe now features a X-pipe, which further improves the gas exchange.

exhaust optimisation

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.

axial gas meter

Aerodynamics

Task

A sports car shall be equipped with a plug'n'play front spoiler and rear wing. These are designed to reduce lift while increasing drag as little as possible.

Solution

By means of the selected front spoiler and rear wing, the lift at 200 km/h is reduced by approx. 500 N. At the same time, the resistance increases only by approx. 80 N (Results base on a modified DrivAer model).

aerodynamics

Further projects / innovations

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