Final-year course in Mechanical Engineering Design

IN THE MECHANICAL ENGINEERING

MSc PROGRAMME AT

LULEÅ UNIVERSITy OF TECHNOLOGy

2006

SIRIUS 2005/06 IS A COLLABORATIVE PROGRAMME

involving Luleå University of Technology in collabo-ration with the Polhem Laboratory partners Volvo Aero Corporation, Volvo Car Corporation’s design center Volvo Monitoring and Concept Center, Hägglunds Drives AB and several other industrial and academic partners. Sirius prepares students for work in product development. The product development projects of this course are firmly based on close collaboration with manufacturers or on real product development needs identified in other ways. Work is conducted in project groups with the support and guidance of academic and industry advisors.

Collaboration benefits both students and industry partners.• Students are given an opportunity to apply their knowledge when developing proposals with optimal solutions to real design problems with a limited time frame and budget. A unique insight into present and future working methods and cooperation in product development is gained.

• Manufacturing companies gain access to innovative product development performed by well-educated engineers who are unbiased by traditional modes of thinking and problem solving.

Luleå University of Technology and industry partners in collaboration

Pho

to w

ith p

erm

issi

on

of

Volv

o M

oni

tori

ng a

nd C

onc

ept

Cen

ter

�

Creative product development

Sirius is a final-year course for students in the Mechanical Engineering MSc degree programme at Luleå University of Technology. Sirius is also open to final-year students from other MSc engineering pro-grammes at the university, thereby ensuring a broad base of knowledge for the course’s project groups. During most of the 20-credit course, product devel-opment projects are conducted in close national and international collaboration with companies and uni-versities.

The aim of Sirius is for students to acquire, apply and integrate knowledge considered essential for prod-uct developers in modern manufacturing industries. Students gain knowledge in project management, pro-duction of creative concepts, mechanical engineering design and computer-aided design, as well as command of all stages in the integrated product development chain, from needs analysis to the finished product. Under realistic industrial conditions, they must carry out product development in teams, in collaboration with manufacturing companies or based on real prod-uct development needs presented in some other way. Experience from Sirius prepares the participants well for teamwork with colleagues from other disciplines.

Students also take courses in product development methods, computer-aided modelling and analysis, and

project management as a support to their development projects.

Sirius students engage in a valuable exchange of knowledge and ideas with graduate students and staff from the Polhem Laboratory and other departments of Luleå University of Technology. Not only do Sirius students from Luleå University of Technology have solid theoretical knowledge, they also have the benefit of valuable experience from work in an integrated environment and the use of advanced computer tools in industrial projects.

For more information about previous Sirius projects, please visit www.cad.ltu.se/sirius.

traditional produCt development

integrated produCt development

Concept

manufacturing

design testing

Concept design testing manufacturing

�

PRODUCT DEVELOPMENT PROJECTS

Manifold for rocket engine nozzle

Volvo Aero Corporation

Students were given the task of developing an interface between a manifold and a rocket engine sandwich nozzle. The design of the interface had to contain proposals for design, manufacturing method and material. Reindeer versus Predator

PolhemRegio and Sarekren

During recent decades, the number of predators has increased to a level that has put reindeer keepers in a bad economical situation. A design group of seven engineering students worked with a Sámi reindeer keeper with the purpose to decrease reindeer losses and bring reindeer herding into the 21st century with new technical solutions. New innovative brake concept

Hägglunds Drives AB

A student design team developed a completely new and cost efficient combined emergency and parking brake for Hägglunds Drives hydraulic motors. The design project involved intense simulation.

Rethinking blood-glucose monitoring

Abbott Laboratories

Students from LTU and Stanford University, USA collaborated in this global project to develop a new type of glucose monitoring system for children with diabetes. The project’s success has been dependent on the daily global collaboration and communication. Innovative Door Opening Solution

VCC and VMCC

Students from LTU and Chalmers collaborated with Volvo Car Corporation’s design center, Volvo Monitoring and Concept Center in Camarillo, California, USA, in an international distributed collaborative engineering design project. The project’s aim was to develop an innovative door opening sys-tem for a two-door vehicle that improves the ingress/egress to the car and minimizes door opening and closing efforts. Future Elderly Environment

Polhem Laboratory

In this international project, students from LTU and Stanford University worked together to develop a product that enhances the wellbeing of the elderly. Formula SAE

Polhem Laboratory

The students involved in the Formula SAE project developed and fabricated a complete racing car to compete in the international Formula Student event in Bruntingthorpe, England.

Sirius 2005/06

Sirius 2005/2006 is the final course in

the Mechanical Engineering Design pro-

gramme at Luleå University of Technology

(LTU), which this year involved seven

different product development projects

where students from LTU collaborated

with other universities and industry

partners.

�

INTRODUCTION

The Sirius course started in September 2005, with presentations of project proposals from the companies Hägglunds Drives, Volvo Aero Corporation, Volvo Car Corporation and Abbot Laboratories. The proposed projects within the university this year were Design for Wellbeing, Formula SAE and the PolhemRegio and Sarekren project Reindeer vs. Predator.

The different projects contained various tasks, such as engineering design, need finding, computer aided engineering and manufacturing, ensuring a diverse project portfolio with interesting tasks for each student. The final composition of the groups was decided after evaluation of the students’ personal preferences.

THE CREATIVE PHASE

After the needs were surveyed, the project teams used different methods to fulfil them. Brainstorming and brain writing helped the teams to think outside the box and discover unique solutions. The concepts of the project teams were assessed and evaluated with assigners and industry representatives to evaluate which concepts the groups would continue to work with. 3-D CAD software such as I-deas, Unigraphics NX3 and Alias Studio Tools were used with the simu-lation software MSC.MARC and ADAMS to realize the concepts.

PROJECTS

The projects started with electing a project manager. A plan for the future work was detailed as well as a budget covering the financial aspects of the projects. After the initial preparations the different teams set off on their own. The work began by examining the given tasks and then generating some possible solu-tion concepts. All teams used online communication tools such as collaborative workspaces, instant messag-ing and videoconferences to keep track of the work-ing material and to communicate within the group, and in some cases, their affiliates and partners.

The Abbott team researched the needs of child diabetics by conducting surveys and interviewing local expertise. The primary goal was set to create an easy to use and helpful glucose monitoring system. A secondary goal was to give the children’s parents a good way to follow how their children handle diabetes.

Developing and fabricating a highly competitive race car for the Formula Student event was the main goal of the Formula SAE team.

The future elderly environment project aimed to develop a product based on the present and future needs of the elderly. The idea for the final product originated from one of the conceptual prototypes made during the project.

The HDAB brake project focused on designing a cost efficient brake with enhanced technical per-formance. The project’s main issues were to reduce the number of components and brake dimensions by

making use of the shaft’s rotation to multiply the force applied to the brake.

The main purpose of the Reindeer vs. Predator was to develop a unit to prevent predators from attacking female reindeer.

In the VAC project, the main focus was to find an interface between the manifold and the sandwich nozzle. To meet VAC requirements, several simulations were performed as well as material selection.

The task in the VMCC project was to make an innovative door opening solution for two-door cars that park in narrow spaces. A full-scale physical pro-totype was manufactured to test the functionality and reliability for every day use as accurately as possible. The prototype evolved through the use of product development methodologies and modern CAE tools.

�

Background

VAC has developed a new nozzle technology for con-vectively cooled nozzles. The sandwich technology is based on channels inside the nozzle structure that are assembled like a sandwich.

Assignment

The assignment for the project was to develop an interface between the manifold and the sandwich nozzle channel wall. Placed on the outside of the nozzle, the manifold’s function is to collect the cool-ant, i.e. the fuel, from the nozzle and transport it from the manifold to the combustion chamber. The design is limited by weight, pressure and extreme heat expo-sure.

Volvo Aero CorporationManifold for rocket engine nozzle

An Ariane 5 rocket during take-off.

Volvo Aero Corporation (VAC) manufactures and develops

components for the aircraft and space propulsion industry,

where they are one of the largest manufactures of nozzles

to commercial space rockets. In the 1970s, VAC joined the

Joint European Space Programme and began to manu-

facture the thrust chambers for the Viking

engines of the Ariane launch vehicle.

Today, their main focuses are the

development and manufacturing of

nozzles and turbines for the space

industry.

The upper part of the nozzle.

�

Analysis

Besides transporting fuel, the manifold’s main function is to act as a stiffener to the nozzle structure. During the first brain-storming session, many ideas were gener-ated and many concepts were evaluated in several steps through different matrixes. In collaboration with VAC, three concepts were selected for FEM simulation and analysis. After several simulations, modifica-tions and analysis, a final concept satisfying all requirements was presented to VAC.

Results

The final concept was mainly based on the manufacturing technology Metal Deposition (MD), where the interface is added on with a laser fusion process. This technology assures very close tolerances and solidity. The structure is composed of a super alloy to withstand the high tem-peratures during lift-off. During the project, the group learned how a product develop-ment process works from idea to concept choice and preliminary analytical verifica-tion. The Sirius course has given us experi-ence and knowledge of how it is to work with real industry projects.

JAN HäGGANDER

Senior Design Engineer

Combustion Chamber and Nozzles

The SIRIUS-team has demonstrated leader-

ship and a professional attitude in pursuing

the project. The planning was clear and

the goals were met. The students quickly

grasped the task and demonstrated the

ability to use good engineering judgment in

generating concepts and in down selection

between the concepts. The specification

leaves little parameter room for successful

design of the rocket nozzle cooling manifold.

In spite of this, interesting concepts were

generated and plastic thermo-mechanical

verification analysis showed the demanding

specification to be fulfilled.

The final interface

and manifold.

�

Reindeer versus PredatorPolhemregio and Sarekren

Background

For hundreds of years, the Sámi have lived on what nature has had to offer, the largest income com-ing from herding reindeer, along with fishing and hunting. During the last few decades, the number of predators has increased and reached a level that has set reindeer keepers in a dire economical situation.

Assignment

Develop a unit that prevents predators from attack-ing female reindeer, which are more valuable than male reindeer since female reindeer will give off-spring. The unit has to withstand extreme climate, i.e. temperature and humidity, and the collar has to be expandable to be attached onto young reindeer. The project also considered the natural behaviour of the reindeer, thus delimiting the size and weight of the resulting product, so that the reindeer are able to carry the unit for many years.

A design group of seven engineering students worked

with Sarekren with the purpose to decrease the loss of

reindeer through technical solutions that bring reindeer

herding into the 21st century.

�

Pho

to: M

agnu

s E

land

er

Reindeer’s worst

enemy, Lynx.

Prototype attached on reindeer.

Design proposal.

Method

There is no commercial product worn by livestock that actively protects them against predator attacks; hence, a significant amount of time was spent in surveying the needs. The Internet, books and data-bases were used to gather information and gain an increased understanding of the problems and their possible solutions. The information and feedback that Sarekren provided helped the students during the entire project. Several brainstorming sessions were conducted in different work phases to generate ideas and solutions and creatively solve any kind of problems. Concepts were evaluated in collaboration with Sarekren and one concept was selected for the electrical application and three concepts were selected for the expandable collar. In the detail design phase, Computer Aided Engineering software such as I-deas and MSC. ADAMS were used to build virtual models and conduct toughness tests.

Results

In an early stage the group aimed the work to prevent attacks caused by Lynx since they cause the greatest loss of reindeer in the area where Sarekren keep their reindeer.

Ten prototypes were manufactured and applied on reindeer in their natural environment. The prototypes were evaluated by the design team during a one week long trip with the purpose to assess if the prototypes affected the natural behaviour of the reindeer.

The prototypes are also to be evaluated during the coming years by the assigner.

�

The students improved their skills in modern product development and learned much about the Sámi culture and reindeer herding. They have also acquired great knowledge in manufacturing methods and electrical applications. The project has shown the strength of what fresh thinking and unconventional problem solving approaches of young engineers can accomplish.

The Reindeer vs. Predator team

at the summit of mount Aime,

928 metres above sea level.

Lars-Anders Gillenbjörk – Sarekren.

10

HDAB New innovative brake concept

Background

Hägglunds Drives AB is a Swedish company special-ized in delivering complete high torque hydraulic systems. An eight-student design team has been working with Hägglunds Drives for nine months to develop a new brake for their hydraulic motors.

Assignment

The assignment from Hägglunds Drives AB was to develop a completely new combined emergency and parking brake. The brake is a crucial system compo-nent that works as a backup if the first system fails. Therefore, reliability was of the utmost importance and Det Norske Veritas (DNV) had to approve the brake.

Substantially lowered manufacturing costs, enhanced technical performance and maintained reliability compared to their current brake were identified as main project objectives. To lower manu- facturing costs the new design had to be smaller

To stay ahead in a high-tech market with ever-growing

competition, companies like Hägglunds Drives AB need

to continuously update and improve or replace their com-

ponents. In this case, they needed to cut manufacturing

costs and enhance the technical performance of their

MDA brake series. The task of the students was to design

a completely new and innovative brake to replace the

MDA brake.

Students working in live projects such as this enable

the company to see issues from another perspective, with

fresh ideas and new technology, as well as create strong

positive relationships with university students.

3D Topography scan of friction material after tribology testing with Vision32.

11

and contain fewer parts. Maintained reliability meant amongst other things that the brake had to be fail safe, fatigue safe for pulsating force, have an activation time of less than 25 ms and deliver a constant high torque (approximately 50,000 Nm) when activated.

Computer Aided Engineering

Digital models of design concepts were evaluated in a virtual environment to speed up the design proc-ess. 3D-models were created in I-deas and optimised in terms of strength and size using methods such as FEM. Dynamic and static simulations were carried out in MSC.ADAMS and Simulink, which proved to be crucial in guaranteeing proper function before manufacturing the prototype. The use of a shared online workspace allowed for project material to be available to project personnel independent of loca-tion. Combined with frequent videoconferences with company representatives, this made the physical distance between company and design team less of an issue.

Results

Design concepts were generated through various intensive brainstorming sessions. After the concept evaluation phase, the team devised a new and innova-tive brake design. The outer dimensions were reduced and technical performance enhanced, allowing for steel balls to be used in an ingenious servo application together with the use of the rotational speed from the motor’s shaft. A prototype was manufactured for visual inspection and function testing. The complete design concept was delivered to Hägglunds Drives AB at the end of May 2006. The group members developed their ability to function as a part of a project team with given roles and individual fields of responsibility. The close cooperation with an international company such as Hägglunds Drives AB provided the students with valuable insight into the complexity of an indus-trial product development process.

Brake cover with grooves and balls,

an important feature of the servo

application.

12

AbbottRe-thinking the user interface of blood glucose monitoring

Background

The project was initiated by Abbott Laboratories and performed with their close collaboration. Abbott Laboratories, based in Alameda, California, is one of the largest companies in the diabetes care sec-tor. Today’s market is moving towards usability and design.

Assignment

The assignment was to re-think the user interface of blood glucose monitoring systems, including gener-ating design concepts and prototypes that consider mechanical inputs, the graphic design, human factors and data management.

Abbott Laboratories sells their products world-wide – an important consideration in the design

The project is a global collaboration between LTU and

Stanford University. Four students from each university

formed the global design team, whose goal was to

generate innovative solutions and create a concept

for an intuitive blood glucose monitoring system for

children with diabetes.Concept sketch.

1�

process. Another difficulty was the large spectrum of diabetics, ranging from children with diabetes type I to elderly people with diabetes type II.

Design process

Since large distances separated the team, the coopera-tion relied greatly on communication technology. The work was conducted with the Sirius master plan and Stanford’s deadlines side by side. Based on the ini-tial need finding, the team chose to concentrate on child diabetics.

Focus of the process was on need finding to understand the user’s view of glucose meters and diabetes. Interviews and surveys were used to collect

knowledge and opinions from diabetics and healthcare professionals, providing an understanding of the dis-ease and everyday problems related to diabetes. The knowledge was transformed into software fea-tures, interface solutions and several design concepts.

In February, two Stanford group members visited Luleå and the LTU members visited Stanford in April.

To achieve collaboration over large distances, videoconference systems, instant messaging and shared virtual working environments were extensively used.

Engineering software, such as Alias StudioTools and Unigraphics NX3, was used simultaneously with traditional techniques like clay modelling and sketch-ing to illustrate concepts throughout the design process.

Result

The decision regarding the final concepts was done after meeting Abbott Laboratories representatives in California. The result is a blood glucose monitoring system that targets primarily children followed by their parents during the transition phase when child diabetics begin to take responsibility for their own care. Knowledge about conditioning and positive reinforcement was implemented into a medical device with the purpose to improve the overall diabetes per-formance of children. Several features were included to improve the children’s knowledge of their disease. The global design team created a design that considers children and their parents.

The Team: Ihab Daouk, David Yao, Karthik Manohar,

Maria Marklund, Elin Karlsson, Maria Hedin, Erik Mossing.

Nick Reddy is absent.

Concept sketch.

1�

Background

VMCC designs concept cars and predicts and moni-tors trends in the automotive industry. Most new Volvo cars are designed at VMCC, one of the leading car design centers and trendsetters in the world.

Assignment

The main focus in this project has been to develop an innovative new door opening solution for two-door cars that improves the ingress and egress of the car and minimizes the opening-closing effort. The design-team consisted of students from Luleå University of Technology, Chalmers University of Technology.

To collaborate on a daily basis, the distributed design team used videoconferences and a common project portal from which information could be shared.

VCC and VMCCInnovative Door opening solution A design-team from Luleå University of Technology and Chalmers worked together in an international distributed collaborative engineering design project. An innovative door opening solution for the concept car 3CC was developed in collaboration with Volvo Car Corporation’s design center, Volvo Monitoring and Concept Center (VMCC) in Camarillo, California, USA.

Volvo concept car 3CC. Innovative door opening solution

for Volvo concept car 3CC

1�

Project evolution and result

In the early design phase, design ideas were generated using vari-ous design theories and methodologies. The project evolved from various ideas in different concepts. Modern CAE-tools such as Ideas and Unigraphics NX3, MSC.ADAMS and MSC.MARC were used to design, simulate and analyse mechanisms and parts. A virtual prototype was made and one full-scale physical proto-type of the doorframe and the opening mechanism was manu-factured. The prototypes were sent to Volvo for further validation and testing.

LARS ERIk LUNDIN,

Vice President and General Manager VMCC

The SIRIUS team was assigned a challenging task to invent a new door

opening system for a Volvo concept car. Their efforts were directed at the

3CC, a small two door car with long doors. Any improvement over exist-

ing and well proven door systems is an ambitious goal. The design had to

be unique and innovative but still meet challenging performance require-

ments for robust operation and provide good accessibility when parked in

narrow parking spaces. The design also had to be feasible for production.

The team has created a design solution that meets our expectations. We

will incorporate the results of their design work in the concept develop-

ment activities at VMCC. It is also worth mentioning that the design effort

involved two groups of students from two universities. Their collaborative

working methods will contribute toward advancing the state of the art of

distributed engineering design. We are pleased to have this cooperation

with the students of Luleå University of Technology and Chalmers Institute

of Technology.

kOLITA MENDIS,

Structures and Safety Engineering Manager, VMCC

The SIRIUS team investigated unique door opening solutions for our small

car concept. They have made a careful assessment of all issues starting

with market research to understand the needs of customers, then pro-

ceeding to ergonomic evaluation and mechanical design. They have pre-

sented us a concept that is interesting and unique while meeting a set of

demanding functional requirements. They have demonstrated the ability to

successfully work together in a collaborative setting. The participation of

the students from Luleå University of Technology and Chalmers Institute of

Technology brings in fresh new input to our concept development work.

The Sirius-VMCC

team visiting VMCC

in Camarillo, USA.

Finite element analysis

of detail in door opening

mechanism.

1�

Future elderly environments

Background

Elderly care is changing. The expected retirements of many born in the 1940s combined with the limited resources in elderly care means that fewer employees will care for more elderly. Employees have a variety of technology to facilitate their work, e.g. lifts and alarms, though technological solutions are limited to increase the wellbeing of the elderly.

The team is convinced that the quality of life for the elderly can be improved in many ways.

Assignment

The mission was to enhance the wellbeing for peo-ple in their latter part of life. This statement was all the team had to start out with. To achieve this, the meaning of ‘wellbeing for elderly people’ had to first be investigated. To narrow down the task the global design team chose to focus on people living at eld-

In this international project, students from LTU and Stanford University worked together to develop a product that enhances the wellbeing of the elderly.

The main goal was to develop a product based on the present and future needs of the elderly.

Testing prototype on elderly home.

3D model in Alias, Studio Tools.

Göran is adding an idea in a brainstorm session.

and promotes social interaction between the elderly and relatives will increase the wellbeing of the elderly.The presented product will be implemented at a new elderly home in Luleå.

1�

erly homes. The project began with a need finding process to discover the needs of the users, and later translate those needs into concepts. From the needs found, certain activities were singled out and focused upon. The team proceeded to develop a solution that met the requirements and thereby could enhance the wellbeing for people living at elderly homes. The use of conceptual prototyping to create various artefacts during the project was emphasised. Implementing the final prototype for users in a new retirement home is the goal. The project was unique because of its heavy focus on the needs of the users and their participation in the product development process.

Collaboration

The whole project was conducted through global collaboration between four students from Luleå University of Technology, and four students from

Stanford University, USA, working together as a team. This proved to be a challenging task due to the two universities having different theories of approaching product development and cultural and geographical separation. The experience of working internationally was still worthwhile, since diversity in views offers the best ideas of two worlds. Each group contributed with their professional and personal skills to the process and brought different points of view into the design process.

The Result

In this open-ended project, the team members devel-oped a product based on the needs revealed through their need finding. Interactions between the elderly and even their relatives were infrequent. The elderly have much to tell and if their stories and knowledge disappear, it is our loss. A product that is individual

The Future elderly environment team.

Fieldtrip at Lytton Garden. Distributed collaborative work. Palm drive: The entrance of Stanford University.

1� 1�

Formula SAE STATIC EVENTS

Presentation 75

Engineering Design 150

Cost Analysis 100

DyNAMIC EVENTS

Acceleration 75

Skid-Pad 50

Autocross 150

Fuel Economy 50

Endurance 350

Total Points 1,000

Graphic design: bo.berggren@gmail.com

The Formula SAE team has developed a complete race

car for the Formula Student competition in England.

To compete successfully in England, the car

has to be able to gather points in various

areas. This challenges participating teams

to be creative and innovative, while

managing time and

cost issues.

Background

Formula SAE started in 1981 in the USA as a com-petition for students to compete in engineering and design. Today, this global competition attracts hun-dreds of teams every year from all over the world that enter one or more of the six events held in Australia, Italy, Brazil, Great Britain and the USA. Formula Student is the competition in England where four previous cars from Luleå have participated.

Assignment

The assignment was described at the presentation of the projects in September. The main goal was to develop and fabricate a highly competitive race car for the Formula SAE series, following in the footsteps of four previous cars. The car had to be tested for at least 20 laps on 5 separate occasions before the pres-entation on May 19. The weight of the car could not exceed 195 kg and acceleration from 0-75 metres, which is one of the events, could take no more then 4.1 seconds. A top 10 finish in the design event, a better economical strategy and a higher theoretical knowledge of the car were additional goals.

Development

Two project leaders, one technical and one adminis-trative, were initially appointed. The team was then divided into three subgroups - engine, driveline and chassis. Students from other parts of the university

1� 1�

were recruited to handle the electronics and eco-nomical aspects.

Product development of all parts of the car was distributed among the three subgroups. Some solu-tions of the previous car were retained to ensure that the goal of a test period would be met.

The use of Computer Aided Engineering enabled the team to simulate, for instance, rigid body dynam-ics and fluid dynamics, as well as permitting the use of Computer Aided Manufacturing.

Fabrication of the car involved, among other things, carbon fibre moulding. This was a new expe-rience where the students learned how to fabricate carbon fibre sandwich structures.

New features of the car included a carbon fibre sub frame, the rear part of the chassis, and an engine without a turbo. The engine group realized that the restrictor, which limited the amount of air into the

engine, greatly reduced the benefits of a turbo. It was thus decided to enhance the performance of the engine by optimising the intake and exhaust systems instead.

Results

The team successfully developed and fabricated a fully functional racecar for the Formula Student event. The decision to run the engine without the use of a turbo proved wise, and meant a decrease in weight and cost and an increase in reliability and drive-ability.

The car weighs less than 190 kg and has a max power output of 90.5 bhp. These figures and the dynamic properties of the suspension should ensure a highly competitive race car.

These figures might be improved before the competition in July with increasing driver abilities and further development of the car. For additional

information on the project, please visit the project’s homepage at www.formulasae.ltu.se.

Finally, a huge thanks to sponsors and all com-panies that have supplied the team with parts, know-ledge and time. The project is dependent of your resources and expertise.

Simulation of rear suspension. Fluid dynamics simulation of the intake. Driveline assembly.

The Formula SAE team.

20

HANS FOLkESSON,

SENIOR VICE PRESIDENT

Research & Development

Volvo Car Corporation

At Volvo Cars, we are

pleased to be part of the

Sirius Project, which is an

excellent example of coop-

eration between university and industry.

Here enthusiastic students, who solve problems with a

fresh approach, are able to meet with us in the industry and

share our experiences. Furthermore, the student gains con-

tacts that might prove to be advantageous when they later

on apply for a job in industry.

This program also gives students a taste of the challeng-

es that the industry has to face; i.e. bringing better products

to the market faster, with higher quality, more environmen-

tal friendly, safer and at lower cost. Using an integrated

approach, as the Sirius Project suggests, is a true advantage

in order to achieve these goals.

To conceive and create a product according to these

principles is a great learning experience and we are looking

forward to continue the successful collaboration with Luleå

University of Technology.

BENGT-OLOF ELFSTRöM,

RESEARCH DIRECTOR

Volvo Aero Corporation

The Sirius project is an

important element of Volvo

Aero’s technology-, human

resources- and recruit-

ing strategy. It strengthens

Volvo Aero’s 20-year collaboration with Luleå University of

Technology and provides a basis for research- and final

degree projects. Present and future product development

will have an ever-greater focus during the early stages on

enhanced creativity and interaction in the requirement speci-

fication process between business development, products,

services and work in a virtual design environment. For Volvo

Aero’s development in this area, with new modes of work-

ing and new methods and tools, the Sirius project plays an

important role.

At the same time, the project gives participants an

understanding of how the company and the university can

cooperate on joint development of human resources. The

Sirius project also gives rise to creative new design solutions

that will be incorporated in our demonstration project for the

EU’s 6th framework programme, and subsequently, in our

products.

Industry and academia in collaboration

21

PETER THOR,

SIRIUS ENGINEER 2004/05

Volvo Aero Corporation

I was one of ten students

taking part in 2004/2005

years Volvo Aero Corporation

project group. Our task was

to develop a design concept

for a component called a

Turbine Exhaust Case – a structure positioned in the rear of

a jet engine with the main purpose of withstanding intense

mechanical and thermal loads.

During Sirius I gained experience in project planning,

how to evaluate an evolving design and living up to specific

requirements under a limited amount of time. It was impor-

tant to effectively utilise our individual key competence while

at the same time work as a team towards the common goal.

Participating actively from the very beginning in a project

where conceptual ideas flourish, leading on to the delivery

of a prototype at the end of the course, was very rewarding.

Sirius met my expectations on a final-year course since

it allowed me to practically use the knowledge I had learned

throughout the years in a bigger perspective. I recommend

Sirius to anyone seeking knowledge in how product devel-

opment in the industry can be carried out – while still being

a student.

After having completed my final thesis at Volvo Aero

Corporation I was given the chance to continue at the same

company. I currently work with developing tools and meth-

ods that aim to increase the efficiency of the engineer within

multiple fields of product development.

JOHANNA SAHLSTEDT,

SIRIUS ENGINEER 2004/05

Scandinavian Health Ltd.

Contributing to SIRIUS –

Design for Wellbeing was for

me more a coincidence than

a natural choice.

I participated in a couple of

brainstorming sessions for

Design for Wellbeing and became interested. When I was

asked whether I would like to be a member, the obvious

answer was YES. But I would never have imagined that

this choice would become such a big footprint in my future

career.

As earlier mentioned, I participated in Design for

Wellbeing with the chosen theme Future Playgrounds.

The path was long and winding, but with a lot of fun and

learning, including a nice trip to California. We went from

research, brainstorming, concept development, etc. to

finally ending up with a virtual playground at Teknikens Hus

in Luleå.

When I applied for master’s thesis work I was convinced

that I wanted to work within Product Development. I ended

up at SCA developing tissue dispensers for high traffic

washrooms in Gothenburg. After, I continued as a product

developer at Scandinavian Health in Stockholm developing

products for physically disabled persons. Now, I’m a Project

Leader for mattresses that prevent pressure ulcers.

The future? Only time will tell.

Industry and academia in collaboration

22

The Polhem Laboratory at Luleå University of Technology is one of 23 Swedish centres of excellence with partial funding from VINNOVA, the Swedish Agency for Innovation Systems.

Ideas from the Polhem Laboratory

are key concepts of the Sirius

project:

• Integrated and parallel working methods• Close collaboration with industry

The goal of the Polhem Laboratory is to simultaneously develop methods that will shorten lead-times in the product development process, reduce the costs of product development and product support, and improve the quality of the design system and flexibility in the organization.

Research within the Polhem Laboratory focuses on the following areas: simulation, communication of information within product develop-ment and concept development. The

projects of the Polhem Laboratory are conducted in cooperation with divi-sions of Luleå University of Technology, member companies and often interna-tional partners.

Member companies of the Polhem Laboratory are AB Sandvik Coromant, Aerodyn AB, BAE Systems Hägglunds AB, Ferruform AB, Hägglunds Drives AB, Metso Panelboard AB, MSC.Software Sweden AB, SKF Sweden AB, Vattenfall AB Vattenkraft, Volvo Aero Corporation and Volvo Car Corporation.

The methods applied within the Sirius project are also supported by research carried out within the frame-work of the ProViking programme. ProViking is funded by the Swedish Foundation for Strategic Research (SSF) and involves the participation of The Division of Computer Aided Design and Division of Machine Elements.

Furthermore, the results from the VIVACE project, described in more detail to the right, have provided

students with useful insights about state-of-the-art tools and methods for Knowledge Enabled Engineering, which prepares them well for their future work in globally dispersed product development teams, where knowledge ánd expertise is distributed across organizational and functional borders.

University partners in the Polhem Laboratory are the Divisions of Computer Aided Design and Machine Elements at the Department of Applied Physics and Mechanical Engineering.

World-class research is being con-ducted at the Department of Applied Physics and Mechanical Engineering, which is responsible for the disci-pline Engineering Design within the Mechanical Engineering programme. The Division of Computer Aided

Design has the principal responsibility for the final year course called Sirius in the MSc degree programme in Mechanical Engineering Design. Sirius is a result of the Polhem Laboratory and the department’s leading-edge research and excellent contact network within the Swedish industry.

The Polhem Laboratory

PROFESSOR LENNART kARLSSON,

Division of Computer Aided Design

and the Polhem Laboratory,

Luleå University of Technology Pho

to: A

teljé

Gro

dan

www.rolls-royce.com

PolhemRegio is a project that offers an opportunity to small and medium size companies in the regions of Norrbotten and Västerbotten to refine and introduce strategies for the product development process. The companies are manufacturing companies in the metal, wood or plastic industries as well as innovator proposed projects. The project uses the results of research conducted within the Polhem Laboratory and applies it to the local companies.

The goals of the project are to increase product development knowledge and refine the companies’ product development processes through implementation of a systematic product development strategy using 3D CAD and simu-lations to verify the product, and distributed engineering to permit working at different locations and meeting the costumer’s needs.

Researchers at the Division of Computer Aided Design at LTU are taking part in VIVACE [www.vivaceproject.com], a 70MEURO Integrated Project in the EU Sixth Framework Programme (FP6). The acronym stands for ‘Value Improve-ment through a Virtual Aeronauti-cal Collaborative Enterprise’. The main project goal is to support the design of a complete aircraft with engines by providing increased simulation capabilities throughout the product-engineering life cycle. Briefly stated, the goal is to create a ‘virtual product’ in a ‘virtual enterprise’ – thereby aiming to achieve a 5% cost reduction in aircraft develop-ment, a 30% lead time reduction in engine development and a 50% cost reduction in engine development. LTU is active in two of three VIVACE sub projects:• Virtual Engine – a specific global product work area that develops the different engine modules of the aircraft propulsion

The results of the project are the following:• The involved companies will increase efficiency and flexibility.• New companies are formed due to the cooperation of companies participating in the project. • The companies get new products developed according to the method.• Engineers with a master degree in mechanical engineering are recruited to the companies to manage and use the implemented method.

The project is a Mål 1 project,

partly financed by EU struc-

tural funds, the County

Administrative Board of Norrbotten and

Luleå University of Technology.

system and key areas of multi-disciplinary, optimisa- tion, knowledge management and collaborative enterprises.• Advanced Capabilities – a key integrating work area that develops common tools, methodologies and guidelines to be shared amongst the developments in the previous two work areas and provides for further integration of these two. In particular, LTU’s participation is directed towards new methods and technologies to share knowledge and expertise in virtual enterprises.

PolhemRegio VIVACE

www.airbus.com

2� 2�

The vision of a sustainable society forces industrial development into new ways of conducting business. An important way forward is to provide functions rather than the product (i.e. the physical artefact) itself. This means that the product provider will be respon-sible to deliver the function throughout the life-cycle of the product. The product provider will then own the product and be responsible for all costs to develop, manufacture, support and continuously upgrade the product.

Customers who have until now expressed their needs in relation to the physical artefact, i.e. a technical specification, have begun to express what they expect the physical artefact should bring about in their use of the artefact. This shifted view is captured in the concept of Functional Products. An integration of the hardware, software and service aspects is the starting point with the intention to provide customers with a more encompassing offer, the total offer. Despite the intentions of achieving this integration, it is not yet fully understood how this shifted view will affect the development processes of the physical artefact and the technological progress.

The vision of the Faste Laboratory is that func-tional products can be developed and offered to the market with a known risk, lower total cost, and less environmental impact, as well as include better cus-tomer value than traditional products. To achieve this, the centre will examine how physical artefacts and services may be designed and developed to become an element in a total offer, and enhance integrated product development to extend towards functional product development.

The focus on Functional Product Innovation is to build on the strong and innovative research in Functional Product Development, Simulation Driven Design and Distributed Collaborative Engineering. This will create the capability to identify, model and simulate offer components in the early phases of the development process, and support a closer collabora-tion between value-chain partners.

The Faste Laboratory Center for Functional Product Innovation

Realizing Functional Product Innovation.

2� 2�

Sirius 200�/0�

TOP ROw, FROM LEFT:

Peter Strandljung (VMCC), Anders Edwall (FSAE), Patrik Forsberg (FSAE) , Stefan Johansson (VAC), Johan Fällman (FSAE), Anders Olofsson (VAC), Mikael Nybacka (Advisor), Clas Persson (VAC), Johan Nilsson (FSAE), Joakim Wennström (FSAE), Gustav Sandberg (RvsP), Gustav Lundmark (VMCC), Martin Lund (FSAE)

THIRD ROw, FROM LEFT:

Per Wiklund (VMCC), Sverker Svärdby (RvsP), Peter Åström (Advisor), Petter Aspvik (VMCC), Henrik Nergård (Advisor), Anders Brattström (FSAE), Mikael Malmsköld (RvsP), Stefan Sandberg (Advisor), Per Mobacke (VMCC), Stefan Härdin (FSAE), Göran Månsson (FEE), Magnus Löfstrand (Advisor),Christian Johansson (Advisor)

SECOND ROw, FROM LEFT:

John Berggren (VAC), Marcus Persson (VAC), Andreas Wallgren (HDAB), Johan Olofsson (HDAB), Fredrik Persson (HDAB), Erik Mossing (Abbott), Maria Marklund (Abbott), Joakim Lundin (RvsP), Mikael Önnervall (RvsP), Fredrik Eriksson (VAC), Joakim Larsson (VAC), Lennart Karlsson (Professor).

BOTTOM ROw, FROM LEFT:

Magnus Andersson (VMCC), Johan Eriksson (HDAB), Mats Sundin (HDAB), Simon Forslund (FSAE), Anton Ljungberg (HDAB), Caroline Pettersson (VAC), Maria Hedin (Abbott), Anette Aava (FEE), Magnus Astrom (FEE), Johanna Vännström (RvsP), Petter Arlehed (VAC), Jari Leinonen (HDAB), Peter Berglund (FEE).

ABSENT:

Jimmy Westberg (RvsP), David Enbuske (HDAB), Elin Karlsson (Abbott)

Pho

to: A

teljé

Gro

dan

2� 2�

Industry PartnersVolvo Car CorporationVolvo is one of the car world’s strongest brand names. The company’s founders maintained from the outset that its operations should be based on care for the human being. That is why safety, quality and the environment are the core values that characterise Volvo car’s operations, cars and behaviour.

VOLVO VISION: To be the world’s mostdesired and successful premium car brand.

VOLVO MISSION: To create the safestmost exciting car experience for modernfamilies.

Quality is one of Volvo Car’s core values, and all quality efforts are aimed at ensuring satisfied customers. Becoming number one in customer satisfaction is one of the most important long-term goals. A Volvo car is among the safest cars in its class. It is also characterised by functional and attractive design, stable and well-balanced ride and roadholding, high comfort, practical features and powerful engines that are economical with fuel and meet strict environmental requirements.

Volvo Monitoring and Concept CentreIn 1986 Volvo Car Corporation took a significant, visionary step into its future by opening the Volvo Monitoring and Concept Center (VMCC) just west of Los Angeles, California.

VMCC develops, designs and tests a multitude of techniques and software on behalf of the Volvo Car organization, including applications such as 3-D virtual environment programs allowing dispersed teams of engineers and others to present and review projects and ideas together in real time. This can shorten lead times, offering major savings in an industry where it can take 2-5 years to produce a car from the drawing board.

Committing to a bigger purpose than just styling new cars, VMCC has evolved a unique multi-disciplinary working methodology and organization geared to create more value by forging a symbiotic relationship between design, business and technology.

Sources: http://www.volvocars-pr.comVolvo Car Corporation, 2006 Pocket Guide

2� 2�

Volvo AeroVolvo Aero develops and produces components for commercial aero, military aero and rocket engines with a high technology content, in cooperation with the world’s leading aerospace companies.

Service and maintenance represent an increasing proportion of operations in this area. Volvo Aero offers an extensive range of services, including maintenance, repair and overhaul of aero engines and industrial gas turbines, sales of spare parts for aero engines and aircraft as well as sales and leasing of complete engines and aircraft.

Sources: Volvo Aero Corporation

Hägglunds Drives ABMore than an ordinary drive supplier.

dustier. dirtier. Harsher. Heavier. The worse it is, the better equipped we are. After more than four decades of supplying drive systems for heavy industrial applications, Hägglunds is accustomed to difficult demands. We provide what you need to get the toughest jobs done right – no matter how harsh the environment or how specialised the task.

performance. Flexibility. Security.Hägglunds unique hydraulic drive systems – combined with our wealth of experience – provide advantages no other drive supplier can match. With Hägglunds drives on your equipment, you receive: • Maximum torque from zero speed. • High performance regardless of conditions. • Precise control of infinitely variable speed. • Standardised modules for design freedom. • Smaller, lighter, more effective installations. • Superior protection of equipment and processes.

Here. there. everywhere. A global leader in industrial drive solutions, Hägglunds has offices in nearly twenty countries and distribution partners in many more. We are where you are – with short lead times and fast, comprehensive service that answers your needs.

OUR DRIVE IS YOUR PERFORMANCE

Sources: Hägglunds Drives AB

visiting‑address: university campus, porsön, luleå

postal address: SE-971 87 luleå, sweden

telephone: 0920-49 10 00. fax: 0920-996 92

website: www.ltu.se www.cad.ltu.se/sirius