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WELCOME TO BIAX USERS CONFERENCE 2017 AT LBF

Welcome Address by the Head of the Institute – Prof. Dr.-Ing. T. Melz

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BIAX USERS CONFERENCE 2017 AT LBF IN DARMSTADTTHE COMMUNITY EVENT

Our mission: Improving road & vehicle safety by wheel & hub durability

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Fraunhofer Institute for Structural Durability and System Reliability

Founded in 1938 | 80th anniversary next year

R&D services dedicated to lightweighting, polymer technology, reliability and vibration technology

Staff >400 people at 3 sites (campus Kranichstein, Darmstadt university, Stuttgart)

Contract research w/ industry >55 per cent of total budget

No. 1 FhG institute for lightweight structure design + testing

Major research topic is digitization and cyber physical systems

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New LBF/ISYS high frequency material testing device

Piezo-based actuation system as supplementary technology to well established servo-hydraulic devices.

Unrivaled accuracy for material testing at small loads (<1 N) or high frequencies (>500 Hz).

Applicable for constant amplitude loading (Wöhler testing) as well as variable amplitude testing (Gaßner testing).

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Smart and cost effective sensor node

Sensor nodes for integrating data acquisition, data compilation & storage as well as file transfer by Bluetooth® or G4.

Cost effective & flexible operation for condition & health monitoring.

Enabling technology for maintenance on demand.

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Air cooled in-wheel motor and aero spoke (turbine) wheel design

Second iteration of Fraunhofer in-wheel motor for EV’s is air cooled and highly mass efficient.

Stator casing has rib design to ensure proper cooling.

Improving air flow by special turbine wheel design which was developed using FEA and CFD simulation.

Unsprung mass of complete assy increases by 35 per cent which has an impact on vehicle dynamics as well as ride & comfort.

Eliminating unwanted effects from unsprung mass by using an adaptive shock absorber ( next slide).

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New Fraunhofer front strut & in-wheel motor

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Multiaxial shaker table (MAST) for HV battery system testing

Unique environment for service load simulation of HV battery systems for hybrid & electric vehicles.

Concurrent operation of vibration profile, electrical loads and climatic parameters (temperature & humidity).

Minimizing hazard risk due to inert gas atmosphere preventing hazard effects of thermal run-away of Li-Ion chemistry

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BiAx wheel & hub fatigue testing

BiAx wheel & hub fatigue test machines (ZWARP) are the most effective devices for service load simulation of complete assy and now used world wide.

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Total HCV operation | LBF design spectrum

For wheels & hubs of heavy commercial vehicles the minimum durability requirement is given by the LBF standard design spectrum.

This spectrum includes vehicle operation at maximum loaded vehicle weight for straight driving on regular roads as well as on rough roads, and cornering for both, narrow bends and smooth curves at high speed at rugged usage conditions having a small probability of occurrences.

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Operational signatures and their transformation into a design spectrum

Peak load

Peak load

frequency

total mileage

Spectrum shape factor

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Total HCV operation | vehicle applicability

This design spectrum represents total HCV operation by specific parameters related to dynamic peak loads, spectrum shape factor and number of cycles.

Total HCV operation covers the range of buses and coaches, as well as building-site truck application and long-haul traffic (>1,000,000 km) for many countries.

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LBF BiAx test lab operation

LBF is a premium service provider for contract testing, computational fatigue analysis, RLD & flat track data acquisition, load file development & conversion, test rig accuracy control as well as technology integration.

High fidelity results come from technology, processes and people.

At LBF people come first.