Final-year project course for

MSc MECHANICAL

ENGINEERING DESIGN

LULEÅ UNIVERSITY OF TECHNOLOGY

2002

SIRIUS 2001/02 IS A CO-OPERATIVE PROJECT

between Luleå University of Technology, Volvo Car

Corporation (VCC), Volvo Aero Corporation (VAC)

and EDS. Sirius prepares students for work in the

area of product development. The product deve-

lopment projects in the course are closely linked

to industry or to other real product needs. The

work is carried out by groups of undergraduate

students with supervisors from both industry

and the university.

Sirius’ close industry links give advantages for

both students and industrial partners:

• Students have the opportunity to apply their

skills and knowledge to develop optimal solu-

tions to real engineering problems within a

limited time scale and budget and to gain a valu-

able insight into today’s and tomorrow’s ways of

carrying out product development projects.

• Industry gains access to innovative technical

solutions, developed by well-educated students

who are not bound by traditional ways of pro-

blem solving.

Luleå University of Technology and industry in close co-operationPh

oto:

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arki

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ManufactureConcept Design Test

3

Creative Product DevelopmentSirius is one of the final-year course options forengineering undergraduates studying towards aMSc. in Mechanical Engineering at Luleå Universityof Technology. Sirius involves teams of students carrying out a product development project eitherin close co-operation with an industry partner orbased upon other, real world product developmentrequirements. The modular nature of engineeringdegrees at Luleå University of Technology alsomakes it possible for students studying other, complementary disciplines to participate in Sirius.The varied background of the students provides a wide knowledge base in the project groups and an opportunity to gain understanding of the complementary relationship between different engineering disciplines.

Sirius runs over a full academic year andaccounts for half of the total credits gained by thestudents in their final year. Most of the students’time in Sirius is directed towards an engineeringdesign project developed in close co-operation with

industry. To support these projects, students studysystematic product development methods, use ofadvanced computer aided design tools, projectmanagement, mechatronics and industrial design.Students also work closely with postgraduates andstaff at the Polhem Laboratory and many of the academic divisions at the university.

The aim of Sirius is to give students an oppor-tunity to acquire, apply and integrate knowledgethat will enable them to participate in and leadindustrial product development projects. Sirius students gain knowledge of project management,creative idea generation, communication and com-puter aided engineering design and are capable ofhandling all stages of product development fromproblem identification and concept generationthrough to prototype manufacture and test.

Sirius prepares students with both theoreticalknowledge and practical experience of working in an integrated manner in interdisciplinary projectteams using the latest tools and techniques. TRADITIONAL PRODUCT DEVELOPMENT

Concept

Design

Test

INTEGRATED PRODUCT DEVELOPMENT

Manufacture

4

PRODUCT DEVELOPMENT PROJECTS

Electric Parking brake, VCCStudents were given the task of developing an electricparking brake system that could be put into seriesproduction whilst satisfying VCC’s design, safety andcost requirements.

Virtual Pedals, VCCThe project Virtual Pedals was a global project invol-ving students from Luleå University of Technologyand Stanford University, USA, working together todevelop new concepts for safer brake and acceleratorpedals.

Intermediate Case, VACThe students’ task was to develop a so-called inter-mediate case for a next generation civil jet engine.The design had to satisfy tight safety, weight andcost requirements.

Formula SAEFormula SAE involves students from different discipli-nes developing a single seat racecar for participationin the international Formula SAE competition.

Sirius 2001/02Sirius 2001/02 involved four product development

projects and complementary theoretical studies.

For the first time the course has been opened up to

students studying degrees other than Mechanical

Engineering and a total of ten students studying for

degrees in Ergonomic Design & Production,

Industrial Economics, Aerospace Technology, and

Electrical Engineering have also participated.

5

GROUP BUILDING AND PRE-STUDY

This year’s projects began in October 2001 whenrepresentatives from VCC and VAC presented theirrequirements. The Formula SAE project was basedupon the extensive Formula SAE class specification.Project groups were formed based upon the students’ own preferences and the results of a Team Management Index (TMI) test.

THE CREATIVE PHASE

The groups initially developed a number of conceptssatisfying the functional demands outlined in thevarious design briefs. Solid models of these conceptswere created using the I-DEAS CAD-system to helpvisualise the solutions. In order to have good back-ground material for each project, a considerableamount of time was used finding relevant information.

Each group’s design concepts were evaluated usingvarious concept selection and ranking methods.Representatives from industry were also involved inthe concept evaluation process and selection of theconcepts, which were to be taken through to detaildesign.

MAIN PROJECT

Each group chose a team leader whose main task wasto manage the project and ensure that the goals werereached within budget. The selected concepts werethen further refined. Communication during all phasesof the projects was supported by web-based data-bases, which allowed all members of a group to shareinformation.

The development focus of each project quicklybecame clear. The parking brake team aimed towards a simple design with a low cost of manufacture. Thevirtual pedals team prioritised development of physi-cal prototypes so as to allow the ”feel” of the pedal in use to be evaluated; something which would be difficult to do with a computer simulation. The inter-mediate case team put much effort into further deve-loping and evaluating various concepts to ensure thatVAC’s stringent demands were met. The large numberof components in the Formula SAE project placedgreat demands on co-ordinating the efforts of theteam. There was also the additional pressure of having a competitive car ready for the competition in England in July.

PRESENTATION

The parking brake prototype and the virtual pedalprototype were bench tested before being mountedinto Volvo cars for road tests. The intermediate casedesign developed for VAC was evaluated in a virtualtest bed and demonstrated with the help of computervisualisations and prototypes. The Formula SAE carwas entirely designed and manufactured by the stu-dents in close collaboration with industry. The finalassembly and road tests took place in May 2002.

Progress throughout the projects was documentedand then presented in a final report. Each projectgroup also presented their work at the university andat their respective industrial partner company.

The Studio at Luleå University of Technology

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The TaskThe project involved developing an electric parkingbrake system that fulfilled VCC’s requirements as faras function, reliability and modularity were concernedat or below a given cost for a yearly volume of250,000 units. The requirements specified includedbraking effect and balance, activation time, self-adjustment, weight and size.

Creative DevelopmentIt should be possible to use the electric parking brakeboth as an emergency brake and as a ”hill holder”during vehicle take-off in steep slopes. Both theserequirements require some form of dynamic controlof the braking force. Since force sensors are expensiveand the target price low, the students had to use alltheir creativity to develop a solution. The project

Electric Parking BrakeThe anatomical and physical characteristics of individuals vary

depending upon gender and origin. Due to this, it is quite possible

for a naturally strong person to apply a parking brake so that it

can be difficult for a weaker person to release it. VCC was interested

in developing a parking brake system that would over-

come this problem and be easy to use by anyone.

Therese Wikström, Sören Isaksson and Anders Bergkvist discuss

design concepts.

Phot

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anie

l Oge

nste

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I-DEAS FEM analysis of a part of the parking brake.

7

involved working closely with component suppliers inorder to balance total cost against function; a valu-able experience for their future work as product deve-lopers.

ResultsAn innovative electric parking brake system was deve-loped which was less expensive to manufacture thanthe systems offered by many other suppliers. It couldbe fitted directly into VCC’s current range of cars without modification.

In addition to students studying mechanical engi-neering, the team also had members from ErgonomicDesign & Production, Aerospace Technology, andElectrical Engineering degrees. This gave the team awide range of skills to call upon and also helped in-crease the knowledge of the individual students.

Visualisation using IPA of part of the parking brake system.

Controller card for the parking brake manufactured by

the Sirius students.Andreas Branthsson fitting the actuator.

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The TaskThe traditional design of clutch, brake and accelerator pedals can cause injury to the driver’s feet and lower leg in the event of a crash. Another problem with traditional designs is that in order to reach the pedals, shorter drivers must adjust theirseats so that they are much closer to the steeringwheel than is ideal should the airbag deploy.

The Virtual Pedals project was carried out withVCC with the aim of developing a solution that allowed greater possibilities for adjustment, improvedsafety and lower cost. The specification required thatthe brake and accelerator be foot controlled and thatthe solution could be used for a wide range of driverheights and position of the driver’s seat.

International Co-operationThe project team consisted of two geographicallyremote groups; four students from Luleå University

Virtual PedalsTomorrow’s vehicles are expected to have an increasing number

of ”drive-by-wire” systems where mechanical linkages between

the driver and vehicle are replaced by mechatronic systems where

electronics and mechanical systems are closely integrated.

This will allow improvements in both driver safety and vehicle

performance.

The Global Development Team: Jon, Mattias, Jon, Mauricio, Tam, Holger, Niklas and Scott.

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of Technology and four students from StanfordUniversity, California. This international grouping gavean insight into how product development is likely totake place in the future, where geographically sepa-rated groups contribute with their own skills and viewpoints, both culturally and professionally.

The two universities have different ways of approa-ching product development. This, coupled with thedifference in time zones, has given interesting possi-bilities to harness the relative strengths of each teamto best effect. The teams were supported by state-of-the-art technology for distributed engineering, whichhas been developed at Luleå. The use and possibilitiesoffered by this technology in different engineeringsettings were also studied by researchers at both universities.

ResultsThe concept generation and evaluation phase led tothe idea of a single or ”mono-pedal”, which combinesbrake and accelerator pedals in one, as being the bestsolution. The advantages of this configuration aremany; reaction time for emergency braking is reducedsince the driver’s foot need not be moved, the possi-bility of several types of foot injury is eliminated sinceopen floor space is increased and the driving positionis improved from an ergonomic viewpoint. ”Drive-by-wire” braking is also more environmentally friendlysince weight is reduced, which helps to reduce emis-sions, and the need for hydraulic oil is eliminated.

Niklas Grahn testing the prototype mono-pedal in a simulator.

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eter

Tör

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Visualisation of the mono-

pedal in a Volvo S60.

CAD m

odel:

Mat

tias B

ergs

tröm

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The TaskVAC wishes to increase their competitiveness by usingnew methods for developing and manufacturing inter-mediate cases and to give them unique propertiesand function. Critical factors are weight, cost, struc-tural stiffness, number of component parts, sounddamping, reliability, and operating life. This Sirius project has provided much valuable information forthis work.

The project task was to develop new designs forthe intermediate case for motors for long haul jets.The work involved developing new design conceptsand evaluating materials and manufacturing methods.These alternatives were compared in order to developa technical and economically optimum solution whichalso satisfied the stringent requirements of the indu-stry and regulating bodies.

Intermediate Case for Civil Jet MotorsVAC manufactures components for civil jet engines. One of these

components is a so-called intermediate case which is the main

load carrying structure in a civil jet engine. The aerospace

industry places very high demands on component

reliability. Systematic product development

combining materials science, engineering

design, manufacturing technology and

maintenance was used to develop a

design which satisfied these deman-

ding requirements.

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Aer

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kiv

Study of the dynamic characteristics

of the intermediate case.

11

The Whole Engine Model (WEM), which was used as a virtual

test bed, here seen in The Studio at

Luleå University of Technology.

Phot

o: P

eter

Tör

lind

DFA, DFM and FEMThe main focus of the work centred on manufacturingan intermediate case with high stiffness and lowweight. This task was complicated by the intermediatecase’s required geometry and interfaces to otherparts of the aircraft.

The first part of the project concentrated ondesign for assembly (DFA) and design for manufactu-re (DFM). This was coupled to a geometric analysis of the intermediate case where a virtual motor wascreated and the loads experienced during start, hardlandings, turbulence and other demanding flying con-ditions determined using the finite element method(FEM).

ResultsThe final design concept used high strength titaniumand aluminium alloys and optimised geometry. Thespecial demands of working with an aerospace pro-blem gave a stimulating and challenging project. Thecomplex nature of the problem gave the group broadexperience of the challenges of engineering design inthis sector whilst close co-operation with VAC led to a number of feasible solutions being generated.

The Whole Engine Model (WEM) during

analysis showing the forces experienced

by the motor and transferred to the

intermediate case.

A full-scale visualisation of the final

intermediate case. The central struc-

ture is manufactured in titanium and

the outer in high strength aluminium

alloy.

12

The TaskThe Formula SAE competition is governed by a strin-gent set of rules covering vehicle design, performanceand safety which at the same time give sufficientscope for new and innovative solutions to be deve-loped. Key areas that had to be optimised includedstrength and weight of individual components, aero-dynamic performance, ergonomics, and power out-put.

The task of designing a racecar from scratch is a complex and multidisciplinary one. The Formula SAEgroup consisted of 23 students from 4 differentdegree programmes; engineering design, fluid mecha-nics, ergonomics and industrial economy.

From Concept to Finished CarAn important part of the initial work involved develo-ping a digital prototype. The CAD software I-DEASwas used to create, optimise and visualise the design.Weight and cost had to be considered to ensure thatthe car was competitive and could be manufacturedwithin a very tight budget. Project management inclu-ded weekly planning meetings and continuous docu-mentation as the project progressed.

By January, the concept model was complete anddetail design began. Individual components in the 3DCAD model were refined down to the level of indivi-dual fasteners to ensure problem-free build and func-tion. Apart from the engine and a small number ofspecialist components, all manufacturing was carriedout by the students. APC Composit and Tooltechcontributed with valuable knowledge and guidance in

Formula SAEThis year a team from Luleå University of Technology will

compete for the first time in the Formula Student competition;

the European version of the American Formula SAE. The com-

petition, which is open to undergraduate students studying

engineering, involves designing and building a single seat

racecar to a given set of rules or formula.

Manufacture of the carbon fibre composite chassis (left) and bodywork (right).

Phot

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atti

as W

ikst

röm

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Comprehensive use of CFD analysis

has enabled good aerodynamic charac-

teristics and optimised motor perfor-

mance to be achieved. The image shows

a simulation of the air flow around the

rear wing.

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: Dan

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dler

Visualisation of the Formula SAE car

usingI-DEAS.

manufacturing the carbon fibre monocoque chassis,glassfibre bodywork, and CNC machining of severalkey components. The majority of the manufacturingtook place within the final month of the project.

ResultsThe students’ own efforts and contact with expertiseboth within and outside the university have enabled a highly competitive Formula SAE car to be designedand built. The project and car were presented at Luleå University of Technology in May 2002 and atthe competition in England in July, where a formal presentation, project documentation, vehicle designand competition in a series of dynamic events werejudged.

14

The equivalence to Sirius at Stanford University,ME310, is a three-quarter (9 months) graduate cour-se in Mechatronic Systems Engineering where studentteams work with corporate partners on design innova-tion projects. Teams gain experience working on realprojects, with real budgets, to develop real products.This year we worked with ten different companiesincluding Volvo, Ford, Schick, NASA, and Unilever. The Volvo project was of particular interest since theteam members and corporate liaison were distributedamongst three separate locations: Palo Alto, Luleå,and Göteborg. Thus in addition to developing novelconcepts for car pedals of the future, they had theopportunity and challenge of using advanced distri-buted collaboration technologies being developed at the Stanford Center for Design Research and thePolhem Laboratory in Luleå. These technologies pro-vided multiple channels of communication betweenthe team members both synchronously and asynchro-nously, and helped this culturally diverse group of people achieve a level of trust and rapport within a time framework comparable to co-located teams.The net result has been a team whose output was judged to be the best in the class during the winterquarter design review. I am very pleased with this outcome and look forward to further cooperation with the Polhem Laboratory.

Stanford University

LARRY LEIFER

PROFESSOR, MECHANICAL

ENGINEERING DESIGN

DIRECTOR, STANFORD CENTER

FOR DESIGN RESEARCH

School of Engineering

Stanford University, California, USA

15

HANS FOLKESSON,

SENIOR VICE PRESIDENT

Research, Development

& Service

Volvo Car Corporation

The Sirius Project is anoutstanding example of co-operation between univer-sity and industry. We work with enthusiastic studentswho solve problems from new angles whilst we contri-bute with our industrial expertise and experience. The project also helps develop a contact network,which the students benefit from both when lookingfor employment and in their future industrial career.

In this co-operative project, the students get towork in a real development process, work towards agiven goal and develop an idea for a product, whilst at the same time being constrained by time, resourceand cost limits. This is valuable experience that thestudents take with them to industry.

We believe that this is an excellent way of workingwhich has developed further in the right direction thisyear. Volvo Car Corporation look forward to workingwith Luleå University of Technology again in the future.

BENGT-OLOF ELFSTRÖM,

RESEARCH DIRECTOR

Volvo Aero Corporation

The Sirius project is animportant part of VolvoAero Corporation’s tech-nology, competence deve-lopment and recruitmentstrategy. It further strengthens the 20-year relation-ship we have had with Luleå University of Technology in the form of research and development projects andfinal-year undergraduate placements. In the future weexpect to see even greater emphasis placed on earlyproduct development and creativity, balancing oftencontradictory functional demands and the use of vir-tual and distributed product development tools suchas those used by the Sirius students. Volvo AeroCorporation’s development in all these areas has beengreatly strengthened by the experience gained fromthe Sirius project.

The project is also important in that it gives stu-dents a good understanding of academic and indu-strial constraints, culture and aims. The Sirius projecthas been invaluable in helping create new, innovativeengineering solutions which will be further developedin European-funded Framework 6-demonstrators andlater in Volvo Aero Corporation’s products.

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The Polhem Laboratory at Luleå Universityof Technology is one of 23 competencecentres funded by the government via VINNOVA.

The working methods promoted by the

Polhem Laboratory are central to the

Sirius project, namely:

* Application of integrated, concurrent working methods

* Close links with industry

The long-term aim of the PolhemLaboratory is to develop techniques toreduce product development lead-times,product development costs and cost ofownership whilst increasing quality andorganisational flexibility and competi-tiveness.

The research carried out at the PolhemLaboratory is currently focussed on simula-tion, technical information systems andconcept development. The projects carriedout at the Polhem Laboratory involve co-operation between research units at theuniversity, international expertise and withclose industrial involvement. The compa-

nies which are currently involved in thePolhem Laboratory are: ACCRA Teknik,Aerodyn, Swedish Rail, Ferruform,Hägglunds Drives, Indexator, Metso Paper,MSC.Software Nordic, Sandvik Coromant,Swedish Hydropower, Volvo AeroCorporation and Volvo Car Corporation.

The methodologies that are used withinthe Sirius projects are also closely linked toresearch within the ENDREA programme(Engineering Design Research andEducation Agenda) which is financed bythe Swedish Foundation for StrategicResearch (SSF). The Division of ComputerAided Design is also an active partner inENDREA.

The research units at the universitywhich are most actively involved in thePolhem Laboratory are the divisions ofComputer Aided Design, Fluid Mechanicsand Solid Mechanics in the Department of Applied Physics and MechanicalEngineering and the Division of QualityTechnology and Statistics at the BusinessSchool.

Research at the Department of AppliedPhysics and Mechanical Engineering is

recognised as being world class. Thedepartment is also responsible for themechanical engineering programme at theuniversity whilst the division of ComputerAided Design is responsible for the Siriuscourse. Sirius is the result of the high quali-ty research which is carried out by the staffof the Polhem Laboratory and the depart-ments and their contact network withinSwedish industry.

The Polhem Laboratory

PROFESSOR LENNART KARLSSON,

Division of Computer

Aided Design

The Polhem Laboratory

Luleå University of Technology

Phot

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teljé

Gro

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SIRIUS STUDENT 2000/2001

Sirius was one of the most enjoyable and rewardingcourses that I took during my studies at university.The thing that makes Sirius so special is the possi-bility to be involved in the whole development pro-cess, from the start of the project to producing afinished prototype, within an integrated productdevelopment framework. Since the course is run as a project, it also gives experience of working with

others, taking responsibility andproject planning. My technicalknowledge increased throughthe courses that are given aspart of Sirius as well as throughthe Sirius project itself.

The fact that Sirius projectsare closely linked to industry

gave an insight into how industry works. Developingdesign solutions for a company which have a goodchance of being implemented increased motivationconsiderably.

I am currently continuing my studies at LuleåUniversity of Technology as a postgraduate studentwithin the area of functional products with a particu-lar focus on service reliability. Experience from parti-cipating in Sirius has proved valuable in my researchwhich is also carried out in close co-operation with a number of companies.

Fredrik Nytomt, MSc. postgraduate student at

Luleå University of Technology

SIRIUS STUDENT 1997/1998

When I look back at my studiesin Luleå, I regard Sirius as one ofthe most valuable courses that I took. In addition to the techni-cal knowledge and skills that thecourse gave, Sirius also gavepractical experience of productdevelopment projects requiringteamwork, planning, management of resources andfinances and communication. The opportunity to beinvolved as an undergraduate in a real developmentproject, commissioned by a major Swedish company,where a working prototype must be created withintight time and budget constraints is not only inspi-ring, but also makes the first steps out into industry a lot easier; it is no different to working in Sirius!

I now work at Volvo Car Corporation as a test engineer involved in vehicle dynamics and active safety. My work involves planning, co-ordinating andoverseeing the tests necessary to ensure that the systems or functions that we develop work in actualvehicle applications. The development work and testsare carried out in interdisciplinary teams which require the team members to work effectively witheach other. In this work I have benefited greatly from the experience that Sirius gave me.

Fredrik Lundholm, MSc.

Volvo Car Corporation

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FIRST ROW:Therese WikströmNicklas MorénEva-Lis WestmanLars ThunbergMauricio PalmgrenLinda PeterssonKrister RuisniemiFredrik SahlinRobert RaskMikael HolmströmAnna Carlsson

SECOND ROW:Henrik KarlssonAndreas Larsson, supervisorRikard ÖhmanMattias BerglundMattias BergströmDaniel EdlerTim LiljaAnders BergkvistNils StenbergLars JonssonDaniel EkbågeTorbjörn OdenbergerAndreas LarssonNiklas GrahnRoger Tuomas, supervisor

THIRD ROW:Peter Åström, supervisorAnders NilssonAndreas RosénFredrik SamuelssonAndreas de HaanMichael ViklundJerker JakobssonFredrik HisvålsDominik DymarekJan ArvidssonMarkus BengtssonTommy BorgMarkus SelinHolger Andersson

BACK ROW:Mikael Jonsson, supervisorJohan BreheimSören IsakssonCarl Erik EnströmMattias FredrikssonAnders LampinenMattias WikströmJohan FahlénHenrik NergårdDaniel OgenstedtAndreas BranthssonPontus GranbergLars-Ola NormarkOlle WestlinPeter Törlind, supervisor

Photo: Ateljé Grodan

Sirius 2001/02 SIRIUS STUDENTSMISSING FROMTHE PHOTO:Tord EngströmAndreas IsakssonHenrik KarlssonKjell LindbergErika SkyttLeif Vestlund

visiting address: UNIVERSITY CAMPUS, PORSÖN, LULEÅ

postal address: SE-971 87 LULEÅ, SWEDEN

telephone: +46 920-49 10 00

fax: +46 920-996 92

url: www.mt.luth.se www.cad.luth.se/sirius

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