Projects in Research Area Drive Train Diagnostics and Prognostics

The development of a reliable product represents one of the primary goals in mechanical engineering, since it is an important sales criterion. Failures occuring during the usage of the product are depending on the one hand on the stength of the product and on the other hand on the load caused by the usage. However, the load occurring in the field is usually only insufficiently known. On the one hand, the individual components are not monitored by corresponding sensors and on the other hand, only a small amount of data is transmitted from the field to the manufacturer. Within the scope of the project, the failure mechanisms of engine parts are analyzed and their influencing factors are determined. The relevant load on the component is then modeled by a soft sensor. The recorded load is used to describe the usage behavior in order to enable a stress-appropriate design. Furthermore, the customer-specific load is transferred into a specific remaining useful life prediction by unsing of a lifetime model and thus the remaining useful life is determined.

 

In the field of remanufacturing, the aim is to maximise the reuse rate in order to save resources and capital. However, this should be done without compromising the quality and reliability of the remanufactured products. In doing so, it must be ensured that the selected components can represent a second product life. Findings from the remanufacturing process of remanufactured car transmissions are used for this purpose.

 

A method is being developed for the design of cylinder blocks which makes it possible to provide information on the reliability of cylinder blocks at an early stage of development. The calculation is based on load collectives from driving operation and experimentally determined material data. By linking and comparing calculation and field analysis, a consistent strategy for reliability analysis is to be developed.

Investigation of the rattling and clattering behavior of dual clutch transmissions, research into existing and generation of new avoidance measures, performance of rattling and clattering noise measurements, demand-oriented quieting of the transmission. The aim is to create a catalog of measures to counteract breakaway noise, specifically for dual-clutch transmissions.

The gear life of a series toothing is to be investigated experimentally on the load test bench for the failure of pittings. A statistical life verification of the gear with regard to the fatigue damage and the influence on the scatter of the degradation model dimples, under the influence of the load, is to be presented. A test methodology with regard to resource planning and a simulation approach are to be verified with the measured data.

 

Gear teeth cause all components of a gear to vibrate due to various mechanisms such as variable tooth stiffness, deviations of the tooth flank geometry from an ideal involute, and impact processes. The resulting noises are known as gear whine and whistling, or as gear rattle and clatter. These noises reach the human ear via direct airborne sound radiation from the housing, or are transmitted as structure-borne sound to add-on parts, which then also radiate these vibrations as airborne sound.