FINAL YEAR COURSEIN THE MECHANICAL ENGINEERING

MSc PROGRAMME ATLULEÅ UNIVERSITY OF TECHNOLOGY

2019

We’reSirius!

Sirius 2019 is a collaborative advanced course in product development,

spanning over three-quarters of a year.

This year involving collaborations with BAE Systems Hägglunds, Husqvarna,

The Cluster of Forest Technology, AB Sandvik Coromant, Scania AB,

Volvo Construction Equipment and Luleå University

of Technology.

2019

Sirius, the final year course in the Mechanical Engineering MSc programme, prepares students for work in product development. The product development projects of this course are firmly based on close collaboration with industrial manufacturers or real product development needs. Work is conducted in project groups with the support and guidance of academic advisors from several divisions at the university as well as industrial advisors. Collaboration benefits both students and industry partners by giving students an opportunity to apply their knowledge when developing 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 soon-to-be engineers who are unbiased by traditional modes of thinking and problem solving.

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Needfinding Needs play an important role in innovative or radical product design, since the starting position includes no existing solution. Ob-servations, interviews and creative methods are used to identify, analyze, categorize and communicate needs to drive product development in Sirius student projects. The main principles of Needfinding are to first be close to the users, and then look for needs rather than solutions. This keeps the early phases of product development open to unexpected insights, and supports the generation of numerous concepts which broadens the opportunities for innovative products. Needfinding is part of the Sirius guidelines that provide students with capabilities beyond classical engineering design education. The insights into needs provide a solid ground for the activities in concept generation, concept evaluation, detail design and product launch, which are also main elements in the Sirius guidelines.

Concept generation As Needfinding activities unfold, students gradually perceive insights into people’s need and concept ideas. To work the ideas into comprehensible concepts, creative methods is used to encourage an open mindset, since judgemental attitudes are not allowed and all ideas are good ideas. The concept generation phase has a focus on quantity and is highly iterative. The gen-eration activities occur on different levels throughout the entire product development process as the product matures..

Concept evaluation Concept evaluation comprises activities that highlight some desired qualities in each concept, and can be seen as a stage in the design process in which the design space is narrowed down. The aim is to extract a few concepts that best meet the needs in focus and that are feasible for further development into a product. Evaluations can be performed by using creative tools where the focus is on judging the value of the idea. During the later stages, measurable criterias and matrix-based methods, e.g. House of Quality and Pugh’s matrix, are used. Small models or prototypes may be used to test if a concept should be further developed. Concept generation and -evaluation are closely related phases and are used to narrow down and open up the design space. The needs in focus are used in the evaluation activities to, for instance, judge a user-perceived value of the concept.

Detail design Detail design is a stage where the few selected concepts become more explicit in terms of solutions and functionality. Still, the chosen concepts are at various stages of completion. Therefore, a range of approach-es are used. Computer-aided engineering tools such as multi-body dynamics analysis and finite element analysis are used, along with engineering design methods and methodologies, e.g. case-based reasoning, simulation-driven design, and industrial design approaches.s.

Product launch The expectations of the products are often high, since the students work at the company’s development frontier. It is not only important to create a competitive product in terms of its intrinsic value, but it is also important that the students can sell and explain their ideas to their involved company. After finalized project, the products developed within the Sirius programme are further refined by the companies in preparation for market launch.

Product Development Process

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BAE Systems Hägglunds AB

BackgroundBAE Systems Hägglunds is known for their world-leading combat vehicles, armoured engineering vehicles and armoured personnel carriers. They focus on provision and upgrade for vehicles in military and civil application. The brand new innovative BvS10 BEOWULF is a tracked vehicle designed for HADR, Humanitarian Aid Disaster Relief, together with fire and rescue service. To remain world-leading within tracked vehicles, BAE Systems Hägglunds needs to be innovative and never stop developing their high quality products.

ChallengeFor the third year in a row BAE Systems Hägglunds is a part of the Sirius course. The task was to further develop the driveline on a BvS10 BEOWULF. The goal was to make it more efficient and competitive and upon completion demonstrate the motion of the driveline on a functioning prototype. The biggest challenge within this project was to develop a driveline that is durable in the harsh environments that a BEOWULF is designed for as well as making it fit withinthe confined space around the track system.

BAE Systems Hägglunds AB is a division of BAE Systems that has a total of 82,500 employees worldwide. With about 1,000 employees Häg-glunds is one of the larger companies in Örnsköldsvik and a world leading company within tracked land vehicles. Their products are exported to Denmark, Estonia, Finland, the Netherlands, Norway and Switzerland among others.

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Top row: Jonathan Jansson, Erik Ögren, Viktor Åström

Second row: Viktor Risberg, Anton Mukka, Edvin Björk, Emil Muhrman

Bottom row: Alex Oddsgård, David Lohse, Karl Holmqvist. Absent: Erik Östensson

“Sirius is a perfect opportunity for us to offer students the possibility to work with real problems and find technical solutions and improvements within our products as well as showing them how our company operates and marketing our business. The projects executed during the last couple of years are all perfect examples of just that.”

Peter Sedin Chief of Operations & Supply Chain, BAE

A more efficient and competitive driveline for the Bvs10 BEOWULF

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ProcedureThe project started with gathering information about similar land vehicles across the globe. This was done to be able to make a product specification. The demands were compared with the similar vehicles to get a picture of how the values should be set in the product specification. When the demands were set, different concept solutions developed during different kinds of brainstorming sessions. The concepts were evaluated supported by screening matrices and concepts that did not pass the screening were eliminated. To be able to choose a final solution between the remaining concepts, a deeper analysis was made with CAD and FEM softwares as well as suitable calculations.

ResultsThe project resulted in a functioning prototype that displays a more efficient driveline with a functioning transmission capable of handling the required torque and speed. The results contribute to future development that increases BAE Systems Hägglunds chances to stay competitive and innovative within their market.

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Future Forest Regeneration

BackgroundMechanization of ground preparation oper-ations is a challenge due to the tough terrain in the forests. Obstacles like rocks, stumps and remains from deforestation put high demands on the tools and equipment. Today’s solutions require heavy machinery, which in most cases damage the surrounding environment more than necessary. Minimizing the environmental impact, such as ground damage, is becoming more important when choosing ground preparation methods for the future.

ChallengeThe purpose of this project was to develop an inverse ground preparation tool that is more environmentally friendly than today’s solutions while still being cost effective and preparing the ground for seedlings to grow efficiently. A modular test unit of the concept was manufactured and is going to be used in various field tests. The test unit will be used to measure the loads needed to perform the operation, prove the function of the concept and eventual-ly optimize the operation.

This project is a part of a collaboration between The Cluster of Forest Technology, Luleå University of Technology and Bracke Forest. The objective is to develop forest regeneration technologies for the future. The project is funded by Holmen Skog, SCA, Sveaskog and Norra Skogsägarna through the funding initiative SNI (Skogens Nya Innovationer), managed by The Cluster of Forest Technology.

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Top row: Samuel Hedström and Kalle RehnströmBottom row: Hampus Persson and Anders Nilsson

CAD and calculations of the critical parts were made. Drawings were made for all parts and controlled before they were sent for manufacturing.

Results The final test unit is based on a concept using a rotational motion and shearing to cut through the top layer of the ground before performing an inverse ground preparation. The test unit is modular and has multiple adjustment possibilities to perform a variety of different field tests, to optimize the operation.

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ProcedureUnderstanding of forest regeneration was achieved by reading scientific articles, reports and interviews with scientists, entrepreneurs and machine operators in the forest industry. The collected information was used to specify the needs of the customers. Based on these needs, a product specification was generated to get a clear picture of what the finished product should be able to deliver. The concept development stage was iterated multiple times to achieve the best concept in order to fulfill all the needs. The final concept was designed in

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test rig with sensors, along with a digital twin in order to validate the simulation results of the forming and shearing processes and the material behavior. This knowledge could lead to an increase in tool life, or alternatively, proactive tool failure prediction in the production line.

ProcedureIn the beginning of the project, the group had a meeting at Husqvarna in order to

BackgroundHusqvarna’s first factory was founded in Huskvarna, Sweden, in 1689. The factory initially produced rifles and was powered by hydropower. In the beginning of the 18th century the company had over 1000 employees. Over the centuries the company grew, and production evolved into including sewing machine, bicycles, motorcycle, household appliance and boat motors. Experience in two-stroke engines from the motorcycle production was applied to chainsaws, and production of those started in 1959. After years of chainsaw development, the company expanded into producing chainsaw chains, and today, Husqvarna has a large factory dedicated solely to producing those.

ChallengeThis is Husqvarna’s first year involved in the Sirius project. The purpose of this project was to take the next step in understanding sheet metal forming and shearing for product and production development at Husqvarna. The goal was to have a working

Husqvarna Group is a global leading producer of outdoor power products for forest, park, and garden care. The company has a wide range of products such as chainsaws, trimmers, robotic- and ride-on-lawnmowers. Husqvarna has a long history of innovation; more than 330 years and the first factory was established in 1689. Nowadays, Husqvarna sells their products in over 100 countries and the group has over 13000 employees in 40 countries.

learn about the cutting process for saw chains. Then the group started working in three different areas; machine design, simulation, and sensors. Husqvarna and the project team created a product specification for all areas of the project which was used to evaluate concepts. The machine design group worked on concepts for how to change the geometry in the test rig and how to place sensors. Together with Husqvarna, one of the concepts was chosen

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Husqvarna Group

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for further development. Meanwhile, different kinds of sensors were evaluated, and the most appropriate ones were selected based on initial requirements. In order to produce accurate simulations of the cutting process, the group performed experiments to create an accurate material model, including material parameters describing failure-strain and post-necking behavior. Subsequently, this data was used to simulate the shearing process of the material. The performed simulation was later compared to the data obtained from the test rig to validate the results.

ResultsThe project resulted in a modular test rig with an easy-to-change cutting geometry. An integrated load cell, accelerometer, and laser triangulation sensor with a graphical user interface was also developed. The simulation resulted in a new material-failure-model, which can be used to simulate the blanking process.

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Top row: Filip Claesson, Axel Magnusson, Khashayar Shahrezaei, Felix KuiperBottom row: Jakob Lundin, Jamal Choudhry, Fredrik Saliba

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BackgroundSandvik Coromant has found a customer need that is not possible to solve with their current tool assortment. Today’s milling machines comes more and more oriented towards smaller and faster models to make the factories more efficient. This leads to limitations when it comes to the tool size in the magazines. This, in combination with the trend that electrical consumer products such as smartphones and tablets tend to get larger is the background for the identified need.

ChallengeTo develop a new concept that fulfils the identified needs requires innovation and precision. A brand-new tool solution, possibly with a moving mechanism must be developed, while at the same time main-taining tool performance expected by the customers. This interprets to a solution with high demands on reliability and tolerances. At the same time, the concept needs to be designed such that it is possible to manufac-ture at Sandvik Coromant’s current facilities while minimizing manufacturing costs.

Sandvik Coromant is the world-leading provider of machining solutions, tools and know-how to the machining industry. The company has over 70 years of innovation behind it and is continually pushing new boundaries as the market leader in the metal cutting field. Since 1942, the company has its headquarters in Sandviken, Sweden, which is an area known for its metalworking heritage. Now the company is represented in over 130 countries worldwide.

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AB Sandvik Coromant

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Top left: Simon Olofsson, Emil Jansson, Anna Martí Bigorra (coach), Joel Klippås, Fabian BorgedeBottom left: Simon Varedian, Lydia Linse, Erika Holmgren, Martin Wretlind

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ProcedureBased on the given project description requirements, and through surveys from milling machine operators, market needs were found, which were interpreted into a product specification. Several different methods and techniques were then implemented to generate different concepts that could fulfil the product specification. This led to several unique concepts that were evaluated and scored against each other to investigate which concept that best would fulfil the requirements. Eventually, two equally scored concepts were further developed since these were indistinguishable. Computer aided design, finite element analysis and calculations were used to develop the concepts. Also, the production team gave input in the design to optimize the concepts towards easier and cheaper manufacturing. Simultaneously, the production team also simulated the production line to find possible bottlenecks and be able to optimize the manufacturing process.

Top row: Nils Lindvall, William Hagberg, Mattias Karlsson, William Müller.Bottom row: Pontus Holmström, Daniel Gutiérrez, My Malmgren, Jenny Bolle

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ResultsThe project resulted in two concepts with different solutions that makes it possible to fulfil the identified demands. Verifications through 3D-models and finite element analysis have been made as a first test of the concepts. Prototypes has been manufactured for both concepts for further testing and evaluation.

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BackgroundScania’s ambition is to lead the way to cleaner, better cities by providing knowledge and transport solutions in urban environments. In support of this, Scania currently have numerous projects aiming to drive the shift towards sustainable transport systems. Already introduced to the market

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ScaniaScania is a global industrial manufacturer of heavy-duty vehicles, buses, coaches and engines for a wide range of applications, and aims to be the market leader in sustainable transport. Employing a total of 52,000 people worldwide, Scania has production units in Europe, South America and Asia, along with sales and service organizations in more than 100 countries. Research and Development is mainly based in Södertälje, Sweden, with around 3,500 employees. Scania defines the company’s culture and working methods through their core values: customer first, respect for the individual and quality. This guides them in achieving maximum value for all their stakeholders.

are hybrid trucks and buses which also are

capable to be operated on renewable fuel

thus enabling users to lower their carbon

footprint. In addition to this, research and

development of the future technology to go

fully electric are ongoing.

The shift towards more sustainable, elec-

trically-powered vehicles, bring about a set

of problems, which sometimes are of lesser importance when dealing with traditional combustion engine powered vehicles. One of the problems, as many are acquainted with, is the emission of pollutions into the atmosphere. Another, often overlooked, is the emittance of noise.

Current cooling systems for vehicles usually include a radiator, pump, coolant and a fan. The heat generated from the engine is transported to the air through the radiator, by the circulating coolant. This system generates noticeable noise and for urban environments, this is a problem to overcome.

ChallengeThe assignment was to investigate the general trends of sound properties emitted from a vehicle’s cooling system, which contains of a fan and radiator, with respect to its heat transfer performance. The task was also to explore the possibilities to improve the current cooling system for a given operational cycle.

Scania CV AB

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ProcedureDue to the complicated nature of the problem, an extensive pre-study was made to understand the causes of sound emittance from a cooling system. With the identified need, concepts were developed by various methods that stimulates innovation and out-of-the-box thinking. From this, initial ideas were investigated further by calculations and other evaluation methods, which resulted in a final concept. The design of the product was generated next, including components, dimensions and materials.

ResultsThe final concept was to use a heat absorbing material to allow for decreased fan speed which in turn lowers the sound production. 1D-calculations and 3D-simulations of current cooling technology, consisting of a radiator and fan, was used to predict sound characteristics by sweeping impactful parameters.

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Top: Victor AnderssonMiddle left: Tobias Eliasson and Tobias WikströmBottom: Máren Ingá Baer

Top row: André Medin, Oscar Selberg, Lucas Wernelind, Ivar RockströmSecond row: Johan Borgström, Joakim Stenudd, Jonathan MyrsellBottom row: Morgan Johansson, Lovisa Gren, Sandra Benzler

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BackgroundDuring their long history, Volvo CE have developed premium construction equip-ment such as their famous wheel loaders and articulated haulers. One of many workplaces where their wheel loaders and haulers can be seen are in quarries, where they are used to transport the gravel from the crushers to the piles and assist the trucks coming on to the site. To increase efficiency and profitability of these sites, its desirable to keep downtime at a minimum. A simulation

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Volvo Construction EquipmentVolvo Construction Equipment is a business area within the Volvo Group with history ranging back to 1832, when Johan Theofron Munktell opened an engineering workshop in Eskilstuna. Today Volvo CE is a global company that develops and manufactures equipment for the heavy equipment industry, an area in which they are world leading. Their products and services are offered worldwide and range from wheel loaders and excavators to pavers and forestry equipment.

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tool that could help foresee both changes of the site and service needs of the machines would be highly desirable to help the sites keep their downtime at a minimum.

Wheel loaders offers great versatility when it comes to moving large volumes of material and are commonly found in quarries. Quarries are often large and spacious allowing the often bulky wheel loaders plenty of room to maneuver. The distances travelled by the heavy machines

also result in exhaust emissions. To enable the versatility of the wheel loader to reach workplaces where room is scarce, such as urban environments, and to reduce emissions for a sustainable future, a more compact and efficient solution is sought after.

Buckets for loading materials are continu-ously developed by Volvo CE to be used by all their loading machines. This devel-opment process requires a lot of physical prototype testing to find improvements, taking up both time and money. With the rapid development of computing a way to test new bucket designs before prototyping using computers is desired to decrease development time and cost.

ChallengeThe challenge of this project can be divided into three parts. One being to simulate a quarry site and combine it with machine models to be able to foresee both how the site changes over time and monitor the con-dition of the machines. The second being to create a solution that has the versatility of

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a wheel loader that can operate in narrow workspaces. And lastly implementing simulation models to aid in development of new bucket designs by allowing quick and cheap virtual testing rather than time consuming and expensive prototype testing.

ProcedureA quarry was visited to get a clear understanding of the layout and processes that was to be simulated. A need finding for both the simulation tool and the machine was created through literature study and discussion with Volvo CE. A benchmarking was then performed to see which products are already available on the market. Using the collected data from the benchmarking and through dialog with

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Top: Victor AnderssonMiddle left: Tobias Eliasson and Tobias WikströmBottom: Máren Ingá Baer

Volvo CE, a requirement specification was produced to put metrics on the needs our solution had to fulfill. Thereafter, the focus shifted to concept development. In the early concept generation phase, the goal was to generate a wide range of different solutions. Thereafter, a few concepts were chosen and refined and were then compared to each other in a screening and scoring. Through this screening and scoring and discussion with Volvo CE, one concept was chosen to evaluate further.

ResultsThe project presents multiple results. A scale model of a machine with the versatility of a wheel loader but with the ability work in narrower workspaces and with improved

Front: André Väänänen. Second row from left: Pontus Persson, Karl Karlsson, Jim HanssonThird row from left: Martin Wadner, Julius Lundberg, Daniel Andersson, Jacob FagerströmTop from left: Hampus Gunnarsson, Tim Snell. Abscent: Anton Sundström

energy efficiency. The project also results in a proof of concept simulation model of a quarry and a gravel-bucket interaction model that computes force and fill parame-ters to evaluate a bucket´s performance.

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Top row: Kalle Rehnström, Viktor Risberg, Jakob Lundin, Pontus Holmström.

Second row: Viktor Åström, Emil Muhrman, Jonathan Jansson, Erik Ögren, Karl Holmqvist, Daniel Andersson, Tim Snell, Filip Claesson.

Third row: Edvin Björk, Anton Mukka, Andre Väänänen, Johan Borgström, Morgan Johansson, Axel Magnusson, Lucas Wernelind, Alex Oddsgård.

Fourth row: William Hagberg, Hampus Gunnarsson, Mattias Karlsson, Nils Lindvall, William Müller, Jacob Fagerström, Julius Lundberg, Samuel Hedström.

Fifth row: Ivar Rockström, Martin Wadner, André Medin, Joakim Stenudd, Pontus Persson, Oscar Selberg, Jim Hansson, Karl Karlsson

Sixth row: Hampus Persson, Jamal Choudhry, David Lohse, Khashayar Shahrezaei, Jonathan Myrsell

Bottom: Fredrik Saliba, Daniel Gutiérrez, Sandra Benzler, My Malmgren, Lovisa Gren, Jenny Bolle, Anders Nilsson, Felix Kuiper.

Absent: Erik Östensson, Anton Sundström

2019

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