Luleå University of Technology and industry partners in collaboration

Sirius 2006/07 is a collaborative programme involving Luleå University of Technology in collaboration with the Faste Laboratory partners Volvo Aero, Hägglunds Drives AB, Sandvik Coromant 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 know- ledge 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 engi- neers who are unbiased by traditional modes of thinking and problem solving.   Creative product development

Sirius is a final-year course for students in the development in teams, in collaboration with Mechanical Engineering MSc degree pro- manufacturing companies or based on real gramme at Luleå University of Technology. product development needs presented in Sirius is also open to final-year students from some other way. Experience from Sirius pre- other MSc engineering programmes at the pares the participants well for teamwork with university, thereby ensuring a broad base of colleagues from other disciplines. Students knowledge for the course’s project groups. also take courses in product development During most of the 20-credit course, product methods, computer-aided modelling and development projects are conducted in close analysis, and project management as a sup- national and international collaboration with port to their development projects. Sirius companies and universities. The aim of Sirius students engage in a valuable exchange of is for students to acquire, apply and integrate knowledge and ideas with graduate stu- knowledge considered essential for product dents and staff from the Faste Laboratory developers in modern manufacturing indu- and other departments of Luleå University stries. of Technology. Not only do Sirius students Students gain knowledge in project from Luleå University of Technology have management, production of creative con- solid theoretical knowledge, they also have cepts, mechanical engineering design and the benefit of valuable experience from computer-aided engineering, as well as com- work in an integrated environment applying mand of all stages in the integrated product methods and ideas from the research at the development chain, from needs analysis to division of Computer aided design and the For more information about previous Siriusprojects, the finished product. Under realistic indu- use of advanced computer tools in industrial please visit www.cad.ltu.se/sirius. strial conditions, they must carry out product projects.

  Concept Concept Needfinding generation evaluation

A user focus has come to dominate com- Needfinding. Needfinding implies the As Needfinding activities unfold, students Numerous concepts are created during the pany innovation strategies in the last interplay between needs and recognition. gradually perceive insights into people’s concept generation phase; approximately decade, though in reality involving users Observations, interviews and creative needs and concept ideas. To work out the 100-150 concepts are not unusual. This in product development is not as straight- methods are used to identify, analyse, ideas into comprehensible concepts, the vast amount of concepts has to be narro- forward as it sounds. People cannot always categorise and communicate needs to use of creative methods is emphasised. wed down into a manageable size during be precise about what their needs are; drive product development in SIRIUS The use of creative methods spurs a free a phase referred to as concept evaluation. they might just perceive a situation where student projects. The main principles mind and openness to new ideas, since Concept evaluation can be seen as activiti- satisfactory solutions are lacking. In such of Needfinding are to first be close to judgmental attitudes are not allowed and es that highlight some desired qualities in situations, it is naturally more difficult to the users and then look for needs, not all ideas are good ideas. The concept each concept and can be seen as a stage in identify these needs. Needs obviously play solutions. This keeps the early phases of generation phase has a focus on quantity, the design process where the design space an important role in innovative or radical product development open to unexpec- i.e. as many ideas as possible. Examples is narrowed down. The aim is to extract product design, since the starting position ted insights and supports the generation of creative methods are brainstorming, a few concepts that best fulfil the needs in includes no existing solution. of numerous concept ideas. In turn, this method 653, brainwriting, bodystorming, focus and are feasible to be further deve- Thirty years ago, Robert McKim, broadens the design space and the opp- and de Bono’s six thinking hats. The use loped into a product. However, to build the head of Stanford University’s product ortunities for innovative products. This of creative tools, e.g. method cards and upon crazy ideas from the concept gene- design program understood that engineers contradicts a problem-solving approach thinkpak, support thinking outside the ration, the concepts have to be described had to be involved during the earliest sta- of product development, where reducing box and using all senses to be creative in more concretely. ges of product development to understand the number of concepts as early as possible the concept generation activities. needs. He developed an approach, named is important. Needfinding is part of the Concept generation is, in particular, SIRIUS guideline that provides students highly iterative. The generation activi- with capabilities beyond classical engine- ties occur on different levels throughout ering design education. The insights into the entire product development process needs provide a solid ground for the acti- as the product becomes more mature. vities in concept generation, concept eva- luation, detail design and product launch, which are also main parts in the SIRIUS guideline.

  Product Detail design launch

A first round of evaluations can be After iteratively framing and reframing Completing the whole product deve- sell and explain their ideas. Hence, ideas performed, for example, by using creative the concepts in the evaluation phase, a few lopment process from identifying and and concepts are continuously presented tools where the focus is on judging the concepts are chosen for further develop- understanding needs to product launch is to industry partners, teaching staff or both value of the idea. During the later stages, ment. Detail design is a stage where the a basic principle in the SIRIUS guideline. during the whole course. At the end of the measurable criteria and matrix-based met- concepts become more explicit in terms of The SIRIUS student projects are per- course, a public event where the student hods, e.g. House of Quality and Pugh’s solutions and functionality. Still, the cho- formed under realistic conditions, most projects are presented and the products matrix, are used. Small models or prototy- sen concepts are at various stages of com- of which are a collaborative effort with are shown takes place. This is a day when pes may be used to test if a concept should pletion. Therefore, a range of approaches companies. Therefore, the expectations many students are pleased to show what be further developed. The idea here is to are used. Computer aided engineering and on the products are high. Several products they have achieved, and when the SIRIUS keep the prototype as simple as possible, design tools such as multi-body dynamic developed within the SIRIUS course are course personnel are full of pride for their since only particular concepts should be analysis and finite element analysis are further developed and implemented by students. tested. Concept generation and concept used, along with engineering design met- the companies. Not only is it important to evaluation are closely related phases and hod and methodologies, e.g. case based design a competitive product in terms of are used to narrow down and open up reasoning, knowledge based engineering, design, ergonomics, aesthetics, etc., but it the design space. The results from the and industrial design approaches. The is also important that the students have the Needfinding activities, i.e. the needs in SIRIUS course encompasses a diversity possibilities to train their capabilities to focus, are used in the evaluation activities of products to be developed; thus, what to, for instance, judge a user perceived approach or approaches are used depends value of the concept. on the focus in the student project.

  Sirius 2006/07 Product development projects

CLAMPING SYSTEM REDEFINING THE FOR FACE MILLS SLEEPING EXPERIENCE SANDVIK COROMANT VOLVO AERO Due to minor development of new tech- Together with the company the students During development of a new jet engine, nology in the field of spring units, students developed a new clamping system for car- Volvo Aero discovered a need for an from LTU were given the assignment to bide inserts clamped in a cutting position in improved Variable Bleed Valve system. develop an IKEA-unique spring unit for face mills using a knowledge engineering The system is supposed to prevent the mattresses. The new spring unit should approach to use in future delvelopments. engine from stalling. Students from LTU offer improved comfort and quality as well were given the task to develop a concept as permit a cost reduction. limited by weight, cost, materials, durability FORMULA SAE and several different load cases. This year the students have advanced the NEW INNOVATIVE last year’s car with a focus on evaluation in BRAKE CONCEPT order to get an overview of how to design HÄGGLUNDS a more reliable car. In July the Formula SAE DRIVES AB team is going to Silverstone, England, to A student design team has developed a measure their engineering skills and com- completely new and cost-efficient com- pete against universities from all over the bined emergency and parking brake for world. This event challenges participating Hägglunds Drives’ hydraulic motors. The teams to be creative and innovative, while design project involved building a full-scale at the same time manage time, weight and prototype and running tests on it. cost issues.

  Sirius success stories

New innovative brake concept HÄGGLUNDS DRIVES AB has been involved in the Sirius – course since 2003/2004. The projects, that all have been successful in different ways, have reached from optimizing high-performance hydraulic pipes, developing and improving new hydraulic pumps with higher efficiency to completely new concept of emergency brake systems for the hydraulic motors. Taking part in the Sirius course is a possibility both for Balancing on site students, the university and for Hägglunds Drives. Hägglunds ALSTOM POWER SERVICE participated in the 2004/2005 year Sirius Drives is given the possibility to try out new ideas and also gain course. Alstom Power Service performs maintenance and experience of using new methodologies and work methods. upgrade work on generators used to produce electricity in power Highly competetive intermediate case New product concepts are created by unbiased students that plants. The challenge for the balancing on site project group was VOLVO AERO has participated in the SIRIUS activities every year look at the task at hand from different perspectives, with a posi- to develop a tool for balancing a rotor in-situ on site instead of since 2001/2002. The best example so far is from the 2003/2004 tive attitude and a diversity of knowledge. This is an asset for shipping it to a service facility. To balance a rotor on site, balanc- project when we explored the possibilities of using polymer Hägglunds Drives which, in return, have the opportunity to ing weights needs to be transported through the narrow air gap composite materials for load carrying jet engine structures in provide students with interesting master’s thesis projects and between the stator and rotor and mounted in a balancing hole. the cold, forward part of the engine. The work comprised mate- also the possibility to employ students that are familiar with The project started unbiased and resulted in a first prototype rial, manufacturing and design issues and resulted in a patent on Hägglunds Drives products and way of work. of a tool that mounts balancing weights with the rotor in-situ. metallic engine mount integration in a composite structure. The The close collaboration with Luleå University of Technology At remote locations the new invention can significantly reduce final results indicated that we were able to reduce the weight of a and the SIRIUS course also results in ideas to new research the outage time and hence increase the customers’ profit. typical titanium component with 30%. projects that in the long term enhance Hägglunds Drives com- Two students from the Sirius project group continued with The promising results from the project motivated Volvo Aero petitiveness and an edge in our domain of expertise. their master’s thesis at Alstom to further develop the mounting to enter into a collaborative European research project, VITAL, tool and making it more reliable. The new improved mount- where one of the areas to be developed is composite technology ing tool was tested in a real application with satisfactory result. for cold jet engine structures. The final deliverable will be a full The project has also resulted in two patent applications. The first scale demonstrator component taking part in a fan blade out test commercial application of the tool is currently being investigated. at Rolls Royce. Today two students from the Sirius project group are This concrete example proves that the SIRIUS course has employed at Alstom as design engineers. been, and still is, is an important stepping stone towards improved competitiveness for Volvo Aero.

  To stay ahead in a high-tech market with ever-growing competi- tion, companies like Hägglunds Drives AB need to continuously update and improve or replace their components. In this case, they needed to cut manufacturing costs and enhance the techni- cal performance of their MDA brake series. The task this year was to follow up last years work by designing a completely new and innovative brake to replace the MDA brake. Students working in actual 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.

Background Hägglunds Drives AB is a Swedish company motors. The brake is a crucial system com- specialized in delivering complete high torque ponent that works as a backup if the main hydraulic systems. A design team of seven system fails. The main objectives this year students worked with Hägglunds Drives for were to run a series of full-scale tests on a nine months to develop a new brake for their prototype brake. Other objectives were that Compact-series of hydraulic motors. the brake had to be fail safe, fatigue safe for pulsating force, have an activation time of less Assignment than 0.2 seconds and deliver a constant high This year’s assignment from Hägglunds torque (approximately 50,000 Nm) when acti- Drives AB was to continue last year’s work by vated to meet the demands. Lowering manu- facturing costs is also a goal, which means a building a combined emergency and park- OSKAR WESTBERGH, JOEL ANDERSSON, JOHANNES NORBERG, TOBIAS LÖÖF, ing brake for their Compact-series hydraulic more compact design containing fewer parts. JONAS BYSTRÖM, FREDRIK AHLQVIST.

  Computer aided design Since a full-scale prototype was to be manu- like pressures, rpm and position to validate Hägglunds factured, design for manufacturing were our theoretical values from dynamic and FEM Drives AB keywords. 3D-models were created in UGS simulations. The group members developed More than an ordinary NX4 and optimised in terms of strength and their ability to function as part of a project drive supplier. size using the built-in FEM-module in NX4 team with given roles and individual fields DUSTIER. DIRTIER. HARSHER. HEAVIER. and MSC.Marc. To test the function of the of responsibility. Close cooperation with an The worse it is, the better equipped we are. brake, dynamic and static simulations using international company such as Hägglunds After more than four decades of supplying MSC.Adams were conducted. The proto- Drives AB provided the students with valua- drive systems for heavy industrial applications, type was manufactured using only digital ble insight into the complexity of an industrial Hägglunds is accustomed to difficult demands. models. The manufacturing company used product development process. We provide what you need to get the toughest jobs done right – no matter how harsh the environment CAM software to translate our models into or how specialised the task. machine code. The use of an online meeting centre, where pictures and simulation results PERFORMANCE. FLEXIBILITY. SECURITY. Hägglunds unique hydraulic drive systems – combined could be uploaded, together with regular with our wealth of experience – provide advantages telephone conferences made the physical no other drive supplier can match. distance between Hägglunds Drives AB and With Hägglunds drives on your equipment, you receive: the design team less of an issue. • Maximum torque from zero speed.

• High performance regardless of conditions. Results • Precise control of infinitely variable speed. The team continued the work of last year’s • Standardised modules for design freedom. • Smaller, lighter, more effective installations. group by refining their brake design. The • Superior protection of equipment and processes. brake was designed for manufacturing, using only digital models. A local manufacturing HERE. THERE. EVERYWHERE. A global leader in industrial drive solutions, company used the digital models to manu- Hägglunds has offices in nearly twenty countries facture the brake with CAM software without and distribution partners in many more. We are any traditional two-dimensional drawings. where you are – with short lead times and The tests were run on a prototype with com- fast, comprehensive service that answers puter logging sensor-values on crucial data your needs. OUR DRIVE IS YOUR PERFORMANCE

  Sandvik Coromant strives to increase productivity and reduce costs for their customers. In this Sirius project, students at LTU in collaboration with Sandvik Coromant have developed the clamping systems of tomorrow.

Background Assignment of clamping systems. Precision in positioning processed into a specification of require- Sandvik Coromant, with headquarters in Numerous metal cutting tools use inserts and easy change of inserts have been key ments, which served as the base from brain- MODIFY INSERT TO A PROTOTYPE Sweden, is an international leading tooling clamped in a cutting position. The task of throughout the project. storming workshops where ideas for the new company specialized in the development and the project was to develop a new clamp- milling clamping system were generated. The manufacturing of cutting tools for the metal- ing system for face milling together with Design process ideas from the brainstorming sessions were working industry. Sandvik Coromant is part of designing support tools to store knowledge The project group started collecting the composed into six different concepts. the Sandvik group, a global industrial group generated within the assignment. The design necessary information through need finding The project group used a CAD program with 42,000 employees in 130 countries. support tools enhance future development by asking customers. This information was to build virtual models of the concepts.

10 11 Sandvik Coromant OSKAR VESTERMARK, ALEXANDER LINDBLOM,

MATS OLOFSSON. JONAS HELLSTRÖM, Winning inserts ANNA KARLSSON, HELENA PÄBEL. Sandvik Coromant is the internationally leading name when it comes to solid

carbide tools for turning, milling and drilling, as well as modular tooling sys-

tems for turning and multi-task machines. With about 7,000 employees, Sandvik

Coromant is represented with sales and specialist personnel in over 60 coun-

tries. There is also a well-developed network of retailers.

With a business idea to help customers lower their manufacturing costs and

improve profitability, customers and Sandvik Coromant personnel are continu-

ously educated in tooling solutions for increased productivity at 20 well-

equipped Productivity Centers worldwide.

Sandvik Coromant is a part of the Sandvik business

area Tooling and has business operations in four

locations in Sweden – head office in Sandviken,

manufacturing in Gimo, Norduppland, research and devel-

opment in Västberga, Stockholm and a Swedish retail office in Kista.

97% of Sandvik Coromants sales are outside of Sweden.

Calculations were made to ensure the func- knowledge within the project was document- program to predict forces, for use in the early tion of the clamping systems. The different ed and used with Maple and Microsoft Excel stages of product development, was gene- concepts were evaluated through Pugh’s to create design support tools. rated. The main concept matrices in terms of performance, cost, was manufactured function, etc. In collaboration with Sandvik Results in a production Coromant, two of these concepts were cho- The main concept extended an existing unit of Sandvik sen for further development. Simulations in solution by making it more user-friendly and Coromant. dynamics and strength were carried out dur- solved the positioning request. The other ing detail design. Physical prototypes were concept reduced the number of parts. The

created at Luleå University of Technology’s design support tools were primarily created machine park to ensure that the clamping for the main concept and consisted of com- systems actually worked. All generated puter programs and manuals. One computer

10 11 The Formula SAE team has advanced last year’s racing car for the Formula Student competition in Silverstone, England. To compete successfully in England, the car has to gather points in various areas. This challenges participating teams to investigate and eval- uate previous cars and then use their engineering skills to design and build an advanced car.

Background car should not exceed 195 kg and accelera-

ANDREAS HELLMAN, ROBERT LUNDQVIST, ELIN STRÖM, MAGNUS SUNDIN, Formula SAE started in 1981 in the USA as tion from 0-75 metres should take no more MIKER FRANTES, EMIL HEDLUND, MARKUS NILSSON. a competition for students to compete in than 4.1 seconds. An overall top-3 finish in engineering and design. Today, the competi- class 1 (200 series), a better economical

tion is global and every year hundreds of strategy and a higher theoretical knowledge teams from all over the world enter one or of the car were additional goals. more of the six events held in Australia, Italy, Germany, Great Britain and the USA. Formula Development Student in England is the competition where The first step for the team was to decide upon LTU has participated with five previous cars. areas of responsibility, namely Project leader, Engine, Subframe, Ergonomic and design, Assignment Chassie, and Manufacturing. Each person in The main goal was to improve last year’s car, charge of the different areas estimated how by making it stiffer and more reliable with a much their changes would cost and together greater focus on strength. The weight of the the team developed a budget.

12 13 Students from other parts of LTU were To develop these parts, the use of Computer Sponsorer 2007 recruited to handle the electronics and web- Aided Engineering enabled the team to simu- LULEÅ UNIVERSITY OF TECHNOLOGY BAE SYSTEMS HÄGGLUNDS page. Early in the project the team made a late, for instance, multi-body dynamics and SCANIA detailed time schedule for each responsibility FEM as well as allow the use of Computer SANDVIK COROMANT area with milestones according to the Sirius Aided Manufacturing. Fabrication of the car HENKEL masterplan. involved welding, milling, turning, and carbon LULEBO This project differs from the other Sirius fibre moulding, which was a new experience CARAN projects lacking a single large company where the students learned how to fabricate SVERIGES INGENJÖRER sponsor, thus the support from several spon- carbon fibre sandwich structures. LULEÅ KOMMUN UDDEHOLM sors was a necessity to maintain budget. Results PERMASCAND Step two was, therefore, to search for poten- were designed in close cooperation with The most distinct feature of the car is the car- ATMEL tial sponsors. To save critical time this task the Department of Computer Science and ACCURATE TECHNOLOGI bonfibre monocoque chassis that is manu- took place during the concept design and Electrical Engineering at the university. Some STATOIL factured with a prepreg carbon fibre material, prototyping phases. The main changes to the of the features include an inhouse engine ALKIT COMMUNICATION AB i.e. the same technology used by Formula1 car are to improve: management, wireless telemetry, automatic COMPANY LINE teams. A benefit of using a monocoque chas- • Subframe –new stronger steel pipe gearshift, launch control, traction control, SAMCO SPORT sis is that many features can be integrated CRC INDUSTRIES solution front-to-rear brake ratio and inertial measure- in the same part, such as load bearing MEXOR • Monocoque –stiffer with a new core and ment unit. structure, exterior bodywork and mounts for NOMO KULLAGER more layers of carbon fibre Finally, the team would like to thank all DIAB subcomponents. • Front and rear suspension – improve the sponsors (see the list on the right) and SWEBOLT Most suspension components were driver handling of the car companies that have supplied the team SIEVI milled and turned by the students themselves • Pedal rack –stronger and stiffer design with parts, knowledge, and time. SMURFIT KAPPA in Uddeholm Alumec aluminium. Other parts with aluminium This project is dependent on all of their LAGOTECH AB were sent out to various companies and SICOMP • Steering wheel –make an ergonomic resources and expertise. We are confident production students at LTU to save time. The design with improved interface that the car is going to be highly competitive. team used materials with high strength, low • Nose cone –a different radius to comply Read more about the project at weight, and good detail finish, resulting in with the rules www.formulasae.ltu.se high quality components. • Noise level/ muffler –has to be less than The electronic systems on the car 110dB

12 13 BOEING 787 DREAMLINER

Volvo Aero has been developing complex engine structures for the Boeing 787 and Airbus A350. One of these structures is the Fan Hub Frame. During its development new technolo- gies and concepts were identified, but not all of them could be realised in the series version.

Background Introducing new technologies and concepts ods. The goal for the construction is to use a such as Multi Body Dynamics and Finite and realising them when upgrading existing mechanism to bleed air past the compressor Element Method and Durability analysis, were and future engines is critical for Volvo Aero’s and prevent the engine from stalling. The sys- used to ensure proper function. The project competitiveness. One of these technologies tem is limited by weight, durability, materials material was shared using online workspace is the Variable Bleed Valve system (VBV), and several different load cases. that allowed all involved personnel to be up to located in the Fan Hub Frame. The VBV sys- date during the different phases. tem regulates the incoming airflow to the Method High Pressure Compressor by send- The project was initiated from a thorough Results ing a large amount of air into the needfinding to really understand the func- A virtual prototype was created, showing the bypass air. tion of the jet engine and survey the needs. function of the concept and analytical verifica- Several design ideas were generated using tion of the parts in the system. The prototype Assignment different methods, such as brainstorming. shows Volvo Aero a concept that consists of The main focus of the project was to con- Together with Volvo Aero these ideas then fewer parts and is a less complex mechanism. struct and evaluate a new VBV system evolved into concepts that were selected for There is some hope to implement the concept FINITE ELEMENT ANALYSIS OF

A DETAIL IN THE CONCEPT through new innovative engineering meth- further analysis. Several different techniques, in the next generation of jet engines.

14 15 JOHAN OLSSON, PATRICK SANDLUND, ERIKA Volvo Aero ANDERSSON, HENRIK VUOPIO, MIKA TUULIAINEN.

SIMON SAMSKOG, ANDREAS EKHOLM. Volvo Aero develops and produces components for com-

mercial aero, military aero and rocket engines with a

high technology content, in cooperation with the world’s

leading aerospace companies. Service and maintenance

is an important part of our operations. 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.

The team consists of seven members from different backgrounds and with different experience, providing the team with a wide range of knowledge that has proven to be val- uable for a project of this kind. Together with an international company such as Volvo Aero the students gained valuable knowledge in the product development process. In May 2007, one final concept satisfying the requirements was presented to VAC. The concept was sent to Volvo for further valida- tion and testing.

3D CAD MODEL SHOWING PARTS OF THE CONCEPT

14 15 There has been minor development of new technology in the field of spring units. The first spring unit, made with Bonnell springs, was introduced in late-19th century and over 100 years later, only a few innovations have emerged. What will the next generation of spring units look like?

Background Assignment IKEA has developed a wide range of mat- The assignment from IKEA of Sweden AB tresses throughout the years. They previously was to develop an IKEA-unique spring unit had a basic range of mattresses as a com- for mattresses. The new spring unit should plement to the bed frames. Their mattresses have improved comfort and quality and per- are today sold worldwide and spring units mit a cost reduction. are one of the main components. It is and always has been a goal for IKEA to exceed Analysis the expectations of their customers regarding What is comfort? Very little research has comfort, quality and price. This is where we, been done on sleep and sleeping qual- the Sirius IKEA Comfort group, come in. ity because the sleeping environment is considered to be private. Hence, to find out Results more, a mattress blind test was performed. After the selection, three of the concepts The research done by the SIRIUS Comfort remained for the final stage, where digital group showed that comfort is perceived to models of the design were evaluated in a be rather individual. Since a huge quantity of virtual environment and real live tests were mattresses will be produced, manufacturing performed to investigate the durability of dif- and storage are also important factors. ferent materials used in the concepts. Is it possible to satisfy all the different needs At the end of May 2007, the complete in one spring unit? and optimized design concepts were pre- The results from the Needfinding served sented to IKEA of Sweden. It is not yet known as a basis when specifying the design if this is the next generation of spring units, requirements. Design concepts were gener- but you might be sleeping in a bed partly ated through various brainstorming sessions developed by the SIRIUS Comfort group in and other creative methods, and mock-ups the future. were built to illustrate and evaluate the char- The close cooperation with an interna- acteristics of the different concepts. After tional company such as IKEA has provided several evaluation steps based on the design the students with valuable insight into the requirements, the number of concepts was complexity of a product development pro- reduced in preparation for concept selection cess. in consultation with IKEA. The Faste Laboratory Centre for Functional Product Innovation

In June 2006, Luleå University of Technology Functional Product Innovation and the Department of Computer Aided A perspective of sustainable Design in collaboration with the Division of society forces industrial deve- Fluid Mechanics, the Division of Mechanics of lopment into new ways of Materials, the Division of Solid Mechanics and the conducting business. For Division of Entrepreneurship were informed that manufacturing companies, VINNOVA, the Swedish Agency for Innovation a way forward is to develop Systems, had granted the application to start a Vinn physical artefacts to provide Excellence Centre. The Centre, named The Faste functions that can be sold as services. Laboratory, is in memory of Rolf Faste, Standford A long-term service contract means that the University, and has goal to realize Functional provider is responsible to deliver these functions Product Innovation through research and edu- throughout the life cycle of the cation in collaboration with both academia and product. The product provider is industry. Research and education are joined in responsible for all costs to devel- the SIRIUS course. op, manufacture, support and Industrial partners are: continuously upgrade the prod- • AB Sandvik Coromant (SC) uct. Hence, how to reengineer, • BAE Systems Hägglunds (BAE) reuse and recycle the product • Gestamp HardTech AB (GHT) becomes important. • Hägglunds Drives AB (HD) • LKAB (LKAB) pia sandvik wiklund, the president of luleå university of technology, • Metso Panelboard (MP) at the faste laboratory inaugural • Volvo Aero (VA) speech. • Volvo Car Corporation (VCC) • Volvo Truck Corporation (VTC)

The Faste Laboratory formally opened March 12th, 2007.

18 19 professor lennart karlsson, division of computer aided design and the faste laboratory, luleå university of technology

The vision of the Faste Laboratory is: and technical oriented terms, design teams to Functional products can be developed and offered work closely together by means of methods to the market with known risk, lower total cost, and tools. less environmental impact and will include better • Simulation Driven Design – contributes to customer value than traditional products. bringing several perspectives (e.g. business, engineering and production) into early con- Central in this mission are insights into these areas: cept design in product development. • Functional Product Development – contri- butes to the area of new processes for engi- Funded by the Kempe Foundations and the Knut representatives from luleå university of technology and industry at the faste opening. neering design. Closely related to the concept and Alice Wallenberg Foundation, a research stu- all persons without company name are ltu personnel. of Knowledge Enabled Engineering, i.e. dio was designed and built at LTU. This studio will staffan lundström, mats oldenburg, lisbet markgren, ove isaksson, peter jeppsson, martin jonsson sharing, managing and using knowledge relat- provide unique access to empirical studies, testing (gestamp hardtech), jörgen hansson (volvo), ola isaksson (volvo aero), joakim wincent, ed products and process throughout the entire and evaluation of new methods and tools in dis- k-g forsberg (bae systems hägglunds), christer eberger (bae systems hägglunds). anna dahlstedt (lkab), mats näsström, mats nytorp (hägglunds drives), pia sandvik wiklund, life cycle. tributed work. The use of the studio will contrib- margareta groth (vinnova), lennart karlsson, mats westerberg, magnus wiktorsson (vinnova), • Distributed Collaborative Engineering – ute to research within the Faste Laboratory. martin helgoson (sandvik coromant), Magnus Karlberg. ylva fältholm, lars andersson (volvo cars), karl-david pettersson (volvo aero), vahid kalhori contributes to the area of enabling, in work (sandvik coromant).

18 19 Industry and academia in collaboration

Panos Plegas, Kajsa Dymling Senior Vice President Sirius Engineer 2003/04 Engineering and Technology Volvo Construction Volvo Aero Equipment

The SIRIUS project is a key ingredient in Volvo Aero’s "Our job is to give the client on time and on cost not what he wants but strategy for long term competitiveness by implementing what he never dreamed he wanted and when he gets efficient engineering methods as well as developing people it he recognises it as something he wanted all the time." and competence on all educational levels. The project has for Denys Lasdun several years proven to contribute to our innovation process This quote summarizes my SIRIUS experience pretty well. in exploring new product ideas at the same time as it has As most engineers I immediately started to think about solutions, given us good opportunities for trying novel computer aided but this final year course tought me the importance of engineering methods. In addition to methods and technologies focusing on needs. My experience is that the client can we appreciate the former SIRIUS students that we have been not always put in to words what he wants, but he will able to recruit for master thesis work, research collaborations or try and that has a tendency to narrowing down the employment over the years. Today, 6 years after Volvo Aero’s scope which can lead to solving the wrong problems. first SIRIUS project we regard our involvement here as a success. Needfinding and preserving ambiguity in combination Many of the SIRIUS results have contributed to our engineering with innovation is the winning formula that I bring methods and our concepts for the next generation of space and with me from the SIRIUS recipe. aircraft engines. Since I ended SIRIUS I have had the opportunity to work as a research assistant at the university, with IKEA of Sweden, as a product technician at the sleeping and storing department and now as a product developer within the Young Professionals Program at Volvo Construction Equipment. There is not a day that goes by where I don’t use the tools and/or the network that SIRIUS has provided me with. Per Nordgren, John Kapla, President Sirius Engineer 2003/04 Hägglunds Drives AB DaimlerChrysler

The Sirius projects have given us at Hägglunds Drives a very I came to the Sirius program as an exchange student valuable opportunity to test and work with new product devel- from the USA with a desire to learn, grow and experi- opment methods through the use of simulation tools during the ence the product design process. Well, I experienced early concept phase of product development work. It has also that and much more. been fruitful in obtaining new concept ideas that we have been I was a part of an international team consisting of students from able to evaluate. The interest and dedication combined with a both Luleå University of Technology and Stanford University. very open-minded approach from the students have led to several We collaborated on a mobility device and accessories for people new interesting ideas for future products. At the same time, the with disabilities with winter use in mind. students have gotten the chance to understand the customers’ The project was amazing and provided hands-on exposure to requirements and the customers’ demand for increased perform- the design process. Not only was the team faced with the chal- ance and productivity. Hägglunds Drives is always focused lenges of learning a new method, we were also faced with the upon fullfilling these demands with our products and services. obstacle of collaborating over a vast distance. Sirius aided us by For us within industry, it is important to have close cooperation providing distributed engineering tools. With video conferenc- with universities and thereby get ideas that both parties can utilise ing and an array of other tools we tackled the task head on. Our in future research projects, where the research is more final product was inspirational to me and really pushed me to fol- basic or more applied. The Sirius project is an excellent low this product design path in my career. way for us, in our long-term view, to work From Sirius and my international exposure I had no and recruit top talent, and to find very problem obtaining the job I wanted. I currently work for good candidates as future co-workers. DaimlerChrysler on their Advanced Vehicle Concepts and The Sirius students have shown that they Innovation team. My group not only designs and innovates the are very competent and motivated to concept vehicles but also the new gadgets and features that go take on new challenges. into them. Sirius exposed me to the design process that I needed to succeed. Next stop, we shall soon see! Industry and academia in collaboration

Magnus Ekbäck, Malin Ludvigson Vice President R&D Sirius Engineer 2003/04 AB Sandvik Coromant Volvo Aero

Sandvik Coromant has had common research activities During the year 2003/04, I participated in the SIRIUS with Luleå University of Technology for almost 15 years. project Design for Wellbeing- CRE[ATIVO]2. That year The Polhem Laboratory followed by the Faste Laboratory a lot was of fun, but also a lot of hard work. and other joint activities has made Luleå University of CRE[ATIVO]2 was an international project where students Technology an important partner in supporting us in from Luleå University of Technology and Stanford developing knowledge and skilled students. University developed a lightweight composite wheelchair The Sirius program is a natural continuation and exten- with accessories for winter use. I gained invaluable sion of this long term cooperation with Luleå experience through working in an international product University of Technology. development project, especially the importance of good As we continuously strive to develop our way of work- communication. Through weekly videoconferences and team ing in product development and technology research, meetings we kept in contact with our four colleagues at Stanford the Sirius Project contributes with students and tutors University. full of ambitions, knowledge and willingness to learn. I’m currently employed as a Trainee at Volvo Aero. This presents an additional opportunity for us to establish long- The trainee program has given me holistic view of the company lasting relations with the coming engineers as well as research- and the opportunities for my professional and personal growth. ers that could collaborate in different industrial and academic During the trainee program I was asked to be networks together with Sandvik Coromant in the future. We a half-time coordinator for this year’s VAC- SIRIUS project, also hope that we can give the students an interesting view of and I accepted, of course. This has provided me the possibilities industrial operations in an international environment to create an to keep in contact with LTU as well as gain tremendous energy understanding and exciting experiences to enhance their interest from the engaged and motivated students. for mechanical engineering and advanced methods in product Sirius was the perfect final year course for me. A course development. where I could practically use the knowledge I gained throughout my years in Luleå. The SIRIUS experiences have and will con- tinue to benefit me for a long time, both personally and profes- sionally. 22 23 Sirius students 2006/2007 FOTO: ATELJÉ GRODAN, LULEÅ

Top row, from left: Alexander Lindblom (Sandvik Coromant), Andreas Ekholm (VAC), Antti Wikström(IKEA), Susanne Pettersson (IKEA), Andreas Lantto (IKEA), Andreas Hellman (FSAE) , Helena Päbel (Sandvik Coromant), Stefan Sandberg (Advisor), Henrik Nergård (Advisor)

Third row, from left: Lennart Karlson (Professor), Jonas Lundmark (Advisor), Mats Olofsson (Sandvik Coromant), Fredrik Ahlqvist (HDAB), Nicklas Eriksson (IKEA), Miker Frantes (FSAE), Jonas Hellström (Sandvik Coromant), Pehr Hopstadius (Sandvik Coromant), Patrick Sandlund (VAC), Joel Andersson(HDAB), Robert Lundqvist (FSAE)

Second row, from left: Mikael Nybacka (Advisor), Andreas Gustafsson (HDAB), Tobias Lööf (HDAB), Mika Tuuliainen (VAC), Simon Samskog (VAC), Markus Nilsson (FSAE), Magnus Sundin (FSAE), Jonas Byström (HDAB), Johan Olsson (VAC), Peter Törlind (Advisor) 22 23 Bottom row, from left: Johannes Norberg (HDAB), Emil Hedlund (FSAE), Oskar Vestermark (Sandvik Coromant), Anna Karlsson (Sandvik Coromant), Ida Wikström (IKEA), Erika Andersson (VAC), Therese Eliasson (IKEA), Elin Ström (FSAE), Gustav Nordström (IKEA), Henrik Vuopio (VAC), Oskar Westbergh (HDAB). Absent: Marcus Sandberg (Advisor) GRAFISK FORM: FORMIDABEL + STILETT, LULEÅ. FOTO/BILDREDIGERING: MAGNUS DEGERMAN. ILLUSTRATION: STILETT, HENRIK NERGÅRD & STUDENTER, LTU. TRYCK: UNIVERSITETSTRYCKERIET, LULEÅ 2007. LULEÅ UNIVERSITETSTRYCKERIET, TRYCK: LTU. STUDENTER, & NERGÅRD HENRIK STILETT, ILLUSTRATION: DEGERMAN. MAGNUS FOTO/BILDREDIGERING: LULEÅ. STILETT, + FORMIDABEL FORM: GRAFISK

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 2007

FINAL-YEAR COURSE IN MECHANICAL ENGINEERING DESIGN IN THE MECHANICAL ENGINEERING MSc PROGRAMME AT LULEÅ UNIVERSITY OF TECHNOLOGY