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Examensarbete Maskiningenjör 180 Hp Examensarbete Maskiningenjör 180 hp Konceptutveckling av ett förband/koppling I samarbete med Koenigsegg Automotive AB Maskinteknik 15 hp Halmstad 2021-06-01 Tobias Frank och Andreas Essunger Förord Examensarbetet i maskinteknik på 15 hp har utförts vid akademin för företagande, innovation och hållbarhet vid Högskolan i Halmstad. Studenterna kommer från Maskiningenjörsprogrammet med inriktningen Produktionsutveckling och har under våren 2021 samarbetat med Koenigsegg Automotive AB. Vi vill börja med att tacka Koenigsegg Automotive AB för den unika chansen och möjligheten till att utföra detta intressanta examensarbete. Ett stort tack ska riktas till vår kontaktperson på företaget, Johan Wretborn för givande och intressanta diskussioner under projektets gång och våra varannan-vecka sessioner. Vi vill även rikta ett stort tack till vår handledare från Högskolan i Halmstad, Håkan Petersson som har varit till stort stöd under projektets gång med nyttig feedback och värdefull information. Halmstad, Maj 2021 Tobias Frank & Andreas Essunger Sammanfattning Genom att kombinera traditionell förbränningsmotorteknik med elmotorer kan Koenigsegg Automotive AB dra nytta av vissa fördelar som uppkommer med den här typen av konfiguration, fördelar som sedan kan implementeras i deras supersportbil, Regera. Exempel på en fördel är att förbränningsmotorn kan skalas ner, vilket ger en betydande viktbesparing, men ingen vidare kompromiss på den totala effekten som resultat. Ett annat exempel är att elmotorns karaktär av ”direkt kraftöverföring” kan nyttjas vid en häftig acceleration där en konventionell bensinmotor har en viss fördröjning. Syftet med det här examensarbetet har varit att utveckla ett koncept för ett vridmomentsöverförande förband/koppling. Projektet grundar sig i att dagens förband mellan de olika motorerna tenderar att stämma in på varandras egenfrekvenser, vilket under vissa förhållanden leder till en amplitudökning av vibrationer. Detta ger i sin tur ifrån sig missljud och i förlängningen kan detta leda till att förband utmattas och så småningom leda till brott. Likväl ska företaget även ha möjligheten till att använda konceptet på andra punkter där de idag också använder sig utav bomförband i bilen. Arbetet i detta examensarbete har avgränsats till att enbart behandla konceptutvecklingsprocessen av förbandet/kopplingen. Målet med projektet är att det färdiga konceptet skall tillfredsställa samtliga krav bestämda av produktspecifikationen, detta ska realiseras av en konceptutvecklingsprocess, CAD-modellering och en simplare konstruktionsanalys av konceptprototypen. Utifrån litteraturstudien identifierades de främsta orsakerna till problemet. För att finna ett lämpligt koncept framställdes fem förslag på utformningen av förbandet/kopplingen. De utvalda koncepten genererades med inspiration från referensramen och genereringsprocessen, koncepten illustreras i rapporten med hjälp av modeller i CATIA V5. Resultatet av examensarbetet blev två teoretiska koncept på ett vridmomentsöverförande förband mellan en axel och ett nav. Koncepten AH1 och AH2 principer är tänkt att inkorporeras i bilmodellen och ge upphov till en funktionsförbättring med mindre buller, en längre livslängd, bättre förhållande mellan styrka/vikt men samtidigt vara lätt att montera/demontera i bilen utan att behöva göra allt för omfattande modifikationer. Målet med konceptutvecklingen är att konceptet skall bemöta samtliga krav bestämda av den slutgiltiga produktspecifikationen. Abstract By combining traditional Internal Combustion Engine technology with electric motors, Koenigsegg Automotive AB can benefit from certain advantages that arise from this type of configuration, benefits that can then be implemented in their super sportscar, Regera. Example of an advantage is that the internal combustion engine can be scaled down, which gives a significant weight saving, but no further compromise on the overall effect as a result. Another example is that the electric motor's character of "direct power transmission" is used in a rapid acceleration where a conventional petrol engine has a certain delay. The purpose of the degree project has been to develop a concept for a torque-transmitting joint/coupling. The project is based on the fact that today's connection between the different motors tend to tune in on each other's natural frequencies, which under certain conditions leads to an amplitude increase in vibrations. This in turn gives off noise and in the long run this can lead to the joints becoming exhausted and eventually break down. Nevertheless, the company must also have the possibility to use the concept at other points where today they also use boom connections in the car. The work in this degree project has been limited to dealing only with the concept development process of the joint/coupling. The goal of the project is that the finished concept will satisfy all requirements determined by the product specification, this will be realized by a concept development process, CAD modeling and a simpler design analysis of the concept prototype. Based on the literature study, the main causes of the problem were identified. To find a suitable concept, five proposals were made for the design of the joint/coupling. The selected concepts were generated with inspiration from the frame of reference and the generation process, the concepts are illustrated in the report using models in CATIA V5. The result of the thesis was two theoretical concepts on a torque-transmitting joint between a shaft and a hub. The concepts AH1 and AH2 principles are intended to be incorporated in the car model and give rise to a functional improvement with less noise, a longer service life, better strength / weight ratio but at the same time be easy to assemble / disassemble in the car without having to make too extensive modifications. The goal of the concept development is for the concept to meet all requirements determined by the final product specification. Förkortningar och uttryck ICE – Internal Combustion Engine KDD – Koenigsegg Direct Drive HydroCoupe – En avancerad momentomvandlare utvecklad av Koenigsegg Electrical Torque Vectoring – Elektrisk vridmomentsvektor Regenerative Torque Breaking – Regenerativ vridmomentsbromsning Hypercars – Supersportbilar Crank rpm – Vevaxelns varvtal CAE – Computer Aided Engineering CAD – Computer Aided Design CATIA V5 – Computer Aided Threedimensional Interactive Application V5 GSA – Generative Shape Analysis FEM – Finita Element Metoden SAE – Society of Automotive Engineers ANSI – American National Standard Institute ASA – Assets Standards Authority DIN – Deutsches Institut fur Normung NVH – Noise, Vibrations and Harshness Proof of Concept – Koncepttest FMEA – Failure Mode Effect Analysis Innehållsförteckning 1. Introduktion ............................................................................................................................ 1 1.1. Bakgrund ......................................................................................................................... 1 1.2. Företagspresentation ........................................................................................................ 1 1.3. Syfte & Mål ..................................................................................................................... 2 1.3.1. Problemdefinition ..................................................................................................... 2 1.4. Avgränsningar ................................................................................................................. 2 2. Teoretisk referensram ............................................................................................................. 3 2.1. Produktutveckling med fokus på konceptutveckling ...................................................... 3 2.2. CAE ................................................................................................................................. 3 2.3. Kvantitativt vs. kvalitativt forskning ............................................................................... 4 2.4. Dagens förband ............................................................................................................... 4 2.4.1. Bomförband .............................................................................................................. 4 2.5. Axel – nav – förband. ...................................................................................................... 5 2.5.1. Bomförband .............................................................................................................. 5 2.5.2. Enkla kilförband ....................................................................................................... 5 2.5.3. Polygon koppling / liktjocking ................................................................................. 5 2.6. Axelkopplingar ................................................................................................................ 6 2.6.1. Klokoppling .............................................................................................................. 6 2.6.2. Pin and bush – koppling ........................................................................................... 6 2.7. Strukturdynamik .............................................................................................................. 6 2.7.1 Svängningar ............................................................................................................... 6 2.7.2 Resonans i system
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