COMPANY BROCHURE KONTEC GmbH AUTOMOTIVE ENGINEERING PLANNING, DEVELOPMENT & DESIGN ENGINE. EGA. SYSTEM SOLUTIONS. A COMPANY OF THE TwintecBaumot GROUP

Transcription

1 COMPANY BROCHURE KONTEC GmbH AUTOMOTIVE ENGINEERING PLANNING, DEVELOPMENT & DESIGN ENGINE. EGA. SYSTEM SOLUTIONS. A COMPANY OF THE TwintecBaumot GROUP

2 FROM POWERTRAIN TO EGA ALL FROM A SINGLE SOURCE COMPANY PORTRAIT Twintec AG is the parent company of TwintecBaumot Group (TBG), a leading supplier in the area of exhaust gas aftertreatment and engine development. In that context, TBG offers its customers high-quality solutions in Design & Engineering and Products & Solutions as well as Testing & Validation Services. TBG applies those products and services across a wide range of industries in the business fields OEM (original equipment), retrofitting, aftermarket (repair, spare parts). In so doing, it covers the entire value creation chain for the exhaust gas aftertreatment sector. The market segments include, in particular, on-road (e.g. cars, Homologation/ Certification Production Exhaust System Development Development of Functionalities Software Development trucks and other commercial vehicles), off-road (e.g. construction machinery, agricultural machinery or stationary plant) and miscellaneous applications such as maritime. Emission testing Simulation of system functionality Project Management 3Dmeasurements Within its five subsidiaries, TwintecBaumot Group has more than 350 employees and decades of experience in the field of exhaust gas aftertreatment. Acquired in 2015, Kontec GmbH, together with its subsidiary DIF (Die Ideenfabrik GmbH), represents the OEM development arm of the company, offering low-emission engines and exhaust gas aftertreat- Validation on engine bench Product Design with CAD/CAE ment systems to well-known original equipment manufacturers. Baumot AG, which was acquired in 2014, together with the Twintec Technologie GmbH is one of the leading providers Validation On road / field test FEM of selective catalytic reduction (SCR) systems as well as active and passive particulate filters in the OEM and retrofitting business sectors. In addition, as a specialist in the development of emissions technology Baumot Technologie GmbH offers its customers innovative solu- Catalyst testing (light-off, aging and poisoning) CFD tions for reducing exhaust gas emissions especially in the OEM segment. Strength and durability tests e.g. Hot shake Benchmarking Rapid Prototyping FMEA STRUCTURE TWINTEC AG Holding Measurement and Data Acquisition System Integration Exhaust Aftertreatment Set up demonstrator vehicles Electronic Control Unit Samples and prototypes DESIGN & ENGINEERING PRODUCTS & SOLUTIONS TESTING & VALIDATION After treatment calibration Set up engine test benches KONTEC Automotive Engineering Sustainable Mobility, Engineering, Automotive Services BAUMOT AG Emission Control Products, Retrofit/Aftermarket KONTEC Testing Validation & LAB Testing & Validation Services KEY KONTEC Maschinenbau Engineering Industry 4.0 Solutions, Industrial Services TWINTEC Technologie Emission Control Products, Retrofit/Aftermarket KONTEC Motorenentwicklung Test Benches DEVELOPMENT DESIGN & SIMULATION PROTOTYPING BAUMOT Technologie OEM Emission Control Solutions DIF Testing Emission Control & Engine Testing APPLICATIONS TESTING 2

3 KONTEC GMBH KONTEC is one of the leading technical development service firms in Germany and has been providing, among other things, development, design, and measurement and test engineering services as well as engine trials on three in-house test facilities to well-known clients since In the automotive development and special applications segment, we work with state-of-theart technical equipment, not only in powertrain and undercarriage vehicle technology, but also in mechanical and plant engineering as well as in equipment engineering and product development. KONTEC offers tailor-made complete solutions in the technical area. Many years of experience enable us to provide a flexible, effective response to every challenge. Our engineers, technicians and specialists are ready to meet those challenges for you with experience, technical expertise, flexibility and dedication. INDUSTRIES AND MARKETS EGA SYSTEMS MECHANICAL CONSTRUCTION PLANT & EQUIPMENT ENGINEERING SENSOR SYSTEMS DRIVE SYSTEMS MEDICAL SYSTEMS OUR PHILOSOPHY PASSION RELIABILITY QUALITY KONTEC AT A GLANCE OEM engineering concept development, CAE: simulation and design Mechanical / Plant engineering Engine development and testing Measurement and testing technology for vehicle, engine and EGA components EGA product development and systems for ON-ROAD applications Support & Services More than 300 qualified employees 13 locations in Germany 5

4 DEVELOPMENT & DESIGN ALWAYS THE RIGHT SOLUTION As a competent partner, we offer you the full spectrum of services ranging from minor tasks for extra credit to the management and implementation of complete development projects. Across the full spectrum ranging from small sub-projects to expert staff for special assignments up to complete project teams we offer you expertise, competence and high quality right there on your premises. We provide you with solutions which result from the innovative force, dynamic, flexibility and reliability of our employees. Collaborative relationships with our customers are the key to our shared success. We promise only what we can also deliver. QUALIFICATIONS Engineers from mechanical and vehicle construction, aerospace, mechatronics and many other disciplines Test engineers and technicians Graduate physicists and mathematicians Quality and FMEA specialists Industrial engineers Technical purchasing personnel Contact us for a closer look we look forward to hearing from you. FROM INSPIRATION TO THE IDEA TO THE FINISHED PRODUCT page 8 page 10 page 12 page 14 page 16 DESIGN CONSTRUCTION CFD, FEM, SIMULATION PROTOTYPING APPLICATION, TESTING 6 7

5 DESIGN NEW APPROACHES AND PERSPECTIVES The assessment of the current situation e.g. functions, package space, specifications, material, production method is the first step toward creating the new concept. It makes no difference whether it involves high quality components or complex assemblies: our highly qualified engineers work together with you to develop tailor-made concepts and economically effective solutions. The analysis of the initial situation and careful planning lays the cornerstone for the success of your products. They also minimize the risk of incurring unanticipated costs during the development phase costs which can slow progress or possibly even endanger the entire project. FROM THE ANALYSIS OF THE INITIAL SITUATION TO BRAINSTORMING TO THE FULLY DEVELOPED CONCEPT EXAMPLE: ENGINE DESIGN Definition of the combustion process, engine concept and preparation of the technical specifications Parameter studies, rough simulation for definition of the number and diameter of cylinders, bore, stroke, mean effective pressure, and combustion, forced induction and injection concept Definition of emission reduction concepts according to target markets Structural, parameterized 3D layout Simulated flow and charge cycle optimization for the purposes of, among other things, determining valve operation and cylinder head geometry REFERENCE V12 ENGINE BASED ON A V8 ENGINE A customer wanted to build a demonstrator to show that an existing V8 engine can be used to develop a V12 engine for use in an existing luxury sedan. AT A GLANCE Preparation of commercial specifications Preparation of technical specifications Development of new design approaches Research of the use of alternative materials with modified design Evaluation of alternative production techniques Using the CAD data of the complete V8 engine, 4 cylinders were added to the base engine, which was then positioned in the engine compartment of the sedan. Subsequently the engine peripherals such as turbocharger, exhaust system, etc. were resized for the new output and integrated into the available package space. A detailed presentation of all required component changes was presented to the customer, which then served as a basis for their project implementation decision. WE TAKE A BROADER VIEW! 8 9

6 CONSTRUCTION OPTIMIZED FUNCTIONAL SOLUTION The design work transforms the previously developed concept into real dimensions, resulting in a product which is optimized for the construction materials and methods. A 3D model in a CAD program makes it possible to check machines and products for functionality and feasibility in advance, enabling us to deliver a product which is both economically viable and practically oriented. But our designers do more than just operate CAD software. For us, design engineering is the art of combining individual components to achieve an optimized, functional solution. A good design provides not only the correct logical structure, but also enables us to further develop the delivered product and make it accessible. That s why our engineers are trained how to use the full range of CAD software, thereby putting us in a position to deliver your CAD model in whatever format you wish. EXAMPLES Exhaust gas aftertreatment systems Engine and drive components Engine block, oil sump top section and similar complex cast parts Components for fuel injection systems in applications ranging from passenger cars to commercial vehicles to marine engines Components and systems in the direct vicinity of the engine Electronic control systems Concepts and systems for engine and component test stands Special purpose equipment and fixtures for manufacturing and assembly REFERENCE DEVELOPMENT OF COMPLEX SAND CAST IRON AND PRESSURE CAST ALUMINIUM PARTS OUR SOFTWARE AUTOCAD INVENTOR CATIA PRO/ENGINEER (CREO) SIEMENS NX EPLAN SOLIDWORKS Our team, which has been working together since our company was established, used our efficient modelling methodology and the top-down principle to develop highly complex cast components such as crankshaft housings, cylinder heads, oil sump top sections, and more. In order to meet the demands of today and tomorrow, we have worked in close collaboration with manufacturing partners, thereby creating optimal components with regard to economy, functionality and feasibility. With complex components, we operated parallel with multiple team members working on a given component in order to make the most efficient use of the short development times. This enabled us to deliver models suited to the tools available for further processing by the manufacturing partners, thus saving additional time and money

7 SIMULATION TARGETED DEVELOPMENT THROUGH FEASIBILITY STUDIES Technical simulation is one of the CAD disciplines which is becoming increasingly important in development work, especially in the automotive industry. It uses computers to simulate properties and stresses on components or assemblies. The simulations can be carried out in one dimension or three-dimensionally. Independently of the product, technical simulations are necessary in nearly all sectors of the industry. They are used to carry out targeted development through feasibility studies on virtual prototypes in advance. This leads to immediate cost reductions during development, because real prototypes are no longer needed. Moreover, insights can be generated for processes which are difficult or impossible to analyse experimentally. Overall, technical simulation leads to product optimisation through the analysis of a wide range of variants. EXAMPLES Exhaust gas systems, including exhaust gas aftertreatment system techniques: e.g. simulation of the injection characteristics, such as urea metering for SCR, HC metering for DPF regeneration Intake systems, including supercharging Injection systems for internal combustion engines, in-cylinder flow simulation with and without injection of different fuels General catalyst efficiency calculations such as inflow simulations and UI/distribution simulations for DOC/DPF systems and SCR systems as well as combined systems Cooling systems (engine, oil and charge-air coolers) Sensor inflows REFERENCE MODULAR EGA SYSTEM FOR ADDRESSING THE WIDE RANGE OF OFF-ROAD VEHICLE VARIANTS OUR SOFTWARE ABAQUS ANSA ANSYS FLUENT ANSYS MECHANICAL FLOWMASTER GT-SUITE ANSYS CFX CCM+ ICEMCFD (HEXA,TETRA) One of the known problems in the off-road segment is the extremely wide range of engine variants. In order to deal with all these different engines, each EGA system has to be specifically tailored and designed for the relevant engine, which incurs tremendous development costs. With the help of CFD flow simulations, during the development of such a system we were able to test its flow dynamics in hundreds of scenarios, which in reality would have taken years. In this way, we managed to develop a modular system which can be used in over 50 different types of vehicle with four different diesel engines (power range: kw), including certification, actual application and vehicle-specific documentation. OPENFOAM STARCD INCL. ES-ICE VECTIS 12 13

8 PROTOTYPING EFFICIENT MANAGEMENT OF MANY DIFFERENT FORMATS For assurance, verification and functional testing of the developed design, we create meaningful prototypes and functional models. They enable the early verification of component designs and their evaluation on test stands. This makes it possible to implement any necessary adjustments prior to series production. In a continuous improvement process, the collective results are then incorporated into the products, thereby ensuring optimal results for utilisation in practical application. We combine internal resources with our established partner network for prototype construction, which enables us to deliver both simply produced functional models and complex as well as near-series equipment prototypes in an extremely short time. PROTOTYP VARIANTS Design prototype: Conceptual model for verification of aesthetic and ergonomic features Geometric prototype: Dimensionally precise model for initial assembly and usage trials and for determining the specific material requirement profile. Functional prototype: Prototype which already features key functional characteristics of a component to be produced in series at a point of time Technical prototype: Near-series trial model REFERENCE BNOX SYSTEM FOR EXHAUST GAS AFTERTREATMENT CONCEPT FEASIBILITY CONSTRUCTION FEEDBACK MATERIAL SELECTION To achieve the goal of improving the air in the inner cities, we developed our B-NOx system, with which nitrogen oxide and particulates are effectively reduced even in heavy traffic. By the use the use of state-of-the-art development methods and tools, such as the latest CFD and CAD tools, FMEA, engine test stands, and PEMS measurements, as well as a highly efficient project management system, and of course a highly competent team of experts, we succeeded in developing a first prototype. With the help of the first prototype series, we were able to carry out extensive field studies which proofed a nitrogen oxide reduction between 90 and 99%, also in city centres, thereby laying the foundation for improving health and quality of life. In so doing, we created a unique solution for the previously unresolved issue of exhaust gas aftertreatment at low temperatures, and set a milestone for future exhaust gas systems. MANUFACTURING PROTOTYPE 14 15

9 APPLICATION & TESTING QUALITY ASSURANCE We support and accompany you as needed throughout the testing process and ensure that your product also meets your quality standards. We will also be glad to help you carry out sub-projects concerning individual tests and product trials. We will conduct complete trials of individual components for you on request. Our core activities are quality assurance, which we cover via our accredited testing laboratory (IEC 17025), where the focus is on environmental simulation, force-displacement measurements and material analyses. Another asset lies in the area of component inspections (e.g. fuel pumps, injectors, etc.), which we can plan and implement according to your wishes. With regard to the complete vehicle, we can offer you full hardware integration of systems which we equip with the desired instrumentation. Our portfolio also includes the testing of systems on board the vehicle on all well-known testing grounds and field trials. We can rely on many years of experience with OEMs and Tier 1 suppliers in order to guarantee the best solutions for your application. EXAMPLES Cable assembly Testing of connectors and harnesses according to US-CAR, Vehicle testing, radar sensors, distance sensors, parking assistant, Engine components (injectors, pumps, ) Engine components on the test stand (catalytic converter / probes / valves / injectors, ) Adaptation of measurement technology (cylinder heads, vehicle, ) Inspection (pumps, injectors, electrical components, crimp test, plug-in connector) REFERENCE TESTING OF ASSISTANCE SYSTEMS FROM SIMPLE INTEGRATION OF ADDITIONAL SENSOR TECHNOLOGY TO COMPLETE INCORPORATION OF COMPLEX MEASUREMENT SYSTEMS ALL THE WAY TO INTELLIGENT CHARGE ELECTRONICS WE TAKE CARE OF EVERYTHING FOR YOU. For a well-known French automotive supplier, we equip test vehicles with instrumentation and sensor technology for testing assistance systems such ultrasound parking assistants, radar sensors, ScaLa, cameras and e-mirrors. Our range of services here includes the design and manufacture of prototype parts, and the integration of those parts in the vehicle. The initial start-up takes place in close collaboration with the customer. The vehicle is delivered only after its functions are fully operational. Our experienced test drivers support the customer during commissioning and remain available at all times to provide technical support during testing

10 REFERENCES WE ALSO HAVE THE RIGHT SOLUTION FOR YOU OUR REFERENCES VEHICLE CONSTRUCTION Design of highly complex cast parts in iron sand casting and aluminium pressure casting // Development of single-cylinder diesel test engine // Development of basic engine of all model series V-engine diesel // Component package on the basic engine and in near-engine environment for DTM and Le Mans vehicles // Development of components and test fixtures in the diesel area, e.g. wear test stand for radial shaft seal ring on high-pressure injection pumps // Inspection, including report preparation, of highly stressed components, e.g. for diesel injection systems, active exhaust gas aftertreatment, transmission control // and much more MECHANICAL ENGINEERING Conception and design of new suspension gear for a body in white to transport a new type of vehicle into the existing assembly line // Conception, design and fabrication of a mud test stand for testing heavy commercial vehicle axles and auxiliary drives // Design of torque test stands for axle component test stands with hydraulic motors up to 200,000 Nm. // and much more AND MANY OTHERS

11 TWINTEC AG TWINTEC TECHNOLOGIE GMBH BAUMOT TECHNOLOGIE GMBH BAUMOT AG DIF DIE IDEENFABRIK GMBH KONTEC GMBH A COMPANY OF TwintecBaumot GROUP POWERTRAIN. EAT. SYSTEM SOLUTIONS. EXHAUST AFTERTREATMENT SYSTEMS I ON ROAD OEM ENGINEERING I OFF ROAD OEM ENGINEERING I MEASUREMENT AND TESTING TECHNOLOGY I Version: KONTEC GmbH Siemensstr Korntal-Münchingen P. +49 (0) / F. +49 (0) / vertrieb@kontec.de