Topology Optimization of a Ship Gearbox Housing 3rd European HTC Ludwigsburg November 2nd 4th, 2009 Arnulf Deschler ZF Friedrichshafen AG
Content ZF at a glance Initial situation Conception of the catamaran Propulsion system Engine room layout Loading conditions Definition of the optimization problem Results Interpretation of the results Implementation by means of a produceable structure Assessment of the final design Conclusions 2 3rd European HTC Ludwigsburg November 2nd 4th, 2009 copyright 2009, ZF Friedrichshafen AG
Sales 2008 12,501 million* Car Driveline Technology 2,011 Car Chassis Technology Commercial Vehicle and Special Driveline Technology Off-Road Driveline Technology and Axle Systems Powertrain and Suspension Components 1,951 1,955 2,235 2,387 Rubber-Metal Technology 489 Marine Propulsion Systems 284 Aviation Technology Electronic Components** 32 71 Services 1,025 Steering Technology*** 2,594 * Adjusted by ZF-internal supplies of 1,321 million ** Proportionately as of November 2008 *** ZF Lenksysteme GmbH (50 % ZF, 50 % Bosch) 3 3rd European HTC Ludwigsburg November 2nd 4th, 2009 copyright 2009, ZF Friedrichshafen AG
Marine Propulsion Systems Market position transmissions Market share in Europe World Market position in Europe World Marine Pleasure Craft 80% 75% 1 1 Marine Fast Craft 65% 60% 1 1 Sales & Service Network 4 3rd European HTC Ludwigsburg November 2nd 4th, 2009 copyright 2009, ZF Friedrichshafen AG
Initial situation existing transmission line for fast ferries derivation of a new application for catamarans 5 3rd European HTC Ludwigsburg November 2nd 4th, 2009 copyright 2009, ZF Friedrichshafen AG
Example for new application INCAT-catamaran L.O.A.: 98 m beam: 27 m 6 3rd European HTC Ludwigsburg November 2nd 4th, 2009 copyright 2009, ZF Friedrichshafen AG
Example for new application INCAT-catamaran L.O.A.: 98 m beam: 27 m 900 passengers 260 cars speed: 48 kn 7 3rd European HTC Ludwigsburg November 2nd 4th, 2009 copyright 2009, ZF Friedrichshafen AG
Propulsion system waterjets 8 3rd European HTC Ludwigsburg November 2nd 4th, 2009 copyright 2009, ZF Friedrichshafen AG
Engine room layout topview gearbox waterjets in parallel engines in a row with slight offset offset between crankshafts and impellershafts impact on loading conditions 9 3rd European HTC Ludwigsburg November 2nd 4th, 2009 copyright 2009, ZF Friedrichshafen AG
Schematic illustration of the previous installation separatly mounted thrust bearing in fast-ferry applications drive thrust thrust bearing 10 3rd European HTC Ludwigsburg November 2nd 4th, 2009 copyright 2009, ZF Friedrichshafen AG
Schematic illustration of the new installation new: thrust bearing intergrated into the gearbox drive thrust 70 t entire catamaran propulsion is transmitted by the housings 11 3rd European HTC Ludwigsburg November 2nd 4th, 2009 copyright 2009, ZF Friedrichshafen AG
Principle of the problem clamped plate thrust bearing wall axial thrust on excentric circular ring area 12 3rd European HTC Ludwigsburg November 2nd 4th, 2009 copyright 2009, ZF Friedrichshafen AG
Objective situation to be expected objective is a limited parallel displacement lower limit upper limit 13 3rd European HTC Ludwigsburg November 2nd 4th, 2009 copyright 2009, ZF Friedrichshafen AG
Design space interior of the thrust bearing wall is defined as design space 14 3rd European HTC Ludwigsburg November 2nd 4th, 2009 copyright 2009, ZF Friedrichshafen AG
FEA-Model housing without ribs (blue) design space (yellow) 15 3rd European HTC Ludwigsburg November 2nd 4th, 2009 copyright 2009, ZF Friedrichshafen AG
Definition of the optimization problem objective: minimize mass s constraint: limited parallel displacement of the bearing seat 16 3rd European HTC Ludwigsburg November 2nd 4th, 2009 copyright 2009, ZF Friedrichshafen AG
Topology optimization results design space 17 3rd European HTC Ludwigsburg November 2nd 4th, 2009 copyright 2009, ZF Friedrichshafen AG
Design interpretation design space intersections suspensions intersection point of supports connections oil channel 18 3rd European HTC Ludwigsburg November 2nd 4th, 2009 copyright 2009, ZF Friedrichshafen AG
Implementation by means of a produceable structure crossection: 19 3rd European HTC Ludwigsburg November 2nd 4th, 2009 copyright 2009, ZF Friedrichshafen AG
Mode of operation undeformed structure red line: belt in unloaded condition 20 3rd European HTC Ludwigsburg November 2nd 4th, 2009 copyright 2009, ZF Friedrichshafen AG
Mode of operation deformed structure red line: belt in unloaded condition 21 3rd European HTC Ludwigsburg November 2nd 4th, 2009 copyright 2009, ZF Friedrichshafen AG
Stress distribution complete belt under tension red line: belt in unloaded condition 22 3rd European HTC Ludwigsburg November 2nd 4th, 2009 copyright 2009, ZF Friedrichshafen AG
Optimality assessment design space completely filled mass 100% 30% optimized final design housing without ribs 100% 92% 0 displacement 23 3rd European HTC Ludwigsburg November 2nd 4th, 2009 copyright 2009, ZF Friedrichshafen AG
Series-production status of the housing 24 3rd European HTC Ludwigsburg November 2nd 4th, 2009 copyright 2009, ZF Friedrichshafen AG
Conclusions high degree of safety against thrust bearing failure maximum housing stiffness reduction of development time reduced time to market cost savings derivation of several concepts based on topology results validation of the optimization process and final design OptiStruct: favorite tool not only but especially for off-standard problems reference to ATZ / MTZ specialized book 25 3rd European HTC Ludwigsburg November 2nd 4th, 2009 copyright 2009, ZF Friedrichshafen AG
ATZ / MTZ specialized book processes practical examples field reports target group: in practice and science employed experts of the automotive, supplier and electronic industry Vieweg+Teubner Verlag, 2008 Ed: Seiffert / Rainer ISBN 978-3-8348-0345-0 26 3rd European HTC Ludwigsburg November 2nd 4th, 2009 copyright 2009, ZF Friedrichshafen AG
Thank you for your attention! www.zf.com 27 3rd European HTC Ludwigsburg November 2nd 4th, 2009 copyright 2009, ZF Friedrichshafen AG