Fyzik ve firmě Continental Automotive Masarykova Universita, Brno 16.11.2011 Jan.Hradil@continental-corporation.com (oníineníal Program přednášky O Představení firmy Continental - autodíly a pneumatiky O Které typy problémů je potřeba řešit O Několik praktických příkladů 2 11-11-22 ©Continental AG Continental S Continental Corporation 140 Years of Innovation and Progress 1871-1900 1901-1930 1931-1960 1961-1990 1991-2011 Spirit of Optimism Continental-Caoutchouc- & Gutta-Percha Compagnie is founded in Hanover on October 8, 1871, as a joint stock company. Manufacturing includes rubberized fabrics, solid tires for carriages and bicycles, as well as soft rubber products. 11-11-22 ©Continental AG (ontiiieniül - Continental Corporation 140 Years of Innovation and Progress 1871-1900 1901-1930 1931-1960 1961-1990 1991-2011 Inventive Spirit > Merger with major companies of the German rubber industry to form Continental Gummi-Werke AG. O Invention of the detachable rim and automobile tires with a patterned tread; first flight across the English Channel with a plane equipped with Continental Aeroplan material. _ Continental 8 4 11-11-22 ©Continental AG Continental Corporation 140 Years of Innovation and Progress 1871-1900 1901-1930 1931-1960 1961-1990 1991-2011 Racing Success O Vehicles with Continental tires win numerous international races. Production of engine mounts, steel cord conveyor belts, air springs and radial tires begins. 5 11-11-22 ©Continental AG _ Continental S Continental Corporation 140 Years of Innovation and Progress 1871-1900 1901-1930 1931-1960 1961-1990 1991-2011 Internationalization O Business is expanded in Europe and America with acquisitions and the establishment of international joint ventures. OThe first studless winter tire is launched. O Polyurethane gaiters and hydromounts are supplied to the automotive industry. _ (gnlinenlal ^ 6 11-11-22 ©Continental AG Continental Corporation 140 Years of Innovation and Progress Driving safety Driving assistance Chassis dynamics Systems for the powertrain Systems for hybrid and electric drives Infotainment and multimedia Telematics and instrumentation Tires and extended mobility systems Technical elastomer products Vibration damping and noise optimization 1871-1900 1901-1930 1931-1960 1961-1990 1991-2011 Automotive supplier ©One of the top five in the global automotive Supplier industry since 2007 OThe first environment-friendly passenger tire is launched O Introduction of the key technology for hybrid drive systems Continental ^ 7 11-11-22 ©Continental AG Continental Corporation 6 Strong Divisions Chassis & Safety Powertrain Interior Passenger and Light Truck Tires Commercial Vehicle Tires ContiTech Electronic Brake Systems Engine Systems Instrumentation & Driver HMI Original equipment Truck Tires, EMEA Air Spring Systems Hydraulic Brake Systems Transmission Infotainment & Connectivity Repl. Business, EMEA Truck Tires, The Americas Benecke-Kaliko Group Sensorics Hybrid Electric Vehicle Body & Security Repl. Business, The Americas Truck Tires, Asia Pacific Conveyor Belt Group_1 Passive Safety & Advanced Driver Assistance Systems (PSAD) Sensors & Actuators Comm. Vehicles & Aftermarket Repl. Business, Asia Pacific Industrial Tires Elastomer Coatings 1 Fuel Supply Two-Wheel Tires Fluid Technology Chassis Components l"j^l Power Transmission Group Vibration Control Other Operations Status: December 31, 2010 _ Continental ^ 8 11-11-22 ©Continental AG Continental Corporation 193 Production and R&D Locations in 37 Countries South America Brazil Chile Ecuador "Headquarters in Hanover Status: January 1, 2011 - Continental 9 11 -11 -22 © Conti nental AG We Shape the Megatrends in the Automotive Industry Safety, Environment, Information, Affordable cars 10 11-11-22 ©Continental AG Continental S Continental Corporation Key Figures for 2010 2010 2009 Sales €26.0 billion €20.1 billion EBIT* €1,935.2 million -€1,040.4 million Adjusted EBIT** €2,516.8 million €1,180.5 million Employees 148,228 134,434 "Earnings before interest and taxes. Before amortization of intangible assets from PPA, changes in the scope of consolidation, and special effects. Continental ^ 11 11-11-22 ©Continental AG Powertrain Division 12 11-11-22 ©Continental AG Continental f§ Business Unit Sensors & Actuators Customers Portfolio: Automotive Manufacturers Continental 8 Continental Frenštát pod Radhoštěm senzory - výroba / vývoj O Vyrábí jak elektroniku pro automobily (např. řídící jednotky), tak i senzory, především: Hladinové senzory 5 Teplotní senzory O Rychlostní senzory Připravuje se výroba tlakových senzorů Některé typy senzorů se ve Frenštátě p. R. i vyvíj 14/Jan Hradil / 24-10-2011 ©Continental AG Continental Něco o mně O Jaroška - olympiády, semináře O Matfyz - odborná fyzika, polovodiče, ultrarychlé lasery (ns, fs), Fykos O Postgraduál v Dublinu, Irsko - senzory, biosenzory, oxygen senzory a aplikace (spojité měření tlaku a teploty na křídlech letadel) O Vývoj hladinových senzorů, Continental Automotive Systems Czech Republic s.r.o., Frenštát p.R. 15/Jan Hradil / 14-11-2011 © Continental AG _ Continental S Co tedy opravdu (občas) dělá fyzik? Vymýšlí nové senzory O Hledá proč ty staré nefungují O Hrabe se v datech a hledá souvisloti 16/Jan Hradil / 24-10-2011 ©Continental AG (oníinenial - This is how scientists see the world. Sensors&Actuators as core elements of Powertrain systems Example: Diesel Piezo Common Rail Injection Architecture Mass Air Flow Air Control Valve Sensor Exhaust Bypass Valve Exhaust Gas Recirculation Valve (EGR) General Exhaust Bypass General Purpose Glow Plug Purpose Valve Actuator Pressure Sensor Actuator Relative pressure sensor xhaust I (Throttle Valve Actuators Sensors Fuel Pressure Active Manifold Sensor Electrothermi Absolute Pressure c Oil level Sensor with integrated sensor temperature sensor Knock Sensor Engine Coolant or Cylinder Head Temperature Sensor High temperature sensor Continental f§ Příklad 1 - ultrazvukový senzor hladiny oleje O Proč měřit hladinu oleje - předvídáme katastrofy © O Popis principu, základní vlastnosti > K čemu je dobré referenční měření, a proč je reference lepší než nic 20 11-11-22 ©Continental AG Continental S Měření oleje - proč a jak -> hladinový senzor d Motory jsou od pradávna vybaveny olejovým tlakovým senzorem O jakmile ten hlásí nízký tlak oleje, znamená to, že se nemaže a musí se okamžitě do servisu O walk home situation = půlnošní zastávka uprostřed dálnice 500km od domova 5 S hladinovým olejovým senzorem jde situaci předejít a dopředu avizovat nutnost doplnění oleje O Metody měření > spojité > electrothermic (vyhřívaný odporový drát) > ultrasonic (princip sonaru) O diskrétní > spínač (plovák, magnet, jazýčkový spínač) _ Continental 8 21/Jan Hradil / 14-11-2011 © Continental AG Ultrasonic Level and Temperature Sensor Best price - performance ratio Benefits Replacement of oil dipstick Detection of low level & overfill Absolute measurement of oil level in static and dynamic conditions Stand-alone sensor with integrated electronics ("active") and ASIC Low power consumption Temperature measurement optional Best price - performance ratio Technical Data Measuring principle: ultrasonic echo Measuring range: 18 mm up to 160 mm Interface: PWM First measurement available: 0.4 - 1 sec after key-on dep. on PWM output protocol ~ 1 sec. Measuring interval: Power supply: Protection class: Operating temperature: ■ Level: Temperature: Accuracy: Level: Temperature: 12V /10mA typical IP 66 0°C ... +160°C -40°C ... +165°C ± 2mm ±2°C (0°C ... +165<€) ±3°C (at -40 °C) Target Customers: All OEMs worldwide Lead customers: 2 German OEMs Expected SOP: 2011 Manufacturing: Frenstat (C Continental 22 / Fluid Level Sensors © Continental AG Ultrasonic Level and Temperature Sensor Measuring Principle O Piezo emits ultrasonic pulse © Part of the pulse is reflected at the O The oil surface reflects the pulse reference, the other part goes to the and the piezo receives the echo, oil surface "Time of Flight (ToF)" Level= ToF(Oil-surface) To F( Reference) ReferenceDstance Continental 23 / Fluid Level Sensors © Continental AG Ultrasonic Oil Level and Temperature Sensor - schematic Standalone Sensor with integrated electronics requires least efforts in ECU Ultrasonic Oil Level Sensor with integrated electronics send & receive \^ ultrasonic pluse \^ convert ultrasonic pulse to el. signals ♦ measure treference and t|eve| I t ♦ convert level to PWM signal JLIUUUUl I calculate level level =h™i;reference reference Engine ECU VBAT 1 typ 4,7kQ- 10kQ ;typ 4,7nF Mc O Sensor output: PWM signal O Efforts in ECU: Pull up resistor to VBAT Continental 8 24 / Fluid Level Sensors © Continental AG Příklad 2 - optimalizace rychlosti odezvy teplotního senzoru Jak pomáhá FEA/FEM při předpovídání vlastností O Svázání teorie a reality - nakonec je realita to co nás zajímá Měření ve větrném tunelu (pnliiieiiíal S 25 11-11-22 ©Continental AG Príklad vývoje s pomoci matematických simulací - přehled různých historických verzí takzvaného EGR senzoru - sleduje se response time, teplota o-ringu, kontaminace venkovní teplotou Connector design concept evolution 1st response 2nd response 3rd response time optimization time optimization time optimization Initial design Calculated T63.2 = 28,4 s Calculated T63.2 = 16,5 S Calculated T63.2 = 15,9 S 5th response time optimization Calculated T63.2 = 14 s Improved design Calculated T63.2 = 13 s Take over design 4th response time optimization Calculated T63.2 = 11 s 6th response time optimization Calculated T63.2 = 15,9 S V této fázi jsme vyráběli první prototypy O Tento vývoj byl a je řízen s pomocí matematických simulací, T. Gajdarus. 26/Jan Hradil / 24-10-2011 ©Continental AG (OllíilH'Ilícll Reálný příklad - dosažená přesnost response time (13.6sec vs 12.2sec) 0 Náš hardware na měření response time teplotních senzorů ve vzduchu, je to v podstatě dvojitý větrný tunel. O K danému problému máme odvozené funkční okr. podmínky. (gnlinenlal ^ 27 / Jan Hradil / 24-10-2011 © Continental AG Příklad 3 - co dělat, když senzor nepřežije testování (vibrace) O Jak zjistit životnost senzoru (15 let) v laboratoři co nejrychleji (do 7 dnů). O Vlastní frekvence výrobku nemusí být příčinou. Únavový lom?!? > S Wehlerovou křivkou je vysvětlení mnohem snazší a optimistické do budoucna. Chyba je na straně testu, ne výrobku. 28 11-11-22 ©Continental AG Continental S Co přináší život mperature sensor Oil level Heating band Oil bath OLS sensors (gntinental ., -n i u 11.9011 © Continental AG 29 / Jan Hradil / 14-11 An i w u Details of fracture 30 / Jan Hradil / 2009 / © Continental AG Continental - Natural frequency measurement O Measured frequency around 600-750Hz for different temperatures oo ■ 0J1S coin -- Temperature of Temperature of Temperature of Ma Sire. 20C air c. so c □ire I5D"C 4* J 64eKz 7i^Hz; -1—1—I—1—I—■—I—■—I—'——I—■—r—-—I—■—I 1» 2D0 300 «00 EDO «0 700 600 HO 10M Frequency OConfirms theoretical FEM analysis of whole sensor 5BUT: sensor moves as whole, reed switch is not stressed itself! -sne sweep 550 - SOCHi (Sj) -Shaker 7 11 Hz r_ i r - - : :c -■CQS- WD 6» HD TDD 72D 7dfl 7« 780 900 «C Frefcverce (Hi) 31 / Jan Hradil / 2009 / © Continental AG (gntinenlal Material analysis with SEM Acc.V SpotMagn Det WD |-ES.OkVS.O 500x BSE 10.8 H 50 O SEM analysis confirms material composition of Ni52Fe48 O SEM shows on wire, which was tested under vibration test (after etching of the surface) micro-cracks at the glass-wire interface O The cracks seems to be from fatigue fracture O Cycles number: O 1500 Hz*3*48hrs ©=> 8*108 Cycles 32 / Jan Hradil / 2009 / © Continental AG Computer simulations - modal analysis Swell, 22.11.2011 natural shape in X shape in Y Von Mises [MP§|nSIOn Biggest Von Mises [Mfe|nS'0n = Biggest stress s ~~ s E Conclusion: ■ 1st rez. fr. 2nd rez. fr. Variant A 1 839 Hz 2 253 Hz Theoretical calculation predicts damage of reed switch in the same place, where damage really occurred. 33 / Jan Hradil / 2009 / © Continental AG (OlllilH'Illcll Resonances at higher frequencies Continental ^ 34 / Jan Hradil / 2009 / © Continental AG Analysis of vibration fixture Oln region above 1000 Hz (in random vibration profile) significant amplification of vibration of fixture is observe Oup to 5-times 9x1 cr1 N X CD c 1x1 cr1 o ro 1x102 CD ?J 1x10~3 8 10 ContrSf 5.0 CD CD, o H—' CD _o 10 0.8 10 Acceleration Profile y-- 100 Freauencv (Hz) Transmissibility (reference = Ch1) 1000 2000 Ch2/Ch1 100 Frequency (Hz) 1000 2000 35 / Jan Hradil / 2009 / © Continental AG Continental FEM analysis of vibration fixture 36 / Jan Hradil / 2009 / © Continental AG Wöhler curve (sample) S-N CURVE FOR BRITTLE AL UMMUM WTH A UTS OF 320 MP A 350 300 250 2. 200 5; Today 3: 150 50 25% reduction -> 10x increased lifetime 1OE+O0 1.0E+Q1 t.OE+02 1.0E+03 1.0E+04 Life {cycles) t.OE+05 t.OE+06 t.OE+07 37 / Jan Hradil / 2009 / © Continental AG (gntinenlal Thank you for your attention! 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