Unterstützung in der Konstruktion

2.1 Introduction Based on the requirements regarding performance and available design space, an FEAD Tensioner (RSEMB) needs to be designed (3D model in all working positions including assembly and component drawings).

The tensioners will be assembled in Automotive Accessory Belt Drive systems. It's function is to guide the belt, to provide a sufficient belt pre-tension over ist complete lifetime and to dampen vibrations in belt drive, mainly caused by engine irregularities.

Access to ProE/Windchill as well as SAP EP4 by the contractor is necessary.

2.2 Work Packages

2.2.1 Overview For sample phase and mass production phase
* Analyze the given input data regarding completeness
* Based on the input data double check feasibility of the tensioner in the given design space (e.g. customer engine model)
* Create detailed CAD model and drawings
* Prove sufficient stiffness of the tensioner by means of a FEA calculation
* Perform design review (released by AMDHZA-LAPD).
* Import and Check the drawings in SAP
* Create and check the bill of materials in SAP

2.2.2 CAD 3D models (ProEngineer Version WF4 / from mid 2015 Creo II)
* Based on the provided tensioner calculation (BeltDrive software and balancing calculation) design the tensioner in the trained way with the target to have a cost- and weight optimized design
* CAD 3D models should have following structure: Top assembly (includes all relevant CAD models) '- Customer engine model (provided by Schaeffler or its customer) '- Belt drive assembly (created acc. to guideline) '- Automatic belt drive tensioner (part which should be designed in detail)
* Tensioner housing '- Aluminum lever arm '-Plain bearing '- Friction element '- Torsion spring '- Back plate '- Steel sleeve (optional) '- Washer or rivet '- Sealing ring (optional)
* Tensioner pulley with ball bearing (assembly provided by Schaeffler)
* Bolt to fix the tensioner pulley
* Dust cap
* Central bolt to fix the tensioner on the engine (optional)
* Assembly pin to keep the tensioner in mounting position before assembly at the engine (optional) '- Belt drive part (includes belt- and pulley dummy parts)
* Perform a design space study using the "top assembly" in order to check the feasibility of the tensioner design in the customer engine
* Create detailed CAD Models based on the given requirements
* Run FEA and optimize geometry in regards of stiffness, fatigue and weight
* Create the drawing set in ProEngineer '- Engineering delivery drawing according to guideline for each specific customer upon request '- Assembly drawings acc. to master drawings '- Component drawings acc. to master drawings
* Production drawings for Schaeffler produced plants
* Inquiry drawings for purchased parts

2.2.3 PDM in SAP
* Create all necessary SAP materials as trained for each specific tensioner type '- Assembly materials '- Component materials
* Create all necessary engineering folders (change management) '- Q-folders for customer delivery drawings, inquiry drawings and cost BOM '- O-folders for production drawings and BOM '- C-folders in case of design changes
* Create the bill of materials acc. to the defined structure '- Create cost BOM including necessary remarks to check the piece and assembly costs '- Create production BOM in SAP and if necessary create BOM in other form (e.g. Excel)
* Release and if necessary update engineering folders in SAP

2.2.4 Calculations Perform calculations in order to confirm sufficient stiffness of the tensioner components
* Perform topology analysis to reduce the tensioner weight (optional)
* Update 3D model if necessary
* Perform FEA to check final design

VORAUSSETZUNGEN:

ProE/ WF4, SAP EP4

EINSATZBEREICHE:

Maschinenbau, Ingenieurwesen/Technik