Cause analysis and resolution for a noisy gearbox
Activity duration : 300 h
INPUT
Research the causes of noise found in a production gearbox and propose remedial design actions
PROCESS
Analysis of operating conditions, gear calculation, modal FEA of the casings, development of a design proposal on the project
OUTPUT
Calculation reports, updating tables and 3D models of some parts
Preliminary study of a DCT for a series sports car
Activity duration : 1800 h
INPUT
First design of hydraulics and layout of DCT for a high performance sports car
PROCESS
Analysis, calculation and setting of the circuit and subsystems of the DCT hydraulic module; preliminary layout study and co-design of system integration with the gearbox manufacturer
OUTPUT
3D model of study layout, reports
Preliminary study of a hydraulic AMT
Activity duration : 2000 h
INPUT
Carry out feasibility study of hydraulic AMT application on manual gearbox for new mass-produced car
PROCESS
Preliminary study and progressive project refinements (direct relationships with the end customer’s work group); layout analysis and integration of the unit under the bonnet; integration of current production carryover parts and subsystems; industrialization pre-analysis
OUTPUT
3D model of study layout, reports
Preliminary study of a electric AMT
Activity duration : 1500 h
INPUT
Carry out feasibility study of electric AMT application, split into two modules (clutch and gearbox) for new mass-produced car
PROCESS
Preliminary conceptual study and progressive project refinements; analytical and FEA calculations where necessary; industrialization pre-analysis; realization of different feasibility variants
OUTPUT
3D model of study layout, reports
Problem solving on a mass-produced DCT
Activity duration : 3000 h
INPUT
Analyze and solve technological and functional problems of DCT application on mass-produced vehicles
PROCESS
Drawing analysis of the issue; calculation/modeling activities for problem evaluation; formulation of proposals for a concrete and sustainable solution
OUTPUT
Calculation sheets, 3D models, drawings, report
Design and prototype of a hydraulic e-clutch
Activity duration : 1000 h
INPUT
Study the concept, feasibility and prototype design of a hydro-mechanical e-clutch unit; create mechanical part prototype
PROCESS
Assembly modeling and gradual refinements; carrying out necessary calculations; co-design with interface suppliers and end customer; shared definitive study and construction tables; construction of mechanical parts and assembling of 5 groups
OUTPUT
3D models, drawings, report and 5 physical protos
Hybrid van transmission design
Activity duration : 2000 h
INPUT
Designing an electric-diesel hybrid transmission to equip a van
PROCESS
Preliminary design and following refining steps Layout analysis and assembly integration under bonnet Critical parts FEA calculations Gears, bearings and shafts calculation
OUTPUT
General and detailed arrangement drawings Calculation report
Electro-hydraulic actuator system design
Activity duration : 800 h
INPUT
Fitting an actuator system concept to a sport car gearbox
PROCESS
Layout analysis and available volumes evaluation Preliminary design and following refining steps
OUTPUT
Detailed arrangement drawings of parts and functional assemblies
Motorcycle gearbox design
Activity duration : 1500 h
INPUT
Designing a dog-clutch gearbox for a road motorcycle
PROCESS
Gear calculation with specialized software and gear profile optimization 3D design of shafts, gears and box FEA calculation of dog-clutch Gear engaging desmodromic system design
OUTPUT
General and detailed arrangement drawings Calculation report
Electric bus axle analysis
Activity duration : 450 h
INPUT
Making a structural analysis on axle and calculate gear system
PROCESS
Load conditions setup with customer agreement FEA analysis on structural parts Gears design and bearings calculation
OUTPUT
Gears data table, castings improvement advices Final report
Self-locking differential implementation on electric vehicle
Activity duration : 430 h
INPUT
Transforming a free differential automotive transfer into a self-locking one
PROCESS
Layout measurement of volumes available inside original case 3D design of self-locking differential Differential gears calculation Drawings and prototype building
OUTPUT
Supply of a new transfer with self-locking differential, ready to be installed on the vehicle
Design of conversion kits for thermal to electric vehicles
Activity duration : 250 h
INPUT
Design a kit for the transformation of vehicles powered by thermal engines into Z.E. electric vehicles
PROCESS
Vehicle surveys of available spaces; installation study of the electric motor unit and related auxiliaries; underfloor battery pack installation study; FEA calculations of critical components
OUTPUT
Mechanical kit drawings; support during physical assembling
Drilling carrier design
Activity duration : 430 h
INPUT
Designing a new 6-axle carrier to equip a self-moving drilling machine
PROCESS
Design of frame, steering geometry and transmission FEA calculation of frame and other main parts Specialized transmission calculation Pneumatic and hydraulic system design Electro-hydraulic actuator system design
OUTPUT
Arrangement drawings and calculation report