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Market development brings with it, alongside a growing range of projects and orders, an increased requirement for shorter development times and increased product quality - with simultaneous cost limitations.
Alongside the high level of qualification of our development and design specialists, the organization of tasks and workflows increasingly profits from the optimum use of resources. The basis for this is the order management system OMS as well as use of different project management methods in a wide range of projects.
Decisive in ensuring a quick and reliable development and design process are the principles and tools used:
The basis for design and numerical calculations is the 3D CAD system. Since 2006, ZAE has been working with Unigraphics NX4 in conjunction with the PDM-system Teamcenter (figure right, top).
With the introduction of this modern CAD system, the foundation stone for the introduction of numerical calculation methods was laid, which we have been building upon ever since. This includes, in particular, the future use of FEM methods for the calculation of complex components, e.g. housings.
ZAE has numerous analytical calculation programs for the design and verification of gear wheels and other components, which are under continuous development so that they always represent the latest available technology.
Component calculations and complete system solutions are undertaken using data from the order management system together with base data, which are then matched to the current production options, thus ensuring they always correspond to the state-of-the-art.
Tailor-made testing technology, which is highly-adaptable, and is to a large extent developed in-house, enables constant comparison between theory and practice creating reliability for both manufacturer and user. All test-benches are PC-controlled, connected to the company network and have the latest drive and measurement technology available. They are used to test both components (gaskets, bearings, gear wheels) as well as end products in respect of transmission behavior and performance. All data are stored in a central data management system.
The transmission behavior of drives is investigated on function test-benches (figure right, middle). Testing torques of up to 7,500 Nm can be produced. The main characteristics of transmission behavior are:
By contrast, drive performance is determined on performance test-benches. Testing speeds of up to 8,500 rpm at powers up to 70 kW yield information about product strength and product behavior under dynamic loading:
A detailed description of our test benches with their different application areas can be found > here (publication in German).
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