Institute for Product Development Karlsruhe

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IPEK - Institute for Product Development
Institute for Product Development Karlsruhe
Category:	research Institute Karlsruher Institute for Technology
Facility location:	Kaiserstr. 10, 76131 Karlsruhe
Type of research:	Applied research
Subjects:	Engineering
Areas of expertise:	Drive systems, tribological systems, development and innovation management, clutches and brakes in drive systems, validation of technical systems, lightweight construction, shape-function relationships in construction, product generation development, NVH and vehicle acoustics, power tools
Management:	Albert Albers, Sven Matthiesen, Sascha Ott
Employee:	approx. 70 scientific employees, 20 employees in administration and workshop, over 350 student assistants
Homepage:	ipek.kit.edu

The IPEK - Institute for Product Development is a research facility at the Karlsruhe Institute of Technology (KIT) and sees itself as a center of scientific product development and innovation with a focus on drive systems, mobility and devices.

The fundamental research concept of the IPEK for the development of the KaSPro - Karlsruhe School for Product Development is the parallel research on methods and processes of the PGE - product generation development combined with research on the synthesis and validation of new technical systems. The aim is to implement this concept through excellent joint performance and to convey the results in a competence- oriented manner through the KaLeP - Karlsruhe teaching model for product development in teaching and further education.

history

The beginnings of the IPEK - Institute for Product Development go back to the middle of the 19th century. From the higher trade school, one of five technical schools of the then still named Karlsruhe Polytechnic , both a chemical-technical school, headed by Karl Weltzien , and a mechanical-technical school emerged in 1847 . Ferdinand Redtenbacher , who presided over the mechanical-technical school, later in 1859 the mechanical engineering school, and is considered the founder of modern scientific mechanical engineering, played a decisive role in the division and the resulting mechanical engineering faculty . He was able to fall back on preliminary work by Wilhelm Ludwig Volz . After Ferdinand Redtenbacher, in 1863 both Franz Grashof , who received great recognition for his achievements in the Association of German Engineers (VDI) , and Josef Hart were appointed to the school as professors.

Karl Keller's appointment as third professor, alongside Franz Grashof and Josef Hart, for the newly established "Machine Elements" chair in 1869 can be seen as the origin of the IPEK - Institute for Product Development . He taught in the subjects of “hydropower machines”, “hoists” and the “machine elements” event that Ferdinand Redtenbacher had already organized. Karl Keller held the chair for 39 years until he was replaced by Hans Bonte in 1908. During his time, he did his first doctorate in 1903 on the then new steam express train with an average speed of 120 km / h. In 1924 Hans Kluge was appointed to the "Institute for Machine Elements and Cars" and took over the chair from Hans Bonte. Under his leadership, the institute developed rapidly and in 1928 received the first test stands specially for motor vehicles. Due to the large space requirements of the test stands and in order to continue to provide each student with their own drawing space, the institute was provided with an additional test room.

After the rebuilding of the institute, which was destroyed in World War II, Karl Kollmann was appointed in 1951 and changed the name of the institute a year later to "Institute for Machine Design and Motor Vehicle Construction" and with it the chair in "Machine Design". In order to do justice to the increasing number of students, a second chair with the designation “General Machine Design” was founded in 1967, to which Herman Reuter was appointed. In 1973, Karl Kollmann was followed by Rudolf Haller, who took over both the chair and the institute's chairmanship. Peter Kuhn was appointed to Herman Reuter in 1977 . After Peter Kuhn's retirement in 1997, the chair “General Machine Design” was not filled again as a result of the austerity measures imposed by the Solidarity Pact.

From 1996 onwards, Albert Albers took over the chairmanship of the institute and the newly named chair for product development and drive technology , formerly the chair for machine design , from Rudolf Haller. In 2004 the name was also changed to Institute for Product Development (IPEK) in order to adapt the name to the main research areas. In order to structure the research activities of the IPEK in a sustainable way, Albert Albers defined both the Karlsruhe School for Product Development , KaSPro for short , and the Karlsruhe teaching model for product development , KaLeP for short . In addition, Albert Albers initiated the re-establishment of a second professorship due to the double Abitur class through the G8 and the associated increasing number of students. In 2010 Sven Matthiesen was appointed to the chair for device construction and machine elements.

Institute director and chair holder

Overview of all institute directors and chair holders

Period	Institute director	image	Chair holder	Name of the chair	Institute name
1847-1863	Chairman		Ferdinand Redtenbacher	no naming yet	At that time it was still a technical and mechanical college, in 1859 renamed the mechanical engineering school
1863-1892	Chairman		Franz Grashof	no naming yet
1863 - 1901	n / A		Josef Hart	no naming yet
1869-1908	n / A		Karl Keller	Machine elements	"Institute for Machine Elements and Cars"
1908-1924	Institute management		Hans Bonte	Machine elements
1924-1951	Institute management		Hans Kluge	Machine elements
1951-1973	Institute management		Karl Kollmann	Machine design	Renamed "Institute for Machine Design and Automotive "
1967 - 1977	n / A		Hermann Reuter	General machine design
1973-1996	Institute management		Rudolf Haller	Machine design
1977 - 1997	n / A		Peter Kuhn	General machine design
since 1996	Speaker of the institute management		Albert Albers	Product development and drive technology,	Renaming to "Institute for Product Development"
since 2010	Member of the collegial institute management		Sven Matthiesen	Device construction and machine elements

research

The institute's research is divided into ten research fields. The focus of research activities is on drive systems and mobility, as well as methods and processes of product development. This research portfolio is spanned by two central frameworks based on system theory: the integrated product development model (iPeM) and the X-in-the-loop approach (XiL) for the validation of mechatronic systems.

Research fields

Drive systems

The research focuses on methods for the development and validation of conventional, hybrid and electric drive systems in different areas of application and scaling. Modern drive systems make a significant contribution to the performance, efficiency and, last but not least, the comfort of an overall vehicle. The increasingly complex interactions between the integrated subsystems, the drive topology and the operating strategy play a decisive role. On the basis of the IPEK-X-in-the-Loop approach (IPEK-XiL approach), the institute researches new types of simulation and test environments that make it possible to develop a system understanding of complex processes in the drive system. The IPEK uses this knowledge to develop innovative drive components and systems.

Development and innovation management

Since 1996 the IPEK has been researching the modeling and support of product development processes for the purpose of innovation management. Associated methods and development processes are always researched in their application and in the development of technical systems. With its process model, the iPeM - integrated product development model, it is possible to map product development processes in an agile manner and to develop products integrated in close connection to the development of the associated validation and production system as well as the appropriate strategy. The problem-solving process SPALTEN, developed and continuously researched at IPEK, supports the consistent understanding of product development as PGE - product generation development. To support development teams in the innovation process, methods and tools for the analysis of future market and customer needs are developed (e.g. scenario technology), methods for the early and continuous validation of generated development generations and methods for the targeted synthesis of mechatronic systems. The situation and needs-based modeling of product development processes and support of development teams is carried out using the approach of ASD - Agile Systems Design. Mechanisms of flexible process design are used, for example, in order to give development teams the right level of agility in the complex context of product development. This ensures, for example, that simple and complicated development activities are planned on the basis of existing product and process knowledge in order to achieve an optimal resource constellation.

C&C ² -A Shape-function relationships in construction

For more than 20 years, the IPEK has been researching under the term Contact & Channel Approach (C & C²-A) on models for mapping the relationship between shape and function in technical systems. The aim is to methodically support the analysis and synthesis processes in the design holistically in order to develop innovative product solutions more effectively and efficiently.

The Contact & Channel Approach (C & C²-A) contains three core elements and three basic hypotheses for their application. The active surface pair (WFP) is created when two surfaces come into contact during the fulfillment of a function. The lead support structure (LSS) connects the WFPs. Depending on the purpose of the model, it can contain parts from components to entire subsystems. The connectors (C) enable influences outside the system boundary of the model to be taken into account and thus support thinking in the system. The basic hypotheses describe the possibilities and limits of modeling with the C & C²-A. The first basic hypothesis describes the necessity of interaction in WFP for functional fulfillment. The second basic hypothesis describes the elements that are at least necessary to fulfill the function (2 WFPs connected by one LSS and integrated by two Cs). The third basic hypothesis describes the fractal character of the model formation, since models of the shape-function relationships can turn out differently depending on their model purpose and level of observation.

Clutches and brakes in drive systems

The IPEK understands clutches and brakes as mechatronic and mechanical actuators and researched in the systemic context. The IPEK focuses on fundamental system properties, such as dynamic behavior, wear behavior, coefficient of friction and drag losses, which affect the design and integration of the clutch and brake unit in the overall system.

Lightweight construction

Methods are being researched that support the entire lightweight design development process. Research focuses on methods for the analysis of lightweight construction potentials in the overall system, system synthesis using multi-material design, and methods for shape synthesis and structure optimization of isotropic and anisotropic materials.

Noise Vibration Harshness (NVH) and vehicle acoustics

The research field deals with the development of methods and the establishment of validation environments in the field of acoustics of the overall vehicle system, its subsystems (components) and the objectification of driving comfort. The focus is on hybrid vehicles, battery-electric vehicles and fuel cell vehicles. In the complete vehicle examination, the focus is on researching the simulated drive-by. This enables the standardized measuring method for homologation of vehicles to be carried out in an acoustic roller test bench. For the acoustics at subsystem level, a method for validating the vehicle interior noise in relation to the electric motor subsystem was developed. In the area of ​​comfort lensing, a method for objectifying the restart comfort of hybrid drives was developed.

Validation of technical systems

In the understanding of the IPEK, validation represents the central activity of product creation and is a guarantee for a successful product on the market. Therefore, efficient systems, methods and processes are being researched that implement holistic and process-accompanying validation.

The basis for this is the system- and function-oriented integration of physical and virtual models of (sub) systems in the entire product development process. The focus of the research is the IPEK-X-in-the-Loop-Approach (IPEK-XiL-Approach) for cross-system and continuous validation of technical systems.

Research focus:

• IPEK-X-in-the-Loop-Approach (IPEK-XiL-Approach) for holistic and continuous validation
• (Distributed) validation environments in a company and across company boundaries
• System and function-oriented integration of physical and virtual models of (sub) systems
• (Model-Based) Systems Engineering to support validation
• Model-based and maneuver-based approaches to formalize validation
• Individual and organizational acceptance of the researched methods and processes

PGE - product generation development

This research field is based on the description model of the same name, which depicts the fundamental phenomena of development projects. Accordingly, every product development is based on already existing technical solutions and is based on the activities of takeover, design and principle variation.

Taking up these models, methods and processes are researched in the research field in order to plan and control the development of new products, also across generations. This not only includes activities for developing the products themselves, but also the development of the associated validation systems, production systems and corporate strategies. Furthermore, designed methods and processes are adapted to specific industries and companies, taking into account the framework conditions and influencing factors that apply there.

Power tools

In the research field power tools, methods to support the development process of power tools are researched. The term power tool is understood to mean the system consisting of a hand-held device (electro-pneumatic hammer drill, angle grinder, etc.), tool (drill, grinding wheel, etc.) and consumable (dowel, screw, etc.). The focus is on the development of measurement, modeling and validation methods taking into account the cross-system IPEK-X-in-the-Loop approach.

Research focus:

• Investigation of the interaction between the user and the hand-held device
• Validation environments for power tools and their components
• Research and development of underground replacement systems
• Investigation of striking tightening procedures
• Machine learning and Industry 4.0 in the field of hand-held devices

Tribological systems

Tribological systems make a significant contribution to the functional fulfillment of modern technical systems. You are u. a. largely responsible for increasing energy efficiency, safe and convenient usability and other product properties and attributes. Research at IPEK focuses on methods for numerical and experimental modeling of tribological systems and their validation, taking into account multiphysics and multiscale phenomena. With a focus on sliding, friction and rolling contacts, suitable validation methods and simulation models are developed and optimized tribological systems derived from them. The validation of tribological systems is supported by research into suitable measurement methods and technology, such as thin-film sensors, structure-borne noise measurement technology or fiber-optic pressure and temperature measurement.

• Development and validation methods for tribological systems
• Development, construction and operation of system tribometers
• Simulation models (FEM mixed friction model)
• Contact modeling
• Measurement methods and condition monitoring

Teaching

Mechanical engineering at the University of Karlsruhe (TH) has a long and mandatory tradition. Outstanding personalities have significantly shaped teaching and research in the field of mechanical engineering. Following this tradition, a didactic concept was developed at the Institute for Product Development, which enables the transfer of the necessary knowledge for an engineer under the boundary conditions of advancing globalization and the resulting changed requirements at a high level.

Karlsruhe teaching model for product development (KaLeP)

The Karlsruhe teaching model for product development (KaLeP) is a continuous training system that is based on the development process in practice. The concept was developed by Albers et al. implemented at the Institute for Product Development (IPEK). The aim of the teaching model is to impart the competence to independently solve new problems. This takes place through independent, accompanying learning in a scientific work environment. Above all, it includes the nature of the learning offer, the learning environment and the acquisition of key qualifications.

According to Albers and Spöttl (2013), the learning process should be accompanied in different ways:

1. Lectures serve to structure and promote knowledge acquisition in a targeted manner.
2. Exercises are intended to stimulate reflection on the learning process.
3. Project work should enable the transfer and application of knowledge.

This triad of different building blocks (see Fig. 1) has been supported by the Karlsruhe teaching model for product development (KaLeP) since 1996 (Albers et al. 2001).

Each of the three modules covers different training goals. In the lectures, the theoretical basics are imparted, which form the basis for the other two building blocks (Albers et al. 2001). Exercises during the semester serve the practical application of theoretical knowledge to various problems (Albers et al. 2006). The accompanying project-based workshops also offer the opportunity to apply the knowledge learned independently. The focus is on independent work in small project groups to simulate real working conditions and, in addition to professional competence, other fields of competence such as B. to develop social skills , creativity potential, elaboration potential and methodological skills .

The essential core of the Karlsruhe teaching model for product development (KaLeP), besides being divided into three parts, is that by doing one's own work, formative experiences can be gained in specifically created teaching situations in company-like working environments (Albers et al. 2009). In this way, students develop practical skills in solving real, complex and technical problems (Matthiesen et al. 2013).

In 2013, the Faculty of Mechanical Engineering at KIT was honored with the VDMA Prize Best Machine House for Teaching Concept and Implementation, in which the Karlsruhe Teaching Model for Product Development (KaLeP) plays a central role (Faculty of Mechanical Engineering at the Karlsruhe Institute of Technology 2013).

Web links

• Institute website
• Karlsruhe teaching model for product development (KaLeP)

Individual evidence

1. ↑ Ferdinand Redtenbacher: Principles of mechanics and mechanical engineering. (PDF) 1859, accessed December 11, 2017 . 
2. ^ Albert Albers: Shaping the future through research . Ed .: Albert Albers. 2006.
3. ↑ Yvonne Bliestle: KIT - Faculty of Mechanical Engineering - Welcome. November 27, 2017. Retrieved December 11, 2017 . 
4. ↑ Brochure “Shaping the future through research”, published by the Institute for Product Development
5. ^ Ernst Terres: The technical university Fridericiana Karlsruhe: Festschrift for the 125th anniversary . 1950.
6. ↑ WiGeP Scientific Society for Product Development (Ed.): Portrait perspectives for tomorrow's products .
7. ↑ Albers, A .; Berger, J .; Boog, S: New approaches to the quantitative characterization of dual mass flywheels on highly dynamic component test benches . 2nd VDI Conference on Vibration Reduction in Mobile Systems 2017: Couplings and coupling systems in drives, Ettlingen, Germany. VDI-Verlag, Düsseldorf May 2017, p. 135-145 .
8. ↑ Albers, A .; Bause, K .; Reichert, U .; Ott, S .: The development of electric drive systems: How to deal with the challenges . EVS30: The 30th International Electric Vehicle Symposium & Exhibition. Stuttgart October 2017.
9. ↑ ^{a b} Albers, A .; Schille, F .; Behrendt, M .: Method for calibrating the clutch system and objectifying the restart comfort of hybrid drive trains on the acoustic roller test bench . In: VDI Wissensforum 2017 . 2017.
10. ^ A. Albers, N. Reiss, N. Bursac, T. Richter: iPeM - Integrated Product Engineering Model in Context of Product Generation Engineering. In: Procedia CIRP 50 (2016b) . 2016, p. 100-105 .
11. ↑ ALBERS, A.; REIß, N.; BURSAC, N.; BREITSCHUH, J .: 15 Years of SPALTEN Problem Solving Methodology in Product Development. In: BOKS, Casper (Ed.): Proceedings of NordDesign 2016 . The Design Society, Bristol, United Kingdom, Trondheim, Norway 2016, p. 411-420 .
12. ↑ ALBERS, A.; REIß, N.; BURSAC, N.; WALTER, B.; GLADYSZ, B .: InnoFox - situation-specific method recommendation in the product development process. In: BINZ, H .; BERTSCHE, B .; BAUER, W .; ROTH, D (Ed.): Proceedings of the Stuttgart Symposium for Product Development . 2015.
13. ↑ ALBERS, A.; HEIMICKE, J.; HIRSCHTER, T.; REIß, N.; MAIER, A.; BURSAC, N .: Managing Systems of Objectives in the agile Development of Mechatronic Systems by ASD - Agile Systems Design. In: Proceedings of NordDesign 2018 . 2018.
14. ↑ Albers, Albert; Matthiesen, Sven; Ott, Sascha: IPEK-Inside, newsletter of the IPEK Institute for Product Development . Ed .: H. Hanselka, KIT, Karlsruhe, Germany. Issue 1-2018, 2018.
15. ↑ Matthiesen, Sven; Grauberger, Patric; Sturm, Carolin; Steck, Michael:) : From Reality to Simulation - Using the C & C² Approach to Support the Modeling of a Dynamic System . In: Elsevier BV (ed.): Procedia CIRP . tape 70 , 2018, p. 475-480 .
16. ^ Lohrengel A., Dietz P .: clutches and brakes . In: Grote KH., Bender B., Göhlich D. (Eds.): Dubbel . Springer Vieweg, Berlin, Heidelberg 2018, ISBN 978-3-642-38890-3 .
17. ↑ Bijwe J, Nidhi, Majumdar N, Satapathy BK: Influence of modified phenolic resins on the fade and recovery behavior of friction materials . In: Wear 259 (7-12) . 2005, p. 1068-1078 .
18. ↑ Fish RL: Using the SAE # 2 machine to evaluate wet clutch drag losses . In: SAE Transactions, Vol. 100 . Section 6: JOURNAL OF PASSENGER CARS, 1991, p. 1041-1054 .
19. ↑ Albers, Albert; Braun, Andreas: The process of product creation . In: Frank Henning and Elvira Moeller (eds.): Lightweight construction manual. Methods, materials, manufacturing . Hanser, Munich 2011, p. 5-10 .
20. ↑ Behrendt, M .; Landes, D .; Albers A .: Implementation of sound intensity measurements into indoor pass-by noise testing . In: Inter Noise 2015 . San Francisco 2015.
21. ↑ Robens, G .: An action system for scaling the simulated drive-by using a microphone array for efficient validation in small semi-open spaces in the vehicle development process . In: Research reports IPEK . tape 61 .
22. ↑ Fischer J .: Methods for the validation of the interior noise of electric vehicles in relation to tonal noises due to torsional excitation by the electric motor . In: Research reports IPEK . tape 106 .
23. ↑ Albers, A .: Five Hypotheses about Engineering Processes and their Consequences . In: Proceedings of the TMCE 2010 . 2010.
24. ↑ Albers, A .; Behrendt, M .; Klingler, S .; Matros, K .: Verification and validation in the product development process . In: Udo Lindemann (Hrsg.): Handbuch Produktentwicklung . Hanser, Munich 2016, p. 541-569 .
25. ^ Albert Albers, Matthias Behrendt, Simon Klingler, Nicolas Reiss, Nikola Bursac: Agile product engineering through continuous validation in PGE - Product Generation Engineering . In: Design science, 3 (5), 19 . 2017.
26. ↑ Albers, A .; Dietmayer, K .; Bargende, M .; Behrendt, M .; Yan, S .; Buchholz, M .; Zaiser, S .; Roessler, A .; Bernthaler, T .: XiL-BW-e - Laboratory Network Baden-Württemberg for Electric Mobility . In: The 30th International Electric Vehicle Symposium & Exhibition . Stuttgart October 2017.
27. ↑ Albers, A .; Behrendt, M .; Klingler, S .; Matros, K .: Verification and validation in the product development process . In: Udo Lindemann (Hrsg.): Handbuch Produktentwicklung . Hanser, Munich 2016, p. 541-569 .
28. ↑ Albers, A .; Almond, C .; Yan, S., & Behrendt, M .: Systems of systems approach for the description and characteriza of validation environments . Ed .: International Design Conference - Design 2018. 2018, p. 2799-2810 .
29. ↑ Albers, A., Bursac, N., & Wintergerst, E .: Product Generation Development - Importance and Challenges from a Development Methodical Perspective . Ed .: Stuttgart Symposium for Product Development.
30. ↑ Univ.-Prof. Dr.-Ing. Sven Matthiesen, lecture at the Knowledge Forum Power Tools, July 7, 2017, KIT, Karlsruhe
31. ↑ IPEK - Institute for Product Development (Ed.): IPEK Inside . Edition 2014, 2014.
32. ↑ IPEK - Institute for Product Development (Ed.): IPEK Inside . Edition 01/2018 edition. 2018.
33. ↑ Albers A. et al .: Potential for reducing drag torque-related losses through new validation and development methods . In: Couplings and coupling systems in drives . VDI-Verlag, Düsseldorf 2015, p. 123-135 .
34. ↑ Albers A., Herbst D .: clutch picking - causes, modeling and countermeasures. In: VDI reports 1416 . 1998.
35. ↑ Klotz T., Ott S., Albers A .: A method for determining the application-specific performance limit of dry-running friction pairs. In: Research in Engineering . Vol. 83. Springer, Berlin Heidelberg, pp. 11-20 .
36. ↑ Matthiesen et al .: University training as a designer in the context of industrial change . 2017, p. 751 .
37. ↑ Albers A., Spöttl G .: Competence orientation in university teaching - training of tomorrow's engineers . Ed .: Plenary Assembly Mechanical and Process Engineering. tape 62 , 2013.
38. ^ Albers A, Burkardt N, Matthiesen S: New Education Concepts for the Training of Creative Engineers - The Karlsruhe Education Model for Industrial Product Development - KaLeP. Derby, United Kingdom 2001.
39. ^ Albers A, Burkardt N, Matthiesen S: New Education Concepts for the Training of Creative Engineers - The Karlsruhe Education Model for Industrial Product Development - KaLeP. Derby, United Kingdom 2001.
40. ^ Albers A, Burkardt N, Düser T: Competence-profile-oriented education with the Karlsruhe EducationModel for Product Development (KaLeP) . World Trans Eng Technol Educ 5 (2), 2006, p. 271-274 .
41. ↑ Matthiesen et al .: University training as a designer in the context of industrial change . 2017, p. 741 .
42. ↑ Albers A, Burkardt N, Robens G, Deigendesch T: The Karlsruhe Teaching Model for Product Development (KaLeP) as an example of the holistic integration of project work into university teaching. Darmstadt . 2009.
43. ↑ Matthiesen S, Mangold S, Klink K, Diez A: Study on the expansion of problem-solving skills in engineering studies. Tangungsband TeachING-LearnING.EU “MovING forward - Engineering Education from vision to mission”, 2013.
44. ↑ Matthiesen et al .: University training as a designer in the context of industrial change . 2017, p. 739 .

Coordinates: 49 ° 0 ′ 34.2 "  N , 8 ° 24 ′ 51.6"  E