Final-year course inMechanical Engineering Design

IN THE MECHANICAL ENGINEERING

MSc PROGRAMME AT

LULEÅ UNIVERSITY OF TECHNOLOGY

2004

SIRIUS 2003/04 IS A COLLABORATIVE

PROGRAMME with the participation of Luleå

University of Technology, Volvo Aero Corporation,

Volvo Car Corporation, Hägglunds Drives and

several other partners from industry and

academia. Sirius prepares students for work in

product development. The course’s product

development projects are firmly based on close

collaboration with manufacturing companies or on

real product development needs that have been

identified in other ways. Work is conducted in

project groups with the support and guidance of

advisors from both industry and the university.

Collaboration benefits both the students and the

industry partners.

• The students are given an opportunity to apply

their knowledge when they develop proposals

for optimal solutions to real design problems

within the confines of a limited timeframe and

budget. They gain unique insight into present-

day and future working methods and coopera-

tion in product development.

• Manufacturing companies gain access to

innovative product development performed by

well-educated engineers who are not biased by

traditional modes of thinking and problem

solving.

Luleå University of Technology and industry partners in collaborationP

hoto

: Airb

us M

edia

Cen

tre

3

Creative product development

Sirius is one of the final-year courses for students in theMechanical Engineering MSc degree programme atLuleå University of Technology. Sirius is also open tofinal-year students from other MSc engineeringprogrammes at the university, which ensures a broadbase of knowledge for the course’s project groups.During most of the 20-credit course, productdevelopment projects are conducted in close nationaland international collaboration with companies anduniversities.

The aim of Sirius is for students to acquire, applyand integrate knowledge that is essential for productdevelopers in modern manufacturing industries.Students gain knowledge in project management,production of creative concepts, mechanicalengineering design and computer-aided design.Theygain a command of all stages in the chain of integratedproduct development, from needs analysis to finishedproduct. Under realistic industrial conditions, they mustcarry out product development in teams, incollaboration with manufacturing companies or basedon real product development needs presented in someother way. Experience from Sirius prepares participantswell for teamwork with people from other disciplines.

In support of their development projects, thestudents take courses in product development methods,computer-aided modelling and analysis as well as

project management.Sirius students engage in a valuable exchange of

knowledge and ideas with graduate students and stafffrom the Polhem Laboratory and other departments ofLuleå University of Technology. Not only do Siriusstudents from Luleå University of Technology havesolid theoretical knowledge, they also have the benefitof valuable practical experience of work in anintegrated environment and the use of advancedcomputer tools in industrial projects. For moreinformation about previous Sirius projects, please visitwww.cad.ltu.se/sirius.

TRADITIONAL PRODUCT DEVELOPMENT

Concept

Design Testing

INTEGRATED PRODUCT DEVELOPMENT

Manufacturing

Testing ManufacturingConcept Design

4

PRODUCT DEVELOPMENT PROJECTS

CRE[ATIVO]2

In this international project, students from Luleå andStanford University developed a light-weight compo-site wheelchair with accessories for winter use.

INTELiCARE, Intel CorporationStudents developed a system, including two devices and a computer application, that enables elderly peopleto increase their independence and promote social connectedness.

Distributed collaborative engineering – a VMCC projectUsing high-end distributed engineering tools andsoftware, a student design team has worked in anengineering design project together with VolvoMonitoring and Concept Center in Camarillo,California, USA.

Formula SAEIn this interdisciplinary project, students from differentdisciplines developed a complete racing car forparticipation in the internationally renowned FormulaSAE competition.

High-performance hydraulic piping, HDAB In this project the students have been developing a piping solution for high-power hydraulic motor systems, in close collaboration with one of Sweden’slarger industrial companies.This design project hasinvolved intense simulation.

Intermediate case for jet engines, Volvo Aero CorporationA development concept for an IMC (IntermediateCase) for the new RM250-2s jet engine was gener-ated.The design concept included proposals for design,materials, production and material testing.

Sirius 2003/04

Sirius 2003/04 comprised six product development projects as well as methodology courses in product development, computer-aided modelling and analysis and project management. Sirius was also open to students from other degree programmes outside theMechanical Engineering Design MSc programme.

5

GROUP SELECTION AND PRE-STUDY

This year’s programme started in September 2003 withpresentations of project proposals by representativesfrom Volvo Aero Corporation,Volvo Car Corporation,Hägglunds Drives AB as well as by the project leadersfor projects proposed within the university. Unlike theother projects, Formula SAE had to adhere to detailedregulations with respect to, among other consider-ations, vehicle-safety requirements. CRE[ATIVO]2 andINTELiCARE added extra diversity to the projectportfolio with their particular interest in the needsanalysis phase.The final composition of groups wasdetermined by personal preferences and the results ofan evaluation of the students’ preferences with the helpof the Stanford Team Construction Method.

THE CREATIVE PHASE

The groups produced proposals for solutions in theform of concepts that fulfilled function specifications.A theoretical background in each respective area wasobtained via information searches, study of internalreports and benchmarking reports, and throughobservations of user behaviour where applicable.

The groups’ proposals were assessed using differentconcept evaluation methods. Solid modelling was donewith the CAD program I-deas. In cases where acomputational basis for design was required, simulationswere also performed.The industry representatives tookpart in the assessment process to select the solutionsthat the students would continue to work with in themain projects.

MAIN PROJECTS

For the main project, a group leader was chosen in eachgroup.The function of the group leader was to ensurethat objectives were achieved and project expenditureswere kept within budget limits. Development of theconcepts continued.The flow of information wasfacilitated by online collaborative workspaces, whichenabled all groups to share relevant information.

CRE[ATIVO]2 prioritized development of physicalprototypes to allow the ”feel” of the wheelchair’s dif-ferent parts in use during different conditions to beevaluated.

The INTELiCARE project quickly began toexplore the needs future clients.The issue of choosingtechnical solutions was a big part of the project as wellas designing the protoypes.

In the VMCC project, the prototype evolved by useof product development methodologies and modernCAE tools.

The large number of components in the FormulaSAE project placed high demands on coordination.By mid-May, when the industrial projects were to bepresented, also the complete racing car had to be readyfor the Formula SAE competition in England.

The HDAB piping project has focused on findinggeometry parameters to optimize the flow in thepiping system.Two different side lines were to alter theuse of the system; first, by implementing functionalproducts, and second, creating an add-on to the systemwith a new directional valve.

Work in the VAC project focused on the productionof new concepts, simulations and selection of materialsto meet the demands from Volvo Aero Corporation.

PRESENTATION

CRE[ATIVO]2 presented both virtual and physicalprototypes of the complete wheelchair concept,including a light-weight composite frame.

The INTELiCARE team chose to present theirresults by building the whole system, including the twodevices.The prototypes were manufactured throughRapid Prototyping.

The VMCC team manufactured a prototype thatwas delivered to Volvo Car Corporation in Gothenburgfor further validation and testing.

Students in the Formula SAE group designed andmanufactured a competitive racing car for the FormulaSAE competition in England.The car has beendeveloped digitally and all components have beenoptimized with respect to weight, strength, manu-facturing and operating reliability.To present the result of the HDAB piping project aprototype was manufactured.This prototype was alsoused to test the design. In addition to the prototype,some animations showing the concepts in work wereproduced.These were presented together with theresults from the analysis.

The VAC team presented their results in the form of full-scale poster showing various angles and cross-sections.The group also performed simulations of theintermediate case to demonstrate its ability to meetrequirement specifications.

In May 2004, the projects were presented at LuleåUniversity of Technology and at the premises ofparticipating industry partners.

Imagine yourself going up a steep grade in the dead ofwinter.There is a light dusting of snow and a thin layer of ice on the ground because it was warm the day before.You can barely keep yourself from falling let alone walkup the hill.That wing-flapping motion with your armsisn’t helping. Now imagine that same scenario but thistime in a wheelchair that is meant for traversing linoleumfloors. If you thought you were getting nowhere walking,try spinning around for a while!

The TaskCRE[ATIVO]2 is part of the Design for Wellbeinginitiative, and its main goal is to enhance the wellbeing of persons with disabilities by using their description of needs as a starting point for product development.

The team started out with only one set of keywordsto frame the scope of the project: active, winter, leisure time.

CRE[ATIVO]2

– mobility devices for an active lifestyle

6

In this international project students worked onexpanding today’s concept of mobility devices for activeusers. The primary goal was to address the challengesthat people with disabilities face due to winterconditions.

7

From these words the team started to focus on mobilitydevices.Through rigorous needs analysis and bench-marking of current solutions the group discovered theneed for winter-adaptable manual wheelchairs.Thus,the mission statement for the CRE[ATIVO]2 projectwas formulated:To develop a safe mobility device that is easy to maneuver onvaried terrains and in multiple weather conditions.The deviceshould also improve user access to facilities and transportation,while being easily transportable.

International CooperationThe work has been conducted in an iterativedevelopment process on a global scale. Eight studentsfrom Luleå University of Technology and four studentsfrom Stanford University, USA, have worked togetheras a single team, where each geographically separatedgroup has contributed its own skills and viewpoints,both culturally and professionally, to solve the task.

This, together with the fact that the two universitieshave different theories of approaching productdevelopment, has allowed the team to apply the best ofboth worlds during their work.All participants werealso exposed to technologies supporting collaborativedesign, providing crucial experiences in multinationalteamwork.

ResultsThrough numerous concept generations andevaluations, a light-weight composite wheelchair and a tire cleaning system was developed. By usingcomposites instead of metal, the weight of thewheelchair was reduced, thus allowing for the additionof extra features while still keeping the chair lighterthan the most popular chairs on the market today.A center of gravity adjustment feature was added,whereby the user can adjust the center of gravityposition while in the chair.This allowed for the

backrest to be adjustable in different positions, givingthe user added comfort.Traction in winter wasimproved by the addition of clip-ons with a uniquetread pattern.

Finally, a wheel cleaning device was created to helpthe user to clean the chair before entering the houseduring late winter and early spring, when pavementsare wet and dirty.

8

The project aim was to prolong elders’ independenceand enhance their quality of life. It was also intendedto encourage elders to maintain and expand theirsocial networks.The solution was to use intelligentsystems at home that control the user’s physical andsocial activity level. By using this system, a relative orcaregiver gets a better insight into the elder’s life.Thesystem also encourages physical and social activities bycreating active networks among elderly people,facilitating lines of communication that encouragethem to socialize with other elders.

A feasible scenario is a widow in her early seventiesliving on her own. She has a son who is in the middleof a stressful career and family life. He does not havethe time to check in on his mother as often as hewould like to.Thanks to the INTELiCARE system,he can get a glimpse of his mother’s social and physical

INTELiCARE

The Luleå INTELiCARE team.

The Social Health Monitoring System.

INTELiCARE is a project where Luleå students collaborated with students from the Royal Institute of Technology, Sweden, and Stanford University, USA, on a commission from technology corporation Intel.

9

activities. He can see her routines and her social andphysical activities as well as being able to send a signal,to which she can respond to indicate that everything isokay.

His mother can see her friends’ keenness to contacther and she can signal her social availability to them.She can also send a signal to her son to say that every-thing is okay.Another possibility with this unit is thatshe can counteract cognitive decline by viewing imagesand explanatory text of relatives and friends byprojecting these images and texts with the unit on, forinstance, a table or a wall.

The system consists of three main components:1. Communication device for next of kin2. Communication device for the elders3. Communication system

Communication device for next of kinThis device enables relatives to monitor how the elderperson’s routines and social and physical activities aregoing. By receiving different vibration patterns fromthe unit the different activities can be interpreted.There is also a possibility to send a ”ping” signal to theelder, a signal that can mean whatever the customerwants.

Communication device for the eldersThis unit gives the elders the possibility to see whattheir friends’ availability is at the moment. If theybrowse through the names of their friends they can see if they want to socialize or not.

Communication systemThe communication system is a computer system thatconnects the two devices and it consists of a number of sensors in the home of the elder.The sensors sense a range of activities that thereafter are interpretered andtranslated into the three main activities that can be seenon the communication device for the relative.

The project was carried out using a productdevelopment methodology that aims to give students a solid foundation for carrying out any productdevelopment project in the future.The methodologyaids the development work by giving a structured wayof carrying out the project and seeing to it that theneeds of the user are satisfied with the new product orservice.

ResultThe result presented in May was the system with thetwo included devices that has been successfully giventhe properties that the project group aimed for.A fewnew creative functions have emerged that aim to fulfiland further exceed the user’s expectations.

Looking back on this project, having used thisproduct development methodology in a distributed collaboration with Stanford University and the Royal Institute of Technology, the INTELiCARE members feel they have been successful in creating new solutions that promote the wellbeing of elderly people.

3D model in Alias|Wavefront Studio Tools.

10

The student team at VMCC in USA.

From top left: Carl Åström, Per Skallefell, Anna Kristiansson,

Sofia Löfstrand, Alexandra Löfvander, Christofer Karlsson,

Jakob Hedlund and Johan Öberg.

Distributed collaborative engineering – a VMCC project

Using high-end distributed engineering tools andsoftware, a student design team has worked in an engineering design project together with VolvoMonitoring and Concept Center in Camarillo,California, USA.

BackgroundVolvo Car Corporation’s conceptual car center,VMCC – Volvo Monitoring and Concept Center – is located in Camarillo, California, USA. As the nameindicates,VMCC designs conceptual cars and predictsand monitors trends in the automotive industry. In theproject, a design team has for nine months been work-ing together with VMCC in a product developmentproject regarding safety in future cars.The team hasbeen using distributed engineering design tools,developed by researchers at Luleå University ofTechnology, in their daily work.

Project environmentThe student team consisted of eight membersdistributed on two locations, Chalmers University ofTechnology and Luleå University of Technology.In each location the team had its own distributed collaborative work environment in which daily workwas performed. Distributed project meetings havebeen held regularly to divide work between teammembers, report on tasks performed and to discussdesign issues.

Manufacturing of system component.

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Distributed collaborative engineeringThe overall aim of the distributed collaborativeengineering framework is to decrease the negativeimpact of geographic distance on product developmentefforts and to further enhance current advantages ofworld-wide, multidisciplinary collaboration. In light ofincreasing globalization, a crucial challenge fordistributed organizations is to make distance less of aconcern.The challenge is even more crucial in the caseof distributed product development because of thewide range of media and channels of communicationsuch as sketches, notes, hardware, 3D CAD models,gestures, and voice that engineers use in order to bringideas into concrete realization.

Project evolution and resultsIn the early design phase, ideas about the design weregenerated using various design theories and method-ologies.The design then evolved in parallel with valid-ation activities such as rigid body dynamic simulationsas well as finite element simulations of stressed parts of the design. During the last month of the project, anincreasing amount of time was spent on preparations,such as computer aided manufacturing and physicalstrength tests.The prototype was then delivered toVolvo Car Corporation in Gothenburg in May for further validation and testing.

LARS ERIK LUNDIN,

Vice President and General Manager,

Volvo Monitoring and Concept Center

”This project involves challenging and ambitious

engineering design tasks, which upon completion

would contribute to advancing the state of the art in

the development of cars using distributed engineering

design methods and also contribute to the safety of

occupants in the vehicles. We are pleased to have the

participation of the students from LTU and Chalmers

in this activity and look forward to evaluating and

integrating their collective efforts in our R&D activities

at VMCC.”

Distributed collaborative work.

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Formula SAELow weight, reliability and performance are the key goalsfor this year’s Formula SAE team. This demanding racingcar competition requires the students to be creative andinnovative in the whole integrated product developmentcycle. To meet the challenge, the team has collaborated with a whole range of institutions within the university and companies from all over the world.

Formula SAE team 2004.

CAD model showing power

train with Torsen differential.

Formula SAE / Formula StudentFormula SAE started in the USA in the early eightiesas a competition for students to compete in enginee-ring and design.Today the competition is global andevery year hundreds of universities enter one or moreof the three finals held in Australia, Great Britain andthe USA.

Presentation 75

Engineering Design 150

Cost Analysis 100

Acceleration 75

Skid-Pad Event 50

Autocross Event 150

Fuel Economy Event 50

Endurance Track Event 350

Total Points 1 000

The main purpose of the event is to provide a globalplatform for students to compare their abilities. Notonly is the racing car an attractive vehicle that offersthe chance to experience the glory of victory, it alsoembodies the very great challenge of designing,manufacturing and assembling a complex product.

The final competition event is divided into eightdifferent categories.Vehicle performance plays a centralrole in the final assessment, but presentation andproduction costs are also important. Points are awardedand the team that earns the most points claims the victory.

The competition comprises several events.

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Finite element analysis ofrear upright in carbon fibre.

The assignmentCritical factors for building a competitive racing car are low weight and high reliability.The objective wasset to develop a car that weighs less than 200kg andfinishes among the top three at the Formula Studentcompetition in Bruntingthorpe, England, in summer2004.

Multidisciplinary developmentThe complex task of designing and building a racingcar requires a wide variety of knowledge in differentareas such as engineering materials, engineering design,solid mechanics, computational fluid dynamics, rigidbody dynamics, electronics and economy.The first stepin the design process was to create a concept thatfulfilled the basic function specifications. Usingcomputer aided engineering (CAE) software such as I-deas and MSC.ADAMS, a complete virtual model of the car was created to enable simulation andoptimization of different functions.

One of the innovative functions is a semi-active suspension with magnetorheological dampers.Theelectronic control system has been built incollaboration with students from the Department ofComputer Science and Electrical Engineering.

The electronic system includes data logging,electronic gearshift, electronic clutch, etc. Data loggingmakes it possible to analyze the testing sessions in moredetail.

In cooperation with APC Composite AB manydetails such as rims, steering wheel and intake mani-fold have been manufactured in carbon fibre to reduceweight.The engine has an optimized electronic fuelinjection system and turbo and is now a fully stressedmember of the chassis.Together with Statoil the teamhas developed a fully optimized racing oil to furtherincrease the power output from the engine.

ResultsThe extensive use of high-grade materials such ascarbon fibre, titanium and aluminum has allowed theteam to produce a car that is highly optimized in termsof both weight and function.

We are confident that the car is going to be highlycompetitive. Read more about the project at www.formulasae.ltu.se.

Sponsors:

APC Composite, Luleå University of Technology, SCANIA,

Akademiska Hus, Tribolab, EXEL, Uddeholm, SEKAB,

Garret, TOOLTECH, ÖRNALP, Loctite, Permascand,

KUBAL, TRW Automotive, ATOM Racing.

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The assignmentThe assignment from Hägglunds Drives AB was tooptimize the design of an entire piping system forconveying oil, from pump to motor, in an applicationthat demands extreme flow rates and allows very lowlosses.The system was to contain the completesolution, from where it leaves the pump until it arrivesat the motor.The main system components are hosingand piping connected with different types ofcouplings.The objectives have been to refine andoptimize these components and to minimize pressurelosses.These losses are dependent on factors like theshape of the pipe, hose and couplings and viscosity ofthe fluid, but mainly the velocity.

HDAB – High-performancehydraulic piping

Directional valve,

slide concept.

Module placed in

virtual system.

In the future, energy will be even more expensive. Therefore it has become extremely important fortoday’s hi-tech companies to produce systems andproducts in which losses are minimized. This isnever more relevant than in high-consumption systems like industrial hydraulics. In this fieldHägglunds Drives AB is one of the world's leading manufacturers. With a unique development programme, they take a gigantic step towards technical perfection by creating strong, positive relations with university students at an early stage.

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Computer Aided EngineeringIn the design phase, speed was of the essence, so therewas no time for trial and error. Models therefore had tobe created and tested in a virtual environment.Toperform these tests numerous CAE tools were used.Analysis with CFD and FEM, and design andpreparation for manufacturing with CAD and CAMhave been decisive for satisfying the requiredspecifications on time. One tool recently introducedand extensively used is DCE, Distributed CollaborativeEngineering.This enables the team to communicatewith Hägglunds Drives AB through video conferencesover a high-speed broadband network, and through filesharing and planning over the internet.

ResultsAfter an intensive concept evaluation the team selecteda flexible and versatile solution that reduces thenumber of hydraulic systems components.To verify theresults a full-scale model of the new component wasmanufactured and subjected to benchmarking in a test facility designed by the team.

The group members have developed their ability to function as a part of a project team with given rolesand individual responsibilities.The close cooperationwith an international company such as HägglundsDrives AB has given the students valuable insight into the complexity of an industrial product developmentprocess.

The test rig in action.

Finished prototype of the module.

Video conference with Hägglunds Drives AB. CFD analysis of module interior.

16

The assignmentA basic principle of aeronautics is that the enginegenerates the necessary thrust.To convert this thrustinto accelerating force on the wings, and hence alsothe body, the jet aircraft is dependent on the IMC,since it is the major link between the engine and thewing.The IMC is the main load-carrying part of theengine. Since this IMC has a diameter of 2.5 meters,it must fulfil exceptionally high demands on e.g.,stiffness, fatigue and manufacturing costs if it is to be ahighly reliable and competitive product.

The main interest for VAC in this project was tofind a suitable material for a light-weight IMC thatcould replace titanium, the most common material inthe applications of today.

Use of a light, yet strong, material such as carbonreinforced epoxy polymer, gives this concept anadvantage that could make it the revolutionary IMCof tomorrow.

Highly competitive intermediate case for commercial jet engineThe aerospace industries are about to enter a new era, theera of light-weight materials in load-carrying structures.

Volvo Aero Corporation, located in Trollhättan, Sweden, manufactures components for jet engines. One of these components is the intermediate case (IMC), a load-carrying structure in the jet engine. In recent years the demands for reduced weight have increased. Lower aircraft weight, including the jet engine, will result in significantly cheaper flights. By introducing a nonmetallic, composite material, this vision could be realized.

The Sirius

VAC 04 team.

A full-scale visualization of

the intermediate case.

17

Carbon fibre reinforced

guide vane.

Whole engine model, WEM,

in nodal configuration.

Study of the

dynamic character-

istics of the inter-

mediate case.

Another parameter, besides the material, has alsobeen considered.This is the introduction of otherfunctions into the IMC, such as integrated guide vanes.The function of guide vanes is to axially redirect theswirling airflow from the fan, and by integrating thisinto the IMC the total part count will be reduced.Thiswill most likely also lower the total engine weight andtherefore make the concept even more advantageous.

The analysesThe somewhat non-conventional choice of materialhas brought a great deal of complexity to every kind of analysis necessary.

Advanced analyses of the material properties havebeen performed to optimize the configuration. Materialtesting has been carried out by SICOMP together withVAC, as verification of the material property analyses.

To analytically verify that the concept fulfils stateddemands, such as stiffness and stress, during differentloads (air gusts, emergency landing, thrust reverse and

so on) several studies have been performed using finiteelement methods in I-deas.

The final major area of study has been the manu-facturing process and estimation of the cost of the finalproduct, since this is vital for creating a competitiveproduct.

ResultsThe final design solution of the IMC is to be manu-factured in eight 45° segments.These eight segmentswill then be joined together. The intermediate case isto be made of carbon fibre reinforced plastics (CFRP),except for flanges and engine mounts, which will bemade of titanium.

Since the IMC will be made of CFRP, resin transfermolding (RTM) will be the manufacturing method.This is the most appropriate considering the large andcomplex geometry. The result from the RTM processsatisfies the high demands with respect to tolerances andstructural strength.Due to the complexity of thismaterial, the manufacturing costs have increased.However, the overall advantage of this project is an IMCwhich is approximately 25% lighter compared toconventional titanium structures.

The result of this project is, according to the maingoal, a highly competitive intermediate case forcommercial jet engines that promises lower flight costsin the future.The overall conclusion is that all membersof the Sirius VAC 04 team have developed their abilitiesin designing components for the multi-faceted aircraftindustry, not only as individuals, but as members of acreative team.

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HANS FOLKESSON,

SENIOR VICE PRESIDENT

Research & Development

Volvo Car Corporation

The Sirius project is an

excellent example of co-

operation between the

university and industry. We

are privileged to work with enthusiastic students who solve

problems with a fresh approach while sharing our industrial

experience. Furthermore, the student gains contacts that

can prove to be a great advantage when he/she eventually

applies for a job in industry.

In this programme, students get to take part in a real

product development process. To come up with a concept

and create a product according to a given set of objectives

while adhering to financial and time constraints is a great

learning experience, one that has real value in a future

career.

We think this is an excellent form of cooperation and we

look forward to a continuing successful relationship with

Luleå University of Technology.

BENGT-OLOF ELFSTRÖM,

RESEARCH DIRECTOR

Volvo Aero Corporation

The Sirius project is an

important element of Volvo

Aero’s technology-, human

resources- and recruiting

strategy. It strengthens Volvo

Aero’s 20-year collaboration with Luleå University of

Technology and provides a basis for final degree projects

and research projects. In present-day and future product

development there is, and will be, an ever-greater focus in

the earlier stages on greater creativity and interaction in the

requirement specification process between business

development, products and services, as well as work in a

virtual design environment. For Volvo Aero’s development in

this area, with new modes of working and new methods

and tools, the Sirius project plays an important role.

At the same time, the project gives participants an

understanding of how the company and the university can

cooperate on joint development of human resources.

The Sirius project also gives rise to creative new design

solutions that will be incorporated in our demonstration

project for the EU’s 6th framework programme, and sub-

sequently, in our products.

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The Polhem Laboratory Luleå at Universityof Technology is one of 23 Swedish centresof excellence with part funding from VINNOVA, the Swedish Agency forInnovation Systems.

Ideas from the Polhem Laboratory are

key concepts of the Sirius project:

• Integrated and parallel working method• Close collaboration with industry

The goal of the Polhem Laboratory is todevelop methods that will shorten lead-times in the product development process.At the same time, the costs of productdevelopment and product support must bereduced while the quality of the designsystem and flexibility in the organization areimproved.

Research within the Polhem Laboratoryis focused in the following areas: simulation,communication of information withinproduct development and conceptdevelopment.The projects of the PolhemLaboratory are conducted in cooperationwith divisions of Luleå University of

Technology, member companies and, often,with international partners.

The member companies of the PolhemLaboratory are:AB Sandvik Coromant,Aerodyn AB,Alvis Hägglunds AB,Ferruform AB, Hägglunds Drives AB,Metso Panelboard AB, MSC.SoftwareSweden AB, SKF Sweden AB, Vattenfall ABVattenkraft,Volvo Aero Corporation andVolvo Car Corporation.

The methods applied within the Siriusproject are also supported by research carried out within the framework of theENDREA programme (EngineeringDesign Research and Education Agenda).ENDREA was funded by the SwedishFoundation for Strategic Research (SSF).The Division of Computer Aided Designhas also participated in this programme.The Sirius project is now also collaboratingwith ProViking, which is funded by SSF.

University partners in the PolhemLaboratory are the Divisions of ComputerAided Design, Fluid Mechanics and SolidMechanics in the Department of AppliedPhysics and Mechanical Engineering.

Research in the Department of AppliedPhysics and Mechanical Engineering, whichis responsible for the discipline EngineeringDesign within the Mechanical Engineeringprogramme, is of world class.The DivisionofComputer Aided Design has the principalresponsibility for Sirius, which is the final-year course in the MSc degree programmein Mechanical Engineering Design. Sirius isa result of the Polhem Laboratory and the department’s leading-edge research and excellent contactnetwork within Swedish industry.

The Polhem Laboratory

PROFESSOR LENNART KARLSSON,

Division of Computer Aided Design

and the Polhem Laboratory,

Luleå University of Technology

Phot

o: A

teljé

Gro

dan

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SIRIUS ENGINEER 1999/00

After three years at Volvo Aero

Corporation I still enjoy the very

stimulating work environment, where

there is considerable room for

creative thinking and solutions.

The work includes developing and

adapting the company's engineering

systems so that Volvo Aero

Corporation can maintain its

competitive position in the industry. The aircraft industry is

facing a decrease in revenue and is changing at all levels,

and Volvo Aero Corporation must adapt to emerging

business models and constantly reduced lead-times.

The company aims to be at the forefront of development of

knowledge-based engineering systems, which are seen as

a condition for successfully managing new and higher

demands on shorter lead-times and an increased

responsibility for the product in a life-cycle perspective.

I have had great use for the different course elements

offered within Sirius, and especially the project that was

performed in collaboration with, in my case, Volvo Car

Corporation. The course gives insight into how to pursue

product development and you feel that you contribute to

the company's development in a positive way. I see Sirius

as a challenge with excellent possibilities to develop in the

areas that interest you, personally, with strong support from

both industry partners and the university.

Petter Andersson, Volvo Aero Corporation

SIRIUS ENGINEER 2001/02

I had the opportunity to work with

the first Formula SAE project; this

was during the academic year

2001/2002. Since I was studying

ergonomics and design I had never

really thought about taking the Sirius

course. However, for this project

there was a need for ergonomics

and exterior/interior design so some

of my classmates and I were asked to join the project.

I thought it sounded really exciting and did not think twice

about taking this chance. I worked mostly with the driver’s

environment, but in the end everybody helped out where

there was a need. I learned a lot about the product

development process and also about the importance of

communication. Being a former Sirius student certainly

made it easier to get a job – we have a really good

reputation! I work as a design engineer at Xdin AB, a

consultancy in Gothenburg, Sweden. I get to work with

different assignments and I use everything I learned in

Sirius.

Anna Carlsson, Xdin AB

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TOP ROW, FROM LEFT:

Tobias Larsson (Advisor)Peter Åström (Advisor)Joakim ErikssonThomas JohanssonHenrik Berguv RautioAnders Pettersson (Advisor)Majid El-AchkarAnders VikströmUlf AugustinRickard HägglundJohan FermMagnus Löfstrand (Advisor)

THIRD ROW, FROM LEFT:

Andreas Larsson (Advisor)Hans WikströmChristian JohanssonMarcus HanssonBoel ArlockMattias AnderssonTomas AlmboMikael NybackaAndreas AronssonKarl MarkströmRikard Mäki (Advisor)

SECOND ROW, FROM LEFT:

Linus RoseniusAndreas NyströmJakob HedlundChristofer KarlssonLinda SjöbladJens HardellJonas StenbergHåkan ÖstmanJens SundinLennart Karlsson (Professor)

BOTTOM ROW, FROM LEFT:

Lars JonssonKristina BulinMartin LarssonJimmy SegerstedtMalin LudvigsonAlexandra LöfvanderKarin DymlingIda BylundJohn KaplaEmma NybergJohan Öberg

ABSENT:

Daniel ErikssonJimmy HolmströmHenrik KarlssonStefan LindholmMikael LindgrenJonas MyrgrenJens Wågberg

Phot

o: A

teljé

Gro

dan

Sirius 2003/04

visiting address: UNIVERSITY CAMPUS, PORSÖN, LULEÅ

postal address: SE-971 87 LULEÅ, SWEDEN

telephone: 0920-49 10 00. fax: 0920-996 92

website: www.ltu.se www.cad.ltu.se/sirius