The master’s thesis deals with the design of an injection mould for manufacturing of a plastic bottle cap with a child safety lock. Firstly, the analysis of the part is done including a detailed specification of its function and criteria, which have to be fulfilled. After the technology is chosen (injection moulding), the analysis of the injection moulding technology and the problematics of design process is provided. In the following practical part of the thesis, the particular mould for the given part is fully designed using simulation and technological calculation. On the basis of the acquired parameters of the mould, the injection machine was chosen. At the concussion of the thesis, the technical and economical evaluation of the proposed manufacturing process for the cap with child safety lock is realised.

The main goal of this master’s thesis is to create a design of robotic cell for operating of blasting machine. Operation of blasting machine consists of robotic manipulation of aluminium castings from input container to the blasting machine conveyor. After blasting operation aluminium castings are manipulated by robot from conveyor to output container. The part of the master's thesis is proposal of several variants of solution of design of robotic cell. Afterwards the best option is selected. The thesis also deals with design and selection of functional components in robotic cell. Functional verification of robotic cell is made in software Tecnomatix Process Simulate. Technical-economics evaluation is also part of this master’s thesis.

Viele Arbeitsprozesse in der Bau- und Fördermaschinentechnik, Lebensmittelindustrie oder Verfahrenstechnik sind gekennzeichnet durch die Interaktion mit Schüttgütern. Beispiele hierfür sind die Gewinnung und der Transport von Erd- und Rohstoffen sowie die Verarbeitung von Getreide, Mais, Pellets oder Granulaten. Zur Abbildung der partikel-mechanischen Vorgänge hat sich die Diskrete Elemente Methode (DEM) als geeignetes Simulationsverfahren etabliert. Für eine prospektive Analyse der Wechselwirkungen zwischen Schüttgut und Maschine ist es notwendig diese Methodik mit einem domänen-übergreifenden Systemmodell zu verknüpfen. Es wird eine Lösung vorgestellt, welche eine geschlossene Modellierung und Simulation der DEM in der Software SimulationX ermöglicht.

This thesis deal with design and implementation of innovative cooling method, intended primarily for medium-power synchronous generators. The main objective of this proposal is to remove the large heat exchanger connected to generator. This heat exchanger unduly increases the space requirements for the machine location. The proposed solution is to use a direct water-cooled stator. It is assumed that the rotor winding will be still cooled by air. Unlike current cooling system, the hot air from the rotor can be cooled in smaller cooler inside the generator. In this work are described methods which can be used for design of water cooling basic parameters, taking required temperatures into account. A small induction motor was selected for practical verification of the proposed cooling concept. This motor was modified into two variants - related to the old cooling of synchronous generators and related to the proposed solution. Both of these variants were measured and compared with each other. Subsequently, CFD models of these two variants were set up. Measured temperatures were used for debugging of models and identification of material properties of components of these machines. The final model of water-cooled variant also makes it possible to simulate the work of motor for higher performance and to determine the overload compared with the old cooling variant. Some knowledge and experience obtained from the small water-cooled induction machine were used in the design of water-cooling for large synchronous generator. In a similar way, CFD models of the old variant of cooling and proposed variant of water- cooling were created. Although these models were not verified by actual measurements on the generators, the results indicated that the application of water-cooling in this type of machine is appropriate and provides many benefits.

Hybrid electric vehicles significantly reduce exhaust emissions and increase fuel economy. Power packs are the most fundamental components in a series powertrain configuration of a hybrid vehicle, which produce the necessary power to run the vehicle. The aim of this project is to design a compact power pack for a series hybrid vehicle, using virtual prototyping. The hybrid electric vehicle characteristics and configurations are analysed, followed by an explanation of the principles of induction machines. A new type of rotary induction machine with an outer rotor construction is designed to be coupled with the novel rotary internal combustion engine with rotating crankcase in order to form the compact power unit for the hybrid vehicle. The starting and generation performance of the designed machine is analysed by an electric machine simulator, called JMAG. ADVISOR software is studied and utilised to simulate the overall vehicle performance, employing different categories of power packs in the powertrain. Results show that the proposed compact power pack has the best performance in terms of fuel economy, emissions and battery charging compared to the existing power unit options. Over the city cycle, fuel economy is increased by up to 47 % with emission reduced by up to 36 % and over the highway cycle, fuel economy is increased by up to 69 % with emission reduced by up to 42 %.

In this paper, a simulation study is carried out for the development of concepts to optimize the tribological contact of valve plate and cylinder block in an axial piston machine in swash plate design. The valve plate/cylinder block contact is one of the three essential tribological contacts in axial piston machines. In a research project at the Institute for Fluid Power Drives and Systems (ifas), this contact is investigated by a specifically designed simulation tool. In addition, a test rig exists for the experimental investigation. With the results of simulation and experiment, it was shown before that the cylinder block is tilting to the high pressure side. Due to this movement, the gap height is not constant. In the area of minimum gap height, not only the fluid friction, but also the danger of solid body friction increases. Because of the higher friction losses in the area of minimum gap height, the temperature increase reduces the lifetime of the leaded coatings. In this paper, the results of the measurements as well as the simulation model are briefly summarized. It is followed by a simulation study of different possibilities to raise the gap height. Based on this pre-study, a first concept for the optimization of the tribological contact valve plate/cylinder block is presented and its applicability is discussed.

In contrast to constant operating states, particle and NOx emissions of internal combustion engines are significantly higher during transient operating states, which occur repeatedly at working cycles of mobile machines. This paper therefore deals with the conception, development and testing of hydraulic hybrid systems to reduce these emissions by phlegmatization of the engine. A wheel loader with its machine-typical working cycle serves as an example for the investigation of the benefits of such a system. Therefore, model based development techniques are used. In a holistic machine simulation, four different typical wheel loader cycles were carried out and the optimum size of the hydraulic accumulator for the hybrid system is identified by a parameter variation. The lowest emitted emissions and the smallest construction dimensions are the key elements for the accumulator selection. With an optimal hydraulic accumulator, a reduction in particle emissions of up to 29.4 % is achieved in one of the cycles investigated.