Development
SHW is an innovation leader not only in the field of oil pumps, fuel pumps and water pumps but also in the field of components and systems for conventional, hybrid and electric powertrains. It is also the technology leader in the field of brake discs.
PLUS SHW-POWER
Driving internationalisation forward with trend-setting core competencies and expanding innovation leadership.
Our vision is to become the leading systems supplier to all major OEMs in the automobile industry – every vehicle platform should be equipped with that extra Plus from SHW-Power – i.e. it should have one of our systems or components on board. Our products contribute to reducing fuel consumption and electrifying the powertrains of cars and commercial vehicles. The SHW of the future will be more efficient, more international and even more innovative.
Calculations and simulation methods
Diverse calculations and simulation methods, our own prototype workshop and an extensive test bench allow us to conduct functional and environmental tests of our components and systems while simulating in detail all the relevant driving conditions for our products on the test bench.
Quality assurance methods, such as design and process FMEAs and software development based on Automotive SPICE as well as safety analyses pursuant to ISO26262 support the development processes right through to the start of production and thereafter.
We at SHW combine all the competencies, such as mechanics, hydraulics, electronics and software, which are required for the development of complex mechatronic systems under one roof.
From the initial concept through to the final series product, our systems are designed and engineered at our own development centre in Bad Schussenried across all phases of the product development process.
In parallel, our engineers develop electronic switches and the associated embedded software hand-in-hand with the hydraulic functionalities.
Precision forming
SHW continues to work on its precision forming and joining processes for the high-precision hydraulic components used in oil pumps and camshaft phasers and are aimed at reducing leaks. Thinner lubricants and motor oils are being increasingly used to reduce CO2 emissions still further. To ensure that hydraulic systems have as little leakage as possible, the tolerances have to be made even smaller. Using innovative moulding and joining solutions, such as the pulse adjustment method, SHW develops high-precision sintered components for engine and transmission oil pumps as well as for camshaft phasers, thereby improving their energy efficiency.
SHW researches and improves the local surface density to make highly durable gear wheels and long-lasting chain wheels. Sintered parts are by nature porous to a certain extent and therefore display inferior mechanical properties to conventional steel.
With a selective surface densification method that targets the zones of the part that are subject to most stresses, the mechanical properties approximate those of solid steel. We therefore combine the special forming advantages of powder metallurgy with the high-performance features of steel. The advantages of surface densification are primarily highly durable gear wheels and long-lasting chain wheels. This results in systems with reduced consumption which can only be economically realised using powder metallurgical components.
Milestone reviews
A number of milestone reviews are held during the development process. During this process, the results are reflected upon to ensure that future brake discs meet the requirements of both sides. The design is only approved when all the specifications are met.
After approval, the casting tools are designed and manufactured. These are produced by SHW’s own toolshop. These casting tools, which are nearly ready for serial production, are then used to cast the first development samples.
To ensure that the later brake disc fulfils all the defined functions, the first development samples are validated on the SHW testing station. This involves conducting a number of tests in keeping with the customer’s test guidelines.
Only after the product successfully passes all the tests and is validated are the development samples sent to the customer. With these samples, the customer can, for example, run the first tests on its vehicles.
The results of the various tests are then discussed with the development team of the customer and any improvements to the product are made. Only then does serial production of the brake disc begin.
SHW has decades of experience in developing and manufacturing brake discs. The motivation to constantly improve products and processes culminates in a high level of competence. SHW can accompany its customers from the original design concept right through to serial production of a product.
The point of departure is the sheet of specifications containing all the requirements expected of the brake disc. This forms the basis for design and engineering work on the brake disc. In the development phase already, various simulations ensure that the brake disc fulfils all relevant functions. This avoids later costs and saves valuable time. For example, simulations study how the brake disc changes shape as the temperature rises while braking. This is also important for braking dynamics. Various development methods, such as Failure Mode and Effects Analysis (FMEA), are used to identify risks and take counteraction.
Naturally, the respective requirements placed on the brake disc must be met in a way that is commercially feasible. For this reason, specialists from the production department assess the casting and machining aspects and suggest changes that are decided on together with the customer. Here too, use is made of simulations. An example is a simulation of the casting process to obtain knowledge of its manufacturing capability and quality of the brake disc.