Courses

I want to recap my courses, which I've attended during my studies. So this lists my subjects from university it it also works as a reference and as a reminder for myself. Because my university allowed to pick and assemble most of the courses oneself, I've always choosen as many as possible and only the most difficult ones. In fact, I had taken classes, which weren't necessary at all. Due to time restrictions, I needed to abort some of them (these are not listed). The course names are denoted in german.

Bachelor:

  • (Technische) Physik
  • Höhere Mathematik 1.1
  • Höhere Mathematik 1.2
  • Höhere Mathematik 2
  • Grundlagen der Sportgerätetechnik
  • Grundlagen der Bewegungswissenschaft
  • Biologische Grundlagen von Bewegung und Leistung
  • Geräte und Materialien in der Praxis
  • Kompaktkurs Winterportgeräte
  • Kompaktkurs Sommersportgeräte
  • Technische Mechanik
  • Konstruktionslehre/Maschinenelemente
  • CAD—Praktikum
  • Darstellungslehre/CAD
  • Werkstofftechnik
  • Werkstoffprüfung
  • Elektrotechnik/Elektronik
  • Einführung in die Sportökonomie
  • Grundlagen der Sportmedizin
  • Grundlagen der Trainingswissenschaft
  • Fremdsprache/Englisch Kurs 1 - study-related standard situations
  • Grundlagen der Statistik/SPSS
  • Forschungsmethoden der Sportwissenschaft
  • Grundpraktikum
  • Fertigungslehre
  • Grundlagen der Kunststofftechnik
  • Methodisches Konstruieren
  • Faserverbundkonstruktion
  • Strukturleichtbau
  • Mechanismentechnik
  • Spezielle Sportgerätetechnik
  • Konstruieren mit Kunststoffen
  • Prüfen von Kunststoffen
  • Sporttechnologische Messverfahren
  • Forschungsgebiete der Bewegungswissenschaft und Sporttechnologie
  • Bewegungswissenschaftliche Messverfahren
  • Messtechnik
  • Steuerungs— und Regelungstechnik
  • Sensor- und Signalauswertung
  • Projektarbeit und mündliche Prüfung
  • Bachelorarbeit
  • Qualitäts- und Umweltmanagement
  • Technische Mechanik III
  • Technische Thermodynamik
  • Grundlagen der Informatik
  • Strömungslehre

Master:

  • Praktikumsbericht
  • Simulation in der Umformtechnik
  • Optimierung
  • Technische Thermodynamik 2
  • Wärmeübertragung
  • Wirtschaftliche Produktgestaltung
  • Rapid Prototyping
  • Elektromotorische Antriebe
  • Projektmanagement
  • Interne Unternehmensrechnung
  • Gesprächsführung
  • Präsentationstechniken
  • FEM 2
  • Kontinuumsmechanik 2
  • Höhere Strömungslehre
  • Materialmodellierung
  • Virtual Reality-Modellierung
  • Thermisches Beschichten
  • Experimentelle Strömungsmechanik
  • Berechnung anisotroper Strukturen
  • Masterarbeit

Studium Generale:

  • Numerische Methoden für Ingeniuere
  • Numerische Methoden der Wärmeübertragung
  • Einführung in die Emotionspsychologie
  • Zeitmanagement

Additional courses (with certificate):

  • Kontinuumsmechanik 1
  • FEM 1
  • Virtual-Reality-Technik im Maschinenbau

Works

In this section I want to show and summerize my works, papers and bigger assignments, which were all done while studying.

Student project work: Innovativer instrumentierter Dummy-Kopf (2013)

Hyundai Patent Nr.US 6,691,585

This was a bigger prerequisite in my undergraduate studies. Before the bachelor thesis, this project work served as practice in writing theses.

Infos

Scope of Work: Here (german).

Abstract:
To examine the safety of bicycle helmets, artificial dummy heads are used. The dummy head with helmet falls from a defined height at a predetermined angles on a base, while forces and accelerations are measured against the fall direction. The aim of this work was to invent a new artificial dummy head, which would take the anatomical structures of the human head more into account. Also the appliance should measure rotatory loads as well as relative accelerations among of each of the parts.

Results

  • Literature research in human brain anatomy
  • Documentation written in Microsoft Word
  • Patent research in crash dummies
  • Cad model in Pro/E created, inclusive drawing.
  • Some morphological analysis (how to attach the sensors)
  • From drawing it was manufactured
  • Theoretical calculations made with MathCad.
  • Carrying out tests and record measurements of accelerations and forces
  • Visualize the measurements (then now it was done in Excel)

Human head anatomical basics

Import of spherical coordinates from patent

CAD model. Inner part represents brain. Outer part represents cranium

Pocket for sensor on the "simplified brain"

Pocket for sensor on the "simplified cranium"

Manufactured model

Experimental set-up

Measurements from impact (edited and cropped)

Lessons learned

  • For the first time, one of my CAD models/drawing was manufactured. This was a nice experience! Although it was correctly manufactured on the first try, due to my mistakes it was totally off with the dimensions/mass (too heavy).
  • Calculations are not really comprehensible (and unfortunately propably not correct). The exported pdf from MathCad was not really nicely formatted, because of my long variable names
  • Experiments are laborious and must be done very carefully.

Bachelor thesis: Festigkeitsberechnungen und Optimierung einer Kurbel (2014)

Real crank

Infos

Scope of Work: Here (german).

Abstract: Here (english).

Results

  • Documentation written in Microsoft Word
  • Investigation of the FKM-Richtlinie
  • Rebuild Cad model from drawing (in Creo)
  • Considerations were made, under which angles the dynamic forces are attacking, which was quite complicated
  • Calculation of moment paths by hand (with MathCad)
  • Comparing to calculations from Kisssoft, to find the best bearing arrangement.
  • Visualizing with Excel.
  • Morphological analysis (how to change the geometry)

Rebuild cad model

Nice Rendering (made with Keyshot)

Front view

Diagram of joint force and angle of attack in dependence of drive angle (Excel)

Crank in machine

Calculation in Kisssoft

Bending stresses made by hand and Kisssoft, visualized with PowerPoint

FEM Simulation from original design

FEM Simulation from optimized design

Variations were done with morphological analysis

Sensitivity analysis

long-term stress investigations

Lessons learned

  • FEM modul from creo was quite easy to use.
  • Much too high stresses were simulated. This was due to a singularity, which back then was not even considered.
  • Calculations made with Mathcad were more comprehensible with additional lines of text between the formulas.
  • PowerPoint as a quasi vector program can be used for nice visualisations!
  • Do not overcomplicate things and start easy.
  • When writing thesis always concentrate on the important parts.

Course work: Virtual reality modeling: "plane" on water (2016)

Infos

Although this course was titled: „Virtual Reality-Modellierung“, it was more about 3d modelling. From reference images a "plane" was remodelled in 3D.

Scope of Work: Here (german).

Results

  • This was entirely done from scratch by me with 3ds Max by autodesk.
  • Geometry as Splines, with multi-material and a specific light setup (HDR)
  • Animated Sea
  • Camera flight
  • Rendered on my own machine
  • Exported to VRML (with adaptations)
  • Presentation on the „Powerwall“

Front view 1

Front reference image

Side view

Side reference image

Underwater view

Front view 2

Lessons learned

  • Working with splines and this kind of technique was fascinating, but smooth results were hard to achieve.
  • I'm surprised that the water looks so well and even more that the plane interacts with the waves.
  • HDR is quite useful
  • I had thought my work represents itself, but a carefully arranged presentation is still very important.

Internship: Simulating a cyclone separator (2016)

Cyclone seperator simulated pressure drop

Infos

This was a prerequisite for my master. I've found some nice firm and choosen a simulation topic in simulating cyclone separators. The task was to establish a software solution for simulating cyclones, where OpenFoam was the preferred software. At this time, I was confident to do everytdhing only with Open Source software.

Results

  • Documentation written in Markdown and converted to PDF with Pandoc (and latex).
  • Extensive literature research on cyclones and cyclone simulations and cyclone simulations with OpenFoam.
  • Along the way, an entire internship report was written. Almost for every day (or at least for every week).
  • Tried to understand the MP-PIC (simulation) method.
  • Tried to understand parts of OpenFoam's source code.
  • Fully parameterized CAD modelling was done with Salome and python (script-based geometry generation)
  • Meshing was done with Salome, SnappyHexMesh and cfMesh
  • Taking the openfoam cyclone tutorial and adjusting everything to my liking. All with CLI and a sole text editor.
  • Whole development chain parameterized! Implemented using bash scripts. From geometry to mesh to simulation to postprocessing and calculations!
  • Calculations were done with Python (Numpy, Sympy, ...)
  • New Math/Documentation/Programming system: Jupyter
  • Taking text output from OpenFoam, reading it in with Pandas, processing it with jupyter and visualize it with matplotlib, optionally automatically save result image.

Front view 1

This is the mesh generated by cfMesh

Seperation curve, small particles are not collected, but bigger ones are

Agglomeration of (white) particles at the lower end

Lessons learned

  • OpenSource software does not lag features
  • Salome has some bugs and Hexablock is even almost unusable.
  • The usage of OpenFoam (without gui) was not that hard, but the code of OpenFoam is very (and I mean VERY) complicated.
  • Although the parameterized cad model with Python was working, it was convoluted at the end.
  • To work with scripts and programming all the way, was often troublesome. But nontheless, it was working and I think with more expertise this will be done with far more ease.

Master thesis: Simulating air bearings (2016/2017)

My own programmed components

Infos

This was my master thesis. It was about simulating air bearings with a 1d-system simulation library and the modelling language Modelica.

Full PDF: Here (german).

Unfortunately, I have not completed it, because Modelica was all new to me and together with my high ambitions, this was just too much, I guess. I wanted do program my own Modelica library within OpenModelica (because, you know, I like open source software).

Results

  • No „real“ results
  • But... I've read through the book by Peter Fritzson: Principles of Object-Oriented Modeling and Simulation with Modelica 3.3: A Cyber-Physical ApproachNov 24, 2014, amazon link. Yes.., most of the 1000 pages.
  • Written in Pandocs Markdown once again, but now with correct layout, equations, citation and much more (only in markdown!)

Lessons learned

  • Programming in modelica is much (and I mean MUCH) harder than the actual use.
  • Maye chose easier tasks? Nah...

Master thesis: Simulating hydraulic cylinder (2017/2018)

Infos

Scope of Work: Here (german).

Abstract: Here (english).

Contents: Here (german).

Results

  • Written in Pandocs Markdown once again, but now with correct layout, equations, citation and much more (only in markdown!)
  • Whole Thesis written in Pandows Markdown
  • Extensive literature research on hydraulic cylinders
  • Building models for hydraulic cylinders
  • Extensive use of vector diagrams (inkscape)
  • As CAD software Freecad was chosen (instead of salome). There is again the possibility to script the geometry with python (fully parameterized)
  • Meshing was done with SnappyHexMesh and Gmesh
  • Solving of specialized mesh problems
  • Simulated 2D and 3D versions
  • Simulated variations
  • One chapter about the underlaying formulas.
  • Taking no openfoam tutorial but building it from the ground up.
  • Calculations were done with Python (Numpy, Sympy, ...)
  • Used almost the same tools as before (notably python, no jupyter though), but for visualizing now Plotly comes into play.
  • Plotly allows interactive and dynamic graphs openable from any webbrowser (self-contained html document), which can be saved automatically
  • Exported from paraview, imported into blender and (with a script) rendering to a video

Hydraulic cylinder geomtrey with Freecad

2D model with simplifications and assumptions

3D mesh with SnappyHexMesh

Pressure field

Velocity stream tracers

Evaluation and comparision, real vs simulated

Variations

Lessons learned

  • There were some really troublesome simulation limitations this time, especially with OpenFoam
  • I'm a fan of parameterized cad modelling, and so I've tried to do with FreeCad the same as with Salome: script generated cad modelling. Normally this method is way superior over other methods, but this time it was extremely time consuming and even more convoluted.