INNOVATIONS / RESEARCH
A young and motivated team, the very best technical equipment, and outstanding contacts with universities and other scientific institutions have allowed brehmermechatronics to be involved intensively with innovative research for a long time. Always open to new ideas, exciting projects for Industry 4.0 as well as innovative mechatronics solutions for passenger and commercial vehicles are taking place here.
Other preliminary designs for Industry 4.0 and vehicle components like a zero power switch, AdBlue sensor, and multiquality sensor are already underway. Many of our research projects are supported with funds from the BMWI and BMBF.
Zero-Power Solar Multi Switch
Project: Zero Power Solar Multi Switch
Funding body: BMWi
Duration: 2009 – 2011
Contents and Objectives
- Development of an energy-self-sufficient wireless switch for buses, construction machinery and agricultural machinery
- Combination of solar cell, capacitive sensor technology and wireless transmission
- Use of the solar cell as an energy source and sensor (zero-power approach)
- Implementation of multifunction buttons (press, swipe, movement)
- Reduction of cabling and flexible retrofitting
Ultrasonic distance measuring device via RFID signal
Project: Time-based ultrasonic distance measuring device with zero point reference via RFID signal
Funding body: BMWi
Duration: 2012 – 2014
Contents and objectives
- Development of a wear-free sensor system for measuring the ride height of trucks with air suspension bellows
- Combination of ultrasonic time-of-flight measurement with RFID reference measurement for zero point determination
- Integration of additional functions such as bellows internal pressure measurement to reduce costs and installation space
- Overcoming the disadvantages of previous pulse-echo ultrasonic systems
I-CHAIN
Project: i-Chain, RFID-supported, intelligent drag chain measuring system for continuous machine monitoring
Funding body: BMWi
Duration: 2013 – 2015
Contents and objectives
- Development of an RFID-based measuring system for monitoring drag chains in industrial plants
- Continuous recording of mechanical loads, voltage peaks and wear indicators
- Analysis of process and status data to prevent unplanned downtime
- Automatic feedback to the control parameters of plants and machines
- Support for developers in the design and optimisation of complex chain drives
- Predictive maintenance capability through early identification of critical load conditions
Integrated multifunctional sensor network
Project: Integrated multifunctional sensor network
Funding body: BMWi
Duration: 2013 – 2015
Contents and objectives
- Development of a modular sensor network for recording temperature, level, density and fluid-related parameters
- Focus on cost optimisation for series production in commercial vehicles and work machines
- Compact, scalable sensor unit that can be easily adapted to different customer requirements
- Preparation of a product family for manufacturers of construction machinery, tractors, forklifts and engines
- Reduction of installation space, interfaces and installation effort through the integration of multiple measurement functions
NOTIERT, Development of sensor-based data acquisition systems for temperature-controlled transport
Project: NOTIERT Development of a standard template for sensor-based data acquisition systems
Funding body: BMWK
Duration: 2014 – 2016
Contents and objectives
- Development of a standard template for a standardised overall system consisting of sensors, data centre and software for monitoring temperature-controlled transport
- Ensuring seamless recording, storage and evaluation of all relevant measurement parameters along the transport chain (temperature, humidity, light intensity, shock, vibration, etc.)
- Development of a modular wireless sensor system suitable for lorries, trailers, cargo and cross-industry applications
- Development of a manufacturer-neutral reference architecture including hardware, mechanics, firmware and testing requirements
SENSA-CHAIR
Project: SensA-Chair – Adaptives Sensor-Aktor-Sitzsystem mit FGL-Technologie
Funding body: BMBF
Duration: 2016 – 2018
Contents and objectives
- Development of an intelligent adaptive seating system that prospectively adapts to the user's anatomy and sitting posture
- Recording of muscle strain and sitting patterns using capacitive sensors and biomechanical models
- Use of shape memory alloy (SMA)-based actuators for micro and macro contour adjustment of the seat surface and backrest
- Development of a self-sensing actuator system for individual contour adjustment without additional displacement sensors
- Construction of a fully functional demonstrator including software, ergonomic analysis and usability assessment
GEAR SELECTION DETECTION (GWEA)
Project: GWEA – Innovative Gear Selection Detection for motobikes
Funding body: BMWi
Duration: 2016 – 2018
Contents and Objectives
- Development of a bidirectional, clutch-free automatic gearshift system that precisely detects gearshift requests and actual gear lever movements
- Combination of force and displacement sensors to reliably detect shift torque, shift travel and shift force
- Implementation of a fully integrated system (mechanics + electronics in the same housing) with extremely high environmental resistance (IP68K, −40 °C … +85 °C, vibration, shock)
- Integration of a spring accumulator for energy buffering for safe gear changes without ‘pressing again’
Microwave-based quality and analysis sensor (MQS)
Project: MQS – Microwave-based quality and analysis sensor
Funding body: BMWi
Duration: 2014 – 2017
Contents and Objectives
- Development of a long-term stable, cost-effective analysis sensor for technical automotive fluids such as AdBlue®, brake fluid, transmission oil or diesel
- Measurement of fluid quality, concentration, purity and identification of foreign media
- Use of a microwave stripline principle for measurement in the depth of the fluid, independent of coating, bubble or surface influences
- Development of a compact measuring probe for tank integration and in-line installation in suction lines
- Construction of a robust system with a wide temperature range (-40 °C to +100 °C), pressure resistance, EMC resistance and maintenance-free operation
SENSA-BOLT
Project: SensA Bolt, Intelligent bolt sensor for condition monitoring
Funding body: BMWi
Duration: 2017 – 2019
Contents and Objectives
- Development of an intelligent bolt system that records mechanical loads, preload force, temperatures and additional environmental variables
- Integration of the sensor technology directly into the bolt or into an element close to the bolt without impairing the function or strength of the connection
- Construction of an energy-efficient, miniaturised sensor node with radio communication (e.g. BLE)
- Implementation of continuous or event-based monitoring of safety-critical screw connections
- Development of a scalable, mechanically robust sensor design including EMC protection, temperature resistance and vibration resistance
Contactless suspension travel sensor for motorcycle suspension forks (BFSK)
Project: BFSK – Contactless suspension travel sensor for motorcycle suspension forks
Funding body: BMWi
Laufzeit: 2018 – 2020
Contents and Objectives
- Development of a contactless, wear-free suspension travel sensor for motorcycle applications
- Use of an inductive measuring principle to determine the distance between the emitter and receiver units
- Contactless measurement of suspension travel, independent of dirt, water, ice or metal surroundings
- Construction of a complete sensor node including electronics, firmware and evaluation algorithms
- Validation through laboratory tests, test bench trials and real-world driving tests (race track and road)
SDeFS / uFrame, Smart Devices Functionally Secure
Project: SDeFS
Funding body: BMWi
Duration: 2018 – 2020
Content and Objectives
- Development of a two-channel, safety-oriented system
- Integration of emergency stop and enable/release buttons
- Establishment of secure, cyclical, redundant Bluetooth communication (BLE) between uFrame and machine control
- Development of safety software with deterministic process management system (PMS) for separate, monitored execution of all safety-related tasks
- App development for Android/tablet: UI, control, safety-related status display
- Ergonomic optimisation of the entire housing
- Development of two hardware variants
- Construction of prototypes, EMC tests, IP tests (IP6X / IPX7), vibration and mechanical tests
KMMI
Project: KMMI Development of an intelligent motorcycle gearbox cover in a single-component design
Funding body: BMWi
Duration: 2018 – 2020
Contents and Objectives
- Development of a single, fully integrated clutch/gearbox cover made of plastic
- Integrated sensor technology for clutch, oil condition and speed
- Substitution of a multi-part system (cover, insert, seals, metal sheets) with a single component.
- Significant reduction in noise emissions.
- Cost neutrality compared to existing series solutions despite higher functionality.
- Development of an injection moulding tool concept, including close-contour cooling channels and FEM-optimised structure
Electronic battery disconnect switch (eBTS)
Projekt: eBTS, Electronic battery disconnect switch
Fördergeber: BMWi
Laufzeit: 2019 – 2021
Contents and Objectives
- Development of a fully electronic battery disconnect switch to replace conventional mechanical disconnect switches and high-current relays
- Switching of up to 400 A continuous current in 12–48 V vehicle electrical systems
- Implementation of a safe emergency stop/safe state in accordance with ADR and DIN EN ISO 13849 (emergency stop, safety-related shutdown)
- Integration into existing vehicle architectures
- Implementation with high packing density
- Overall thermal concept for dissipating heat loss
- Development of a MOSFET-based switching module with high RDSon efficiency
- Firmware architecture for synchronous control of all MOSFETs
watchER, low-maintenance cyber-physical logistics system
Project: watchER, low-maintenance cyber-physical logistics system
Funding body: BMWi
Duration: 2021 – 2023
Contents and Objectives
- Reduction of food waste along the supply chain through seamless real-time condition monitoring of loading units
- Development of an intelligent, virtually maintenance-free reusable load carrier with integrated sensor electronics
- Establishment of a cloud-based IoT platform (watchER Cloud) for mass data collection and AI-based analysis
- Derivation of optimisation potential for cold chains, inventory management and distribution processes
- Development of an active sensory monitoring system (temperature, humidity, acceleration, GPS) with NB-IoT/CoAP data transmission
HitchHike Box, decentralised networked, multimodal smart logistics system
Project: HitchHike Box, decentralised networked, multimodal smart logistics system
Funding body: BMWi
Duration: 2021 – 2023
Contents and Objectives und Ziele
- Development of an intelligent, self-organised logistics system that automatically allows goods to ‘ride along’
- Establishment of a networked infrastructure consisting of smart boxes, dispatch software and multimodal routing
- Relief for existing supply chains through synergies between passenger and freight transport
- Scalable system for urban logistics, rural regions and on-demand transport
ConTAD – Smart Container Tracking and Accident Detection
Project: ConTAD – Smart Container Tracking and Accident Detection
Funding body: BMWK
Duration: 2023 – 2026
Contents and objectives
- Development of a world-first accident detection and communication system for the automatic location of sea freight containers that have fallen overboard
- Drastic reduction in detection time for multi-container accidents Integration into maritime communication systems Improvement of environmental protection and shipping safety in supply chains
- Development of application-specific IoT hardware including GNSS, sensors, radio (mobile/satellite/FM) and energy management
- Development of a firmware platform for energy-optimised tracking, accident detection and radio routing
