Come and see what our Machine Design project (HK) teams have been up to!
Everyone is warmly invited to join the SPOTLIGHT SESSIONS (project presentations) and the EXPO, where our project groups will present and demonstrate their exciting work. Read more below!
Program: 10:00 - 11:45 Spotlight Session 1 in M3 13:00 - 14:45 Spotlight Session 2 in M3 15:00 - 17:00 Expo in LabHallen, Department of Engineering Design
Tribometers are devices that simulate real-life conditions to measure friction, wear and lubrication between two surfaces in relative motion. The data obtained from these devices are crucial for various engineering and research purposes, as they help in developing material for specific applications and testing. Currently, tribometry in vacuum conditions has been one of most researched fields, considering the critical need for reliable data in aerospace and semiconductor industries. Testing in vacuum poses a fundamentally different challenge from atmospheric testing due to absence of air and humidity. Standard tribometers cannot predict performance in vacuum because of outgassing, thermal isolation and loss of oxide regeneration (cold welding). As of today, there are limited tribometers capable of testing on a component-level in vacuum conditions. Accounting for these is vital for aerospace industries, where devices should operate reliably for several years without any means of maintenance or repairability.
This project pertains to the design, manufacturing, assembly, testing of a high-vacuum bearing test rig with conditions simulating contact pressures expected for devices used in different industries. A frameless motor-driven concept to measure the frictional torque of angular contact ball bearings in vacuum environments.
Atlas Copco's inline rotary torque transducer (IRTT) is a tool that measures torque applied from tightening tools to workpieces. The IRTT is calibrated statically but is used to measure torque applied from dynamic tools, which may yield inaccurate measurements. To evaluate the performance of the IRTT in dynamic measurements, a test rig was developed that produces an alternating torque. Using a voice coil, a force is applied to a lever arm, resulting in a torque with a known frequency being applied to the IRTT. The magnitude of the torque and frequency is then validated by simultaneously connecting the IRTT to an inertial body and measuring the resulting angular acceleration. The test rig is to be used at frequencies ranging from 1 to 1000 Hz, with the aim of producing a frequency response curve for the IRTT.
Hybrid offshore renewable systems are emerging as a key opportunity in the global transition to sustainable energy. NoviOcean, a pioneering company in this field, is developing floating Hybrid Energy Converters that combine wind turbines, solar panels, and wave energy on a single platform. At the core of their Alta Wave hybrid energy system is an innovative wave energy converter that uses the relative motion between a seabed-anchored piston and a float-mounted hydraulic cylinder to create high-pressure flow, which is then directed through a turbine to produce electricity.
While the Alta Wave’s simple yet effective design demonstrates strong potential for offshore deployment, the system faces a critical challenge. Extreme waves can push the piston to its mechanical limits, causing end-of-stroke events that may damage vital components.
This project addresses that issue by designing a protective release mechanism that allows the system to temporarily extend during high waves, avoiding end-of-stroke damage. The solution uses a telescopic, pressure-based design that extends the piston rod when critical loads are reached. After the large waves pass, the mechanism automatically resets, restoring normal operation without manual intervention. This innovation represents a step towards making the Alta Wave hybrid energy platform more robust, reliable, and better suited for real-world offshore deployment.
Radio Access Network (RAN) equipment plays a critical role in modern wireless communication infrastructure, serving as the interface between user devices and the core network. Since these radio units are deployed across outdoor sites and contain valuable components, they are frequent targets for theft and vandalism. This project aims to develop a durable, robust, and cost-efficient anti-theft device suitable for mass production, compatible with Ericsson’s most frequently used mounting solutions for radio units, specifically the medium-sized rail brackets.
The design challenge involved balancing two opposing requirements: increasing resistance to tampering while minimizing additional workload for installers and service technicians. The final design seamlessly integrates with the existing equipment, ensuring minimal interference with the RAN's function. Through concept development, mechanical design, simulations, and prototype testing, the project delivers a robust solution that can withstand repeated installation cycles while enhancing the protection of RAN products without unreasonable increases in workload. With the anti-theft device protecting the component, the time it takes to steal was increased by over 650%, which significantly delays thieves' pursuit of valuable components and materials.
This project is a collaboration between Scania and KTH. The project’s objective is to design and develop a compact test rig for evaluating the efficiency of coolant pumps under simulated real-world truck operating conditions. The rig enables controlled testing within a climate chamber and vibration shaker table, replicating temperature ranges from −40 °C to 100 °C and vibration frequencies between 8–2000 Hz. Key objectives included achieving a lightweight, modular, and safe structure that fits within strict geometric limits, while allowing for rapid pump replacement and parallel testing of up to three pumps. The final design features a divided inside–outside configuration to minimize mass within the vibration zone and enhance accessibility and safety. Integrated sensors for pressure, flow, and temperature provide accurate performance data, while flow restriction and automated air-purging systems ensure realistic fluid flow. CAD development, modal analysis, and Simulink-based performance simulations guided design decisions and component selection. An eco-audit assessed material usage and operational energy consumption, identifying opportunities for further optimization. The developed rig meets the functional requirements and provides a reliable platform for simulating various coolant pumps under specific conditions.
Industrial gas turbines play an essential role in modern power generation; however, the connected gearboxes can experience substantial thermal loads due to frictional heating within the gear mesh. Although continuous oil-spray cooling is used to manage the temperatures, the resulting oil mist introduces energy losses that reduce overall system efficiency. The fluid and thermal behavior inside the gearbox is difficult to predict through calculations and simulations, which highlights the importance of direct measurements to validate models and assess the gearbox performance.
The goal of this project was to develop a gear-tooth temperature measurement system that provides precise temperature data for the evaluation of gearbox efficiency, studying gear-tooth damage mechanisms, and optimizing oil-spray during operation. A modular measurement system was designed, which can be adapted to gearboxes from different suppliers without modifications to the housing. The system consists of a rigid structure attached to the inspection hatch, enabling temperature measurements along the pitch diameter, before and after the gear mesh, and across the gear width using PT100 resistance temperature detectors.
