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Fraunhofer-Institut für Betriebsfestigkeit und Systemzuverlässigkeit LBF

Bartningstr. 47, 64289 Darmstadt
Telephone +49 6151 705-0
Fax +49 6151 705-214

Hall map

GIFA 2019 | NEWCAST 2019 hall map (Hall 13): stand C38

Fairground map

GIFA 2019 | NEWCAST 2019 fairground map: Hall 13


Dr.-Ing. Christoph Bleicher

Qualifizierung gegossener Komponenten

Our range of products

Product categories

  • 26  Consulting, design, service and engineering
  • 03  Services
  • 03.02  Product development
  • 03.02.001  Design, development and simulation (design optimization, virtual trials)

Design, development and simulation (design optimization, virtual trials)

Our products

Product category: Consulting, design, service and engineering

Composite fiber wheel with integrated electric motor

In electric vehicles, the conventional internal-combustion engine is replaced with one or several electric motors. To highlight the opportunities this alternative drive system offers, a fiber composite lightweight wheel was developed at Fraunhofer LBF within the framework of a collaborative research project in the field of electromobility.

The CFRP wheel with a wheel size of 6.5 x 15“ has a weight of about 3.5 kg. In comparison to a steel wheel of the same size, this means a reduction of up to 60% in weight, depending on the wheel design. Compared to an aluminium-cast wheel, the weight reduction amounts to up to 56% depending on the design.

The motor adapter flange is not directly connected with the rim base. This prevents radial or lateral loads from being transferred directly onto the electric motor. To align the fibers continuously and with the flow of the forces and to avoid stress peaks caused by sharp edges or sudden variations in rigidity, radii that are in line with the material and smooth transitions have been created in the component. The motor adapter flange is connected with the interior area of the wheel axle. To reduce the mass and increase flexural strength, foam cores have been integrated into the spokes. The electric motor is a small, commercially available wheel hub motor. The motor, consisting of a permanent magnet (outer rotor) and a yoke ring with solenoids (stator) has a power of 4kW and a control voltage of 2 x 24.5 V.

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Product category: Consulting, design, service and engineering

Efficient drive-file-determination by inverse modelling

For servohydraulic test rigs, which are commonly used for fatigue testing of chassis assemblies, there is a significant effort necessary for deriving the drive-files before starting the test. The drive files are needed in order to reproduce the service loads at the specimen on the test rig. This effort is mainly due to non-linearities in the dynamic system formed by the test rig and the specimen. The non-linearities of the test system arise for example from the hydraulics, the geometry, mechanical friction, rubber components and a semi-active damper.

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Product category: Consulting, design, service and engineering

Ice Protection

Fraunhofer LBF developed, manufactured and tested an innovative ice protection system for airplanes, based on Carbon Nano Tubes (CNT). The tests were conducted in a climatic wind tunnel at temperatures as low as -18° C. In total, three leading edge segments of the wing were examined. Two were equipped with the non-metallic heating system in different configurations, one segment, which served for reference purposes, did not have a heating system. These tests crowned several years of development and improvement and were based on, among other factors, the simulation of thermal, electrical and aerodynamic conditions. The wind tunnel tests showed a promising performance, both in the de-icing mode (with an artificially iced wing) and in the anti-icing mode (which prevents icing during a simulated flight through clouds at low temperatures).

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About us

Company details

Traditionally Innovative!

Fraunhofer LBF in Darmstadt is one of the most traditional institutes of the Fraunhofer-Gesellschaft. Over 75 years ago, the former “Laboratory for Structural Durability LBF” shaped a completely new area of research that even back then was already economically significant and, up to today, has lost none of its topicality and pertinence. Particularly in the last decade, the institute developed its competence center both in breadth and depth on the basis of experimental structural durability with a great deal of innovation force and high degree of dynamics. Additional market segments beyond the traditional vehicle and mechanical engineering branches of
industry were opened up.

The latest milestone in the development of the „Fraunhofer Institute for Structural Durability and System Reliability LBF“ was the integration of the renowned German Plastics Institute DKI in 2012. The tried and tested competencies are found today in numerical and experimental structural durability, in smart structures and system reliability and in the area of plastics. Fraunhofer LBF continues to develop these four core competencies
on a technical and organizational level in research divisions of the same name and in a total of 10 departments.

The institute has documented its future plans in a dynamic strategy plan that is checked and assessed by external evaluators on a regular basis. The operative work is critically examined in continuous analyses on customer satisfaction. The management system of Fraunhofer LBF is certified according to DIN ISO EN
9001:2000 and the testing laboratory is accredited according to the requirements of DIN ISO-IEC 17025. This has also led to an extraordinarily high number of customers that has been loyal to the institute for decades.

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