Technical Centre. About Departments Contact

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1 About Departments Contact

2 About History The history of Engineering in Jablonec started in 1952 when the company Autobrzdy was founded. From the early beginning it was focused on the design and development of the braking systems for front and rear brakes. The major customers were Škoda, Tatra, and Wartburg. In 1984 Autobrzdy bought the licence for Colette brake from Lucas Automotive Plc. In 1993 Autobrzdy signed the joint venture contract with Lucas Automotive. Today In 2004, when TRW company asked the government for the subsidy program for Technical Centres, had Engineering in Jablonec only 23 people working on design and development of disc brakes. The subsidy program to extend Engineering in Jablonec was approved and TRW increased the number of people to above 90. Technical Centre was extended by another product lines Actuation, Slip Control, Computer Aided Engineering and Customer Application & System Engineering. Tomorrow We cooperate with Koblenz technical centre and will further reinforce the relationship. We are trying to get higher responsibility within the projects. Our aim is to have own customers. We are already responsible for Mitsubishi, Hyundai, Land Rover. We will support new Shanghai technical centre. We are also working on increasing our testing capacity (new test rigs) and on increasing of headcount.

3 Contacts TRW Automotive Czech a.s. Technical Centre Na Roli 26, Building C1, 9-10 th floor Jablonec nad Nisou Czech Republic Manager Martin Skalický Building C1, 10 th floor HR Supervisor Radka Tomandlová Building C1, 10 th floor

4 Departments Foundation Brakes FB Electric parking brakes EPB Computer Aided Engineering CAE Slip Control Systems SCS Actuation ACT Customer Application & System Engineering CAS

5 Departments - Foundation Brakes Design Development

6 Departments - Foundation Brakes - Design About People and organization What we are doing? Customer portfolio Contact

7 Departments - Foundation Brakes - Design - About Design group in Jablonec Main task : Design the products of brake, especially calipers for front and rear axle from the quotation phase by preparing product offer with first concept over whole development process to production launch, and further technical support during serial production. Other tasks: Participation on core development activities including further design improvements of current products, benchmark activities Software we use: Catia V4, Catia V5, Ansys Workbench

8 Departments - Foundation Brakes - Design - People and Organization Global Local

9 Departments - Foundation Brakes - Design - People and Organization - Global William J. Vander Roest Technical Director, Foundation Brakes Livonia Chris McCormick Chief Engineer FBE (Livonia) M. Schog Chief Engineer FBE (Koblenz) Jens-Peter Kohrt Global Chief Engineer EPB/Electric Brakes (Koblenz) M. Walden Chief Engineer Brake Design Jochen Becker Chief Engineer Advanced Brakes & Product Standards O. Schmitt Chief Engineer Global Friction Engineering M. Schog (acting) Chief Engineer Development Brakes Petr Novák Engineering Manager FB Jablonec

10 Departments - Foundation Brakes - Design - People and Organization - Local Engineering Manager FB P. Novák Assistant M. Ouhrabková Team Leader Design J. Vaněk Team Leader Development P. Herkommer Global Lab Management System Team Leader EPB J. Mandík Designer J. Havlíček W. Kořínek V. Jakoubek L. Skrbek J. Havlová M. Mihalík H. Čapková B. Doležal J. Zajačík A.Bém J. Hnyk Draftsman L. Janečková I. Vrkoslavová Development Engineer P. Polodna M. Haufer M. Francová R. Holubec Technician J. Šantavý L. Kubáček Mechanic M. Černý P. Jonáš J. Vyčítal M. Hrabálek M. Vavruška SW Engineer J. Jelínek System Test Senior Engineer P. Černý P. Kočí SW Test Engineer S. Šilhán L. Veselý System Test Engineer P. Vašát M. Balatka Prototype Mechanic P. Türk T. Harcuba T. Cvrček

11 Departments - Foundation Brakes - Design - What we are doing?

12 Departments - Foundation Brakes - Design - Contact TRW Automotive Czech a.s. Technical Centre - Actuation Na Roli 26, Building C1, 10 th floor Jablonec nad Nisou Czech Republic Engineering Manager FB JBC Petr Novák Building C1, 10 th floor Team Leader FB - Design Jan Vaněk Building C1, 10 th floor

13 Departments - Foundation Brakes - Development About People and Organization What we are doing? Customer Portfolio Contact

14 Departments - Foundation Brakes - Development - About Providing tests Production release tests Requalification tests Testing complaint parts Testing according customer specifications Type of tests providing on test rigs: 1. Functional and performance tests Function Test Rig (OneGo) Function Test Rig for rear brake with integrated parking brake Function Test Rig for rear EPB brake 2. Fatique tests SD 1 Semi dynamic Test Rig SD 2 Semi dynamic Test Rig 3. Endurance tests Climate Chamber (-75 C to 180 C) Heat Chamber (max 250 C) Climate Chamber (EPB) 4. Dynamic tests Dynamometr 5 Dynamometr 6 5. Corrosion tests (dynamic) Krauss 1 Krauss 2 6. Pad Compressibility tests Compressibility Test Rig 7. Strenght tests Burst test rig 8. Thermographic high speed measurements Thermo graphic system

15 Departments - Foundation Brakes - Development - People and Organization Global Local

16 Departments - Foundation Brakes - Development - People and Organization - Global William J. Vander Roest Technical Director, Foundation Brakes Livonia Chris McCormick Chief Engineer FBE (Livonia) M. Schog Chief Engineer FBE (Koblenz) Jens-Peter Kohrt Global Chief Engineer EPB/Electric Brakes (Koblenz) M. Walden Chief Engineer Brake Design Jochen Becker Chief Engineer Advanced Brakes & Product Standards O. Schmitt Chief Engineer Global Friction Engineering M. Schog (acting) Chief Engineer Development Brakes Petr Novák Engineering Manager FB Jablonec

17 Departments - Foundation Brakes - Development - People and Organization - Local Engineering Manager FB P. Novák Assistant M. Ouhrabková Team Leader Design J. Vaněk Team Leader Development P. Herkommer Global Lab Management System Team Leader EPB J. Mandík Designer J. Havlíček W. Kořínek V. Jakoubek L. Skrbek J. Havlová M. Mihalík H. Čapková B. Doležal J. Zajačík A.Bém J. Hnyk Draftsman L. Janečková I. Vrkoslavová Development Engineer P. Polodna M. Haufer M. Francová R. Holubec Technician J. Šantavý L. Kubáček Mechanic M. Černý P. Jonáš J. Vyčítal M. Hrabálek M. Vavruška SW Engineer J. Jelínek System Test Senior Engineer P. Černý P. Kočí SW Test Engineer S. Šilhán L. Veselý System Test Engineer P. Vašát M. Balatka Prototype Mechanic P. Türk T. Harcuba T. Cvrček

18 Departments - Foundation Brakes - Development - What we are doing? SD 2 Semi dynamic Test Rig Chamber I Function Test Rig Krauss I Corrosion Test Rig Strenght tests Compressibility Test Rig Dynamometer 6 Termo Graphic System Prototype Workshop

19 Departments - Foundation Brakes - Development - What we are doing? SD 2 Semi dynamic Test Rig Test Rig for semi dynamic endurance tests two ends

20 Departments - Foundation Brakes - Development - What we are doing? Chamber I Chamber DU1000/80 For fatigue testing at various temperatures

21 Departments - Foundation Brakes - Development - What we are doing? Function Test Rig Provide functional tests and analyses

22 Departments - Foundation Brakes - Development - What we are doing? Krauss I Corrosion Test Rig Testing in corrosive environment

23 Departments - Foundation Brakes - Development - What we are doing? Strenght tests Burst test rig

24 Departments - Foundation Brakes - Development - What we are doing? Compressibility Test Rig Testing compressibility of pads (linings)

25 Departments - Foundation Brakes - Development - What we are doing? Dynamometer 6 Test Rig for dynamic endurance tests

26 Departments - Foundation Brakes - Development - What we are doing? Termo Graphic System For high speed measurements

27 Departments - Foundation Brakes - Development - What we are doing? Prototype Workshop

28 Departments - Foundation Brakes - Development - Contact TRW Automotive Czech a.s. Technical Centre - Actuation Na Roli 26, Building C1, 10 th floor Jablonec nad Nisou Czech Republic Engineering Manager FB JBC Petr Novák Building C1, 10 th floor Team Leader FB - Development Petr Herkommer Building C1, 10 th floor

29 Departments - Electric Parking Brakes About People and organization What we are doing? Customer Portfolio Contact

30 Departments - Electric Parking Brakes - About What is the EPB? EPB is abbreviation for Electric Parking Brake. The EPB system replaces the conventional mechanical parking brake. Additionaly to the basic apply release function the system provides various safety and comfort function, e.g. automatic release and apply during specific driving situation EPB switch EPB system consist of the: EPB calipers E-M actuation Electronic Control Unit (ECU) Software EPB switch ECU & software EPB brakes EPB system functions: Apply and release brake while vehicle is stationary Child lock Automatic release while drive away Braking while driving via EPB switch (emergency) Re-clamp if vehicle parked with hot brakes Detection of unintended roll away Automatic apply at various situations (e.g. ignition off) Support of Start-Stop and Adaptive Cruise Control Mode for Periodical Technical Inspection Fault detection and Failsafe system Diagnostic communication

31 Departments - Electric Parking Brakes - People and Organization Global Local

32 Departments - Electric Parking Brakes - People and Organization - Global Jens Peter Kohrt Global Chief Engineer Electric brakes TRW Koblenz Matthias Jumpertz Chief Engineer PM&SE TRW Koblenz Gundolf Schmidt Chief Engineer Software System Dev. TRW Koblenz Gregor Poertzgen Chief Engineer Actuator Design TRW Koblenz Thomas Maur Chief Engineer Test & Validation TRW Koblenz Erwin Michels Chief Engineer Advanced Systems TRW Koblenz Bert Löhr Team Leader Component Test TRW Koblenz Oliver Hatzel Team Leader Vehicle Testing TRW Koblenz Christoph Hellwig Team Leader SW & Simulation Test TRW Koblenz Kai Dalkowski Team Leader HW / SW Integration TRW Koblenz Ralf Erben Senior Specialist EPB Systems TRW Koblenz Jaroslav Mandík Team Leader Test & Validation Jbc TRW Jablonec

33 Departments - Electric Parking Brakes - People and Organization - Local Petr Novák Chief Engineer Foundation Brakes TRW Jablonec Jaroslav Mandík Team Leader EPB Test & Validation TRW Jablonec EPB system test (HIL testing) Petr Černý HIL model design EPB system test Petr Kočí Software tool design EPB system test EPB software test Lukáš Veselý Comms & Diag test Software tool support Stanislav Šilhán Fault insertion test Runtime analysis test Pavel Vašát EPB system test Miroslav Balatka EPB system test

34 Departments - Electric Parking Brakes - What we are doing? System testing on HIL The EPB system s function and robustness is tested on Hardware-Inthe-Loop test rigs (HILs). HIL simulates the system environment and can create various driving and failure scenarios. HIL is based on dspace architecture. Fault insertion test The robustness of the EPB system is tested by inserting hardware or software faults in the ECU. The fault insertion is performed by ECU s software or PCB modification. Diagnostic communication test The communication of the ECU via diagnostic protocol is tested using custom made library EasyCAN and diagnostic communication SW tool CANoon. All existing diagnostic commands are checked. Even the non-valid data is sent to the ECU to fulfill the completeness test. Runtime analysis tests The system s performance is tested by measuring the processor load. For the test is used a modified ECU with processor emulator.

35 Departments - Electric Parking Brakes - Contact TRW Automotive Czech s.r.o. Technical Centre - EPB Na Roli 26, Building C1, 10 th floor Jablonec nad Nisou Czech Republic Team Leader EPB Test & Validation Jaroslav Mandík Building C1, 10 th floor

36 Departments - Computer Aided Engineering About People and organization What we are doing? Customers Portfolio Contact

37 Departments - Computer Aided Engineering - About What does Computer Aided Engineering mean? It means we do provide aid or support to other development departments. We do analyze the robustness and performance of components and assemblies by means of CAE software and hardware tools Which Hardware we use? For computations we use powerful workstations and Linux computational cluster. Which software we use? We use commercial computational software packages.

38 Departments - Computer Aided Engineering - People and Organization Lukáš Seifert Jan Rubáček Ondřej Tuhovčák Petr Tomek Pavel Urubčík

39 Departments - Computer Aided Engineering - What we are doing? Static structural analyses We do analyze components with respect to static deformations and stresses. Thermal Analyses We simulate thermal behavior of brake components and assemblies. Dynamic Analyses We support NVH department with dynamic analyses of brake parts and assemblies. Topology Optimization We search for optimal design topology of components. Highly Non-linear Analyses We analyze the behavior of highly non-linear materials.

40 Departments - Computer Aided Engineering - Contact TRW Automotive Czech a.s. Technical Centre - CAE Na Roli 26, Building C1, 10 th floor Jablonec nad Nisou Czech Republic Team Leader CAE Lukáš Seifert Building C1, 10 th floor

41 Departments - Slip Control Systems Design Development

42 Departments - Slip Control Systems - Design About People and Organization What we are doing? Customers Portfolio Contact

43 Departments - Slip Control Systems - Design - About

44 Departments - Slip Control Systems - Design - People and organization Technical director SCS Thomas A. Straub Koblenz, Germany Tech center manager M. Skalický Jablonec, Czech Republic Chief Engineer Product engineering V. Berisch Engineering Manager SCS - Acting Koblenz, Germany Team leader design Tomáš Prokeš Team leader dev. N/A Senior manager electromechanical Design & Packaging H. Gegalski Koblenz, Germany EHCU Packaging Tomáš Buďárek Durability tests TBD Hydraulic technician Jan Nechutný Senior manager hydraulic Design & Lab T. Wald Koblenz, Germany Technical director TEE Dr. J. Kiefer Koblenz, Germany Electromechanical ECU design Wolfgang Dewart Koblenz, Germany Designers FMEA, SCB2 BPU Josef Cerman Motor Roman Hodík ECU Mechanics Juraj Sekerák Koblenz, Germany Engineers Pump durability Petr Pelant Environment tests & Analyse Ondřej Rainiš Technicians Electric technician Jiří Blažek

45 Departments - Slip Control Systems - Design - What we are doing?

46 Departments - Slip Control Systems - Design - Contact TRW Automotive Czech a.s. Technical Centre - CAE Na Roli 26, Building C1, 10 th floor Jablonec nad Nisou Czech Republic Team Leader SCS Tomáš Prokeš Building C1, 10th floor

47 Departments - Slip Control Systems - Development About People and Organization What we are doing? Customers Portfolio Contact

48 Departments - Slip Control Systems - Development - About What is the SCS units function? By monitoring environment, velocity information and driver inputs our unit can modulate and apply the brakes to reduce the possibility of loss of driver control or to assist during maneuvers. Typical functions of our units are ABS, ESC, TC, ACC. Our product consist of the: Hydraulic Control Unit (HCU) Motor Electronic Control Unit (ECU) (Bracket) Our equipment consist also from: Humidity chamber VOETSCH Salt spray chamber LIEBISCH SKBWF 1000 A-SC Stereomicroscope OLYMPUS SZX16 Stereomicroscope LEICA M205C Fusion optics Quick Scope MITUTOYO QS-200 Z CNC ECU HCU Motor

49 Departments - Slip Control Systems - Development - People and Organization Technical director SCS Thomas A. Straub Koblenz, Germany Tech center manager M. Skalický Jablonec, Czech Republic Chief Engineer Product engineering V. Berisch Engineering Manager SCS - Acting Koblenz, Germany Team leader design Tomáš Prokeš Team leader dev. N/A Senior manager electromechanical Design & Packaging H. Gegalski Koblenz, Germany EHCU Packaging Tomáš Buďárek Durability tests TBD Hydraulic technician Jan Nechutný Senior manager hydraulic Design & Lab T. Wald Koblenz, Germany Technical director TEE Dr. J. Kiefer Koblenz, Germany Electromechanical ECU design Wolfgang Dewart Koblenz, Germany Designers FMEA, SCB2 BPU Josef Cerman Motor Roman Hodík ECU Mechanics Juraj Sekerák Koblenz, Germany Engineers Pump durability Petr Pelant Environment tests & Analyse Ondřej Rainiš Technicians Electric technician Jiří Blažek

50 This copyright ed document is t he propert y of TRW and is disclosed in conf idence.it may not be copied,disclosed t o ot hers or used f or manuf act uring,wit hout t he prior writ t en consent of TRW. (c) 2011 TRW Inc. prf plr plf prr pmc2 Ival pmc1 Imot Uval Umot Time [ s] s_mc Technical Centre Departments - Slip Control Systems - Development - What we are doing? Functional Tests Tear Down and Analyses Durability Performance, Vacuum Bleed, Fluid flow, Tube Seat Leak Test, Volume Displacement, LJ DIQ_Intermittent Durability_ESP_S LDFII SW-Info : Datum Voltage : Testcode operating : Range Uhrzeit : 12:46:57 Kommentar : PreProcessor 2-5.VBS Kanal Unit plf bar prf bar prr bar plr bar pmc1 bar pmc2 bar Imot A Ival A Umot V Uval V s_mc mm LJ DIQ ; Intermittent Durability ; EBC460 VW120 ESP ; D ; ESP ; 3.5 ; JN We take the whole system apart and analyse every single component for wear marks. Beside the standard durability of the whole Electronic and Hydraulic Control Unit (EHCU), we run special durability cycles of the most stressed components such as pumps Environmental Tests Humidity Salt Spray Thermal Cycle Special measurements Compression Chamber Pressure Air Ingestion Monitoring DC Motor Brush and Coils Temperature

51 Departments - Slip Control Systems - Development - Contact TRW Automotive Czech a.s. Technical Centre - CAE Na Roli 26, Building C1, 10 th floor Jablonec nad Nisou Czech Republic Team Leader SCS Tomáš Prokeš Building C1, 10th floor

52 Departments - Actuation Design Development

53 Departments - Actuation - Design About People and Organization What we are doing? Customers Portfolio Contact

54 Departments - Actuation - Design - About

55 Departments - Actuation - Design - People and Organization Global Local

56 Departments - Actuation - Design - People and Organization - Global Patrick Weiland Chief Engineer, Actuation Development TRW Koblenz Tomáš Valečka Engineering Manager Jablonec (CZ) Lothar Zeuner Engineering Manager Duplex & Core Reservoir Ulrich Zinkan Engineering Manager Duplex Jens Sparfeld Engineering Manager Core Booster Ralph Rothenhäuser Engineering Manager Core Hydraulics Andreas Schupp Engineering Manager Development Tools & Lab Scott Bruder Engineering Manager Livonia (USA) Quan Sheng Liang Engineering Manager Shanghai (VCR)

57 Departments - Actuation - Design - People and Organization - Local Engineer,ing Manager ACT T. Valečka Assistant T. Špilarová Team Leader Design J. Kolář Team Leader Development T. Kroupa Team Leader Laboratory P. Kubín Designer T. Drbohlav D. Macák D. Hušek K. Vitoušová P. Hataš T. Jiřičný Development eng. F. Košťák M. Denk R. Klápště L. Franc M. Truhlář Mechanic R. Balogh J. Kubíček M. Beran D. Varga Technician J. Zajíček

58 Departments - Actuation - Design - What we are doing? Design verification and production release

59 Departments - Actuation - Design - Contact TRW Automotive Czech a.s. Technical Centre - Actuation Na Roli 26, Building C1, 10 th floor Jablonec nad Nisou Czech Republic Engineering Manager Actuation JBC Tomáš Valečka Building C1, 10 th floor Team Leader Actuation - Design Jaroslav Kolář Building C1, 10 th floor Team Leader Actuation - Laboratory Pavel Kubín Building C1, 10 th floor

60 Departments - Actuation - Development About People and Organization What we are doing? Customers Portfolio Contact

61 Departments - Actuation - Development - About What we are doing? Design verification and production release Functional and durability tests Tests according to customer specifications What is the Booster function? The vacuum brake booster has the function of supporting the foot force of the driver (pedal force / multiple amplification) and to convert the generated forces to hydraulic brake pressure (brake pressure clamping force brake torque deceleration). Our products consist of: Booster Assy Control Valve Master Cylinder Reservoir Assy Booster & Master Cylinder Master Cylinder Assy Control Valve Fluid Reservoir

62 Departments - Actuation - Development - People and Organization Global Local

63 Departments - Actuation - Development - People and Organization - Global Patrick Weiland Chief Engineer, Actuation Development TRW Koblenz Tomáš Valečka Engineering Manager Jablonec (CZ) Lothar Zeuner Engineering Manager Duplex & Core Reservoir Ulrich Zinkan Engineering Manager Duplex Jens Sparfeld Engineering Manager Core Booster Ralph Rothenhäuser Engineering Manager Core Hydraulics Andreas Schupp Engineering Manager Development Tools & Lab Scott Bruder Engineering Manager Livonia (USA) Quan Sheng Liang Engineering Manager Shanghai (VCR)

64 Departments - Actuation - Development - People and Organization - Local Engineer,ing Manager ACT T. Valečka Assistant T. Špilarová Team Leader Design J. Kolář Team Leader Development T. Kroupa Team Leader Laboratory P. Kubín Designer T. Drbohlav D. Macák D. Hušek K. Vitoušová P. Hataš T. Jiřičný Development eng. F. Košťák M. Denk R. Klápště L. Franc M. Truhlář Mechanic R. Balogh J. Kubíček M. Beran D. Varga Technician J. Zajíček

65 Departments - Actuation - Development - What we are doing? Type of tests: Temperature range -40 C to +120 C Master cylinder burst test Brake fluid reservoir burst test Component tests Strength tests Volume displacement Funcional test rig Endurance test rig Tensile test rig

66 Departments - Actuation - Development - What we are doing? Funcional test rig:

67 Departments - Actuation - Development - What we are doing? Endurance test rig:

68 Departments - Actuation - Development - What we are doing? Tensile test rig

69 Departments - Actuation - Development - Contact TRW Automotive Czech a.s. Technical Centre - Actuation Na Roli 26, Building C1, 10 th floor Jablonec nad Nisou Czech Republic Engineering Manager Actuation JBC Tomáš Valečka Building C1, 10 th floor Team Leader Actuation - Development Tomáš Kroupa Building C1, 10 th floor Team Leader Actuation - Laboratory Pavel Kubín Building C1, 10 th floor

70 Departments - Customer Application and System Engineering About People and Organization What we are doing? Customers Portfolio Contact

71 Departments - Customer Application and System Engineering - About What we do in Customer Application & System Engineering? Preparation of project documentation and project leading. APDF C40, GDPIM Realization and testing brake system in cooperation with other department. FB,ACT,CEA,SCS,NVH Customer support Complaint Cooperation on test Car preparation for tests

72 Departments - Customer Application and System Engineering - People and Organization Global Local

73 Departments - Customer Application and System Engineering - People and Organization - Global Rainer Lewenz Chief Engineer Base Brake System Application & Workshop Acting Hyundai EU Koblenz Rainer Lewenz (acting) Team Leader Base Brake System Application 1 René Brenner Team Leader Base Brake System Application 2 Gerd Michel Team Leader Base Brake System French Market Jan Mleinek Engineering Manager CA&SE CZ C. Aust W. Neuser H.J. Nickenig Y. Rollin S. Schreiner M. Schütz R. Zech A. Hempel C. Hessling H. J. Mueller Joe. Oster R. Veit (1) Dotted line reporting to Joe Eiser

74 Departments - Customer Application and System Engineering - People and Organization - Local J. Mlejnek Engineering Manager CA&SE Project manager System Engineer System Technician Mechanic Project Coordinator B. Ruzicka I. Linka L.Zazvorka J. Drobnik R. Sramek R. Holasek J. Spáčil M. Trpisovsky J. Jansta M. Chomat A. Chovanova

75 Departments - Customer Application and System Engineering - What we are doing? Preparing of APDF documentation We are cooperating on preparing of pre project documentation. APDF is the master documentation and tracking tool to plan and monitor application projects from engineering point of view. Leading of project We are responsible for leading the project, EPMs Engineering project managers leading the project according C40 and GDPIM. Realization and testing brake system We test the brakes and brakes component on the car and test rigs with cooperation of other departments. Project statistic Preparing car for test Customer support We prepare the statistic of projects - Clarity, FBIP. We prepare the car for test with test equipment installation of measurement systems, sensors and harness. Harness are prepared in our E-lab. We support the customers - complaints solving and testing.

76 Departments - Customer Application and System Engineering - Contact TRW Automotive Czech a.s. Technical Centre - CASE Na Roli 26, Building E Jablonec nad Nisou Czech Republic Engineering Manager CASE Jan Mlejnek Building E

77 Departments - Customers

4850-01 BRAKE SYSTEM OVERVIEW AND OPERATION PROCESS 1. BRAKE SYSTEM GENERAL INFORMATION 1) DESCRIPTION AND OPERATION 16-3.

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