Innovation in research and development

R&D is at the centre of everything that HJS does. Innovation is given absolute top priority at HJS and is de rigueur in light of the ever more stringent exhaust emissions legislation being passed.

To guarantee product durability on the one hand and product performance on the other, HJS makes use of the very latest CAD (Computer Aided Design) and CAE (Computer Aided Engineering) tools:

  • Altair HyperWorks V9.0
  • Pro/ENGINEER Wildfire 4
  • Catia V5 R16 + R19
  • AVL FIRE® V2010
  • Flowmaster V7.0 (1D)
  • DXF, IGES and STEP exchange formats

HJS has also tailored its own product development process to the specific needs of its customers.

Product development process

Project
Start

Concept
Release

A-Sample
Release

B-Sample
Release

C-Sample
Release

D-Sample
Release

Concept release: based on the design review and a CFD analysis (without model)
A-Sample: first functional prototype (does not meet the installation-space requirements)

A-Sample release based on …

  • Laboratory testing with respect to flow mechanics
    (uniform distribution, backpressure)
  • First validation of the software parameters
    (MIL and HIL test benches)
B-Sample: B-Sample meets all technical requirements (except durability)

B-Sample release based on …

  • FEA
  • Repetition of laboratory testing of the flow mechanics
    (uniform distribution, backpressure)
  • Functional validation on engine test benches (detailed calibration of functions and diagnoses, surface temperatures, etc.)
  • First installation in test beds for testing interfaces, recording load profiles and conducting acoustics tests
C-Sample: off-tool parts, all technical requirements met (including durability)

C-Sample release based on …

  • Positive completion of the endurance test
  • Testing on engine test bench (if demanded)
  • Proof of mechanical durability
    (hot-shake test bench, hydropuls)
  • Vehicle endurance test
    (as a rule, performed by the customer; vehicle equipment with mobile measurement equipment and support from HJS)
D-Sample: initial sample parts

D sample release based on …

  • Production with linked production facilities
  • Approved process capability
  • Approved logistics concept
  • Completed "two-day" production
  • Approved initial samples
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