From engineer to software developerfor durable slewing bearings

Making processes more efficient

"Remaining competitive necessitates innovation,says Dr. Thomas Handreck, an engineer at thyssenkrupp rothe erde. Increasing customer demands for slewing bearings typically entail rising costs. Handreck is embracing this challenge by working on the development of efficient software. He describes it as a job for "inquisitive tinkerers with endurance."

In his day-to-day work at thyssenkrupp rothe erde, Dr. Thomas Handreck is constantly seeking new software solutions to enhance processes' efficiency. Even as a schoolboy, he enjoyed tinkering but was hesitant to stick to existing models. According to him, wanting to come up with something of his own, along with an interest in technology and skills in mathematics, is the ideal prerequisite for working in the field of software development.

Tinkering for more efficient slewing bearings

Slewing bearings are his specific field of application - or rather the determination of their utilization with the help of so-called finite element calculations. Handreck's work aims to enhance these processes and calculation methods, making them more efficient and cost-effective. Handreck also states that this makes them more appealing for development partnerships.

The finite element method is a numerical method that allows the strength or deformation of slewing bearings to be investigated by dividing a mechanical structure into many small elements. Due to the often complex applications in which slewing bearings are installed, design and appropriate dimensioning are particularly important in their development. The design is the task of the designers. Handreck and his calculation software come into play for optimal dimensioning.

With his REBA (rothe erde bearing analysis) program, which Handreck himself developed at the company more than 20 years ago, calculations on slewing bearings are more efficient than with commercial finite element software.

"REBA simulates the use of slewing bearings," explains the expert. "While the first version of the program focused on individual bearings, we can now calculate several bearings simultaneously." This further development was necessary because, for example, different bearings in wind turbines, such as rotor, blade and tower bearings, are located very close to each other and influence each other.

Being innovative means staying one step ahead

Thomas’ current project is the development of 3D graphics software for visualizing simulation models and results from REBA multi-bearing calculations. The program currently under development, a 3D viewer, enables users for the first time to quickly and easily check calculation models for accuracy and completeness. It also provides a clear overview of the calculation results and can visualize them directly.

Modern calculation programs - such as REBA for multi-bearing systems - process large amounts of data. "It is often difficult for users to check the plausibility of the calculation or get an overview of the results obtained using text files and tables alone," explains Handreck. While users previously had to struggle with huge amounts of data when working with REBA, REBA's 3D viewer makes interpretation much easier by converting the figures into graphs and other visualizations. The 3D viewer is therefore a further development of REBA and will probably be used in engineering over the coming year.

Curiosity as a driving force for innovation

What excites Thomas Handreck most about his job? He doesn't do repetitive tasks and always follows the same patterns. Instead, he regularly faces new problems in his specialist area and looks for solutions. For Handreck, one thing is certain: "This systematic search and the challenging tasks are the most fun."