Development - Pankl Racing Systems AG

Pankl relies on the latest manufacturing and surface treatment equipment as well as on the outstanding expertise of its process engineers, making it possible to fulfil even the strictest quality and process requirements of customers throughout the process chain.

The ongoing development of manufacturing processes contributes towards continuous product improvement and guarantees new solutions for our partners on a regular basis.

Customers have a defined contact partner at their disposal from the start of a project, throughout the development process and all the way to the finished product; this contact person is in charge of the whole customer project and is supported by a team of experts. The result: direct, efficient project management for their benefit!

MATERIALS ENGINEERING

Materials of the future

Pankl works with worldwide partners and experts on the development of new materials in order to provide our customers with new solutions for future mobility.

This is what Pankl Racing Systems works towards on a daily basis, in close cooperation with customers and experts all over the world.

The mobility of the future is based on new developments and innovative technologies, in particular those using tomorrow’s materials. New ideas and solutions when it comes to material for engine and drivetrain technology also require completely new approaches that go far beyond the current standard.

DESIGN & SIMULATION

Intelligently applied creativity

Throughout the development phase, Pankl and its designers combine customer specifications, legal requirements and material characteristics creatively and intelligently in order to create the perfect part design.

TECHNOLOGICAL KNOW-HOW

During the entire development phase of every single component, the Pankl design engineers are faced with the challenge of putting together highly different, sometimes even contradicting requirements to form a coherent concept. The ongoing dialogue between the design, testing and simulation departments and the regular exchange with customers are essential prerequisites for developing effective solutions that live up to customer-specific guidelines and comply with all applicable legal requirements.

NEW APPROACHES, NEW SOLUTIONS

When it comes to design, Pankl Racing Systems offers creative, intelligent solutions that are based on performance, resilience, cost-effectiveness and environmental performance. These activities range all the way from the development of new materials and processes through prototype development and simulation to optimised manufacturing.

STRONG SYNERGIES

In order to achieve the targets set, Pankl Racing Systems aims to make the most of its strong synergies: The competence of the Pankl forging facilities in Austria are bundled with the machining and assembly competence of the Slovakian site; the Pankl Turbo Systems team in Mannheim, Germany maintains a lively exchange with their colleagues in the US, Japan and the UK. Our solid, global network of partners in the motorsports segment as well as cooperation initiatives with research institutions boost the proficiency of Pankl Racing Systems from preliminary sketches through prototype design to large-volume production of several thousand components a year.
The interdisciplinary cooperation between departments of the company subsidiaries begins already at the start of a project and ensures that all factors relating to manufacturing engineering, cost-effectiveness and quality are taken into account in the development of new engine components from the first inquiry onwards.

MATURE PERFECTION

In-house R&D facilities help us draw up thorough feasibility studies that form the basis of a preliminary design model; whereas already during this early stage, state-of-the-art calculation and simulation tools are used for the effective, targeted development of systems and components. The experience gained from these simulation loops is in turn developed further to improve every single component, all the way to prototype production.
As a link between development and manufacturing, tool design plays a fundamental role in high-precision component manufacturing. As soon as the optimised design of a component and tool allows the manufacturing of perfectly forged geometries complying with the project requirements, the actual production process can begin.
Milling and assembly work constitute the last phase in the development chain. They are also part of the development process and help create an integrated system where no step is neglected, even though it may seem tiny and insignificant at first.

EVERYTHING UNDER A SINGLE ROOF

This development environment creates the perfect interface between design and manufacturing, guaranteeing the shortest possible production times and the highest possible level of efficiency. The unique combination of industry expertise and technological knowledge helps create trendsetting products and makes Pankl Racing Systems a dynamic partner of global market leaders.

TESTING

Strict controls

With its state-of-the-art testing equipment Pankl ensures, that throughout the design development process aside from high dynamic specifications, reduced fuel-consumption requirements and security standards are also met.

HIGH RELIABILITY

Engine and drivetrain concepts are currently undergoing a period of massive transformation. The goal is: best performance and the highest possible safety, combined with minimised fuel consumption and reduced emissions. These new, revolutionary requirements and increasingly complex systems require strict control and test mechanisms – and Pankl has the state-of-the-art test equipment available to fulfil these requirements.

TESTED, RE-TESTED, OPTIMISED AND TESTED AGAIN

All Pankl Racing Systems engine and drivetrain components are tested for a broad spectrum of different applications, tailor-made to fulfil individual customer requests. To provide preliminary results within the development process and for metallurgical research, state-of-the-art component test beds enable tensile, compression and ovalisation tests as well as early results on fatigue and friction analyses for all Pankl products before they enter more complex and costly test phases.

HIGHLY FLEXIBLE TEST RUNS

A unique, dynamic shaft inspection system simulates real track data from Formula 1, rally racing or rally raids, providing industry-specific stress and endurance data. Rotating components of up to 5m in length may be tested at up to 6500 Nm and at a maximum speed of 11500 rpm in the simulation of steering angles and spring deflection.
With a state-of-the-art suspension corner test bed with a frequency range of up to 70Hz and travel paths of up to 300mm, nearly all requirements for different racing applications as well as for the super and hyper car market are covered. Integrated measuring systems, bus integration and extension measurement guarantee optimal compliance with customer requests and reliable testing results.
This way, all Pankl components and systems are tested in conditions that accurately reflect Formula 1 requirements with regard to top speeds as well as under rally conditions in regards to steering movements.

TAILOR-MADE MEASURING SOLUTIONS

The new servo-hydraulic test lab is capable of static and highly dynamic tests of up to 6DOF, using digital controllers with high channel density, high-precision signal conditioning and excellent configurability. Dedicated elongation measurements and electronic developments provide customised measurement solutions.

RELIABLE TEST RESULTS

A state-of-the-art hot-gas test facility (800 kW; 1200° C) is used for the validation of electrically supported turbochargers (up to 800V at ± 500A). The application spectrum ranges from passenger cars to trucks and comprises all types of racing series with and without electrified TCs and boosters.
In addition, a compressor closed-loop unit will be used to test EATs in order to widen the standard compressor scope. For safety reasons, burst and containment tests supply simulated threshold values for special types of wheel and housing materials.

Customer Service

Comprehensive know-how

Even after the product has been delivered, Pankl assists the customer with know-how in order to achieve further performance optimizations. This includes a comprehensive analysis of components that have already found their use in racing or on the road.