Dr. Thomas Bischof
An engineer, a gearbox, and the cardinal question
I am Thomas Bischof, Dr.-Ing., and I run the engineering office that carries my name. For twenty-six years I was responsible for acoustic method development at ZF Friedrichshafen, latterly as Manager NVH & Dynamics and head of the group-wide acoustics expert team. I have run my own engineering office since 2002, full-time since 2022.
I started in optical metrology: at the Bremen Institute of Applied Beam Technology I coupled holographic interferometry with finite element calculations to find flaws in adhesive bonds, fibre-reinforced components and pressure vessels without destroying them. That was also the subject of my doctorate at the University of Bremen, followed by a research stay at Worcester Polytechnic Institute in Massachusetts; those years produced more than fifteen publications on holographic interferometry. What stayed with me is an attitude: a measurement only becomes a statement once the model and the experiment point at each other.
At ZF the work extended to drivetrain acoustics, system acoustics and root cause analysis in end-of-line testing. For seven years I also chaired the FVA working group on NVH; the FVA is a nationwide association of companies that coordinates their pre-competitive research. Drawing on that experience, I have spent the last three years pushing the established methods further and feeding the results into the analysis platform s2m: relative transfer functions and tooth mesh excitations, and the automated attribution of an anomaly to its possible causes. The spark that started my engineering office was the development of AutoPlotter, a tool for the automated evaluation of noise measurements, which I sold from 2002 onwards and whose sources have since gone to ZF.
What has not changed is the question at the end of every campaign: can you name the component that causes the problem, and can you show why. Suitable methods were developed to make that answer defensible rather than plausible.
Background
Foundations of the method expertise
The stages by the year they began, and the work that came out of each.
- 1983
Studies in theoretical mechanical engineering, University of Kaiserslautern
Focus: machine dynamics, modal analysis, numerical methods, engineering mechanics, control engineering and fluid mechanics.
- 1988
Diploma thesis at Tecmath GmbH, Kaiserslautern
On data reduction methods in fatigue life analysis.
- 1989
Research associate at BIAS, Bremen
At the Bremen Institute of Applied Beam Technology, coupling numerical methods with measured results, hybrid working long before the term became common. Concretely: reconciling finite element calculations with displacement measurements from holographic interferometry. The model predicts a displacement field, the interferogram measures it, and wherever the two part company the model is wrong. More than 15 publications on it, among them a chapter on holographic interferometry of adhesive bonds in the Handbuch Fertigungstechnologie Kleben.
- 1994
Doctorate at the University of Bremen
Dr.-Ing., on non-destructive testing, digital image processing and holographic interferometry; the thesis appeared in 1994 with VDI-Verlag, Fortschritt-Berichte series 8, no. 398.
- 1994
Research stay at Worcester Polytechnic Institute
A post-doc at WPI in Worcester, Massachusetts. The subject remained the combination of holographic interferometry and finite element calculation, the same pairing of measurement and model that would later carry the gearbox acoustics work.
- 1995
ZF Friedrichshafen: Manager NVH & Dynamics
Twenty-six years of gearbox and drivetrain acoustics: head of the group-wide acoustics expert team, responsible for fundamental research in NVH. The work was NVH method development, that is automated evaluation, new evaluation methods, reconciling simulation with measurement, and mapping the limits of both: where a model still holds, and where an evaluation method stops carrying. Alongside it, transferring that knowledge into the business units, from designing the training courses to teaching them. Responsible for establishing airborne sound sensitivity, transfer path analysis and blocked forces as methods across the group. As project lead, responsible for an application built on a central repository of ZF’s acoustic gearbox models, which made fast root cause analysis of conspicuous gearboxes possible, in use at every ZF site with an end-of-line test bench.
- 2002
AutoPlotter, automated evaluation as a product
Alongside the employment I have run my own engineering office since 2002, at first as a second occupation. Out of it came AutoPlotter: a software product for the automated evaluation of noise measurements, built on PAK, the measurement software from Müller-BBM. Its sources have since been sold to ZF.
- 2008
Lectureship in machine acoustics
Lecturer for machine acoustics at Ravensburg-Weingarten University of Applied Sciences. The lecture notes grew out of the gearbox acoustics training I was giving at ZF; whatever proved to carry in the lecture hall found its way back into the training material.
- 2011
End-of-line testing and order-based evaluation
Locating acoustically suspicious gearbox bearings on the end-of-line bench, and diagnosing them within the seconds a production line allows. In 2015, at the 22nd ICSV in Florence, deriving the relative transfer function and the relative tooth mesh excitation from ramp measurements, the direct predecessor of today’s evaluation.
- 2015
Chair of the FVA working group on NVH
Seven years chairing the NVH working group of the Forschungsvereinigung Antriebstechnik in Frankfurt, gearbox acoustics not as one company’s problem but as the industry’s shared question.
- 2016
Patents on automated cause attribution
Among them a method that automatically attributes possible causer sources to an acoustic anomaly of a rotation-synchronous noise source, a method for detecting defective bearings, and structure-borne and motion sensing built from electroactive composite material.
- 2022
Ingenieurbüro Dr. Thomas Bischof, full-time
Since 2022 the office in Graben-Neudorf has been my full-time work: tooling that automates evaluation work, automated assessment of acoustic measurements, root cause analysis of suspicious machine noise. The method now sits in s2m, which holds the measurement data, the kinematic models and every analysis run, and makes a result reproducible months later.
Selected work
Publications and patents
A selection, newest first. The complete list is on Google Scholar.
- 2024
Patent
Device and method for generating a speed setting for a machine tool
DE 10 2023 202 705 A1, with D. Stock and J. Glitza
- 2023
Paper
The dynamics of tapered-roller bearings — a bottom-up validation study
Strojniški vestnik – Journal of Mechanical Engineering 69(7–8), with M. Razpotnik and M. Boltežar
- 2022
Patent
Method for determining torsional backlash in a transmission, and transmission arrangement
DE 10 2021 205 346 A1, with J. Pescheck and A. Lauer
- 2017
Patent
Method for automatically attributing possible causer sources to an acoustic anomaly of a rotation-synchronous noise source
DE 10 2016 206 809 A1, with A. Meier-Koll
- 2017
Patent
Method for detecting defective bearings
DE 10 2016 210 547 A1
- 2017
Talk
Improvement of the blocked force method by considering the cross & moment
DAGA, Kiel, with L. Trampus
- 2015
Paper
The influence of bearing stiffness on the vibration properties of statically overdetermined gearboxes
Journal of Sound and Vibration 351, with M. Razpotnik and M. Boltežar
- 2015
Talk
Deriving the relative transfer function and the relative tooth mesh excitation based on ramp noise measurements
22nd International Congress on Sound and Vibration, Florence
- 2012
Talk
Getriebe- und Systemakustik
DAGA, Darmstadt, with H. Naunheimer and others
- 2012
Talk
Root cause analysis of acoustically suspicious transmissions during EOL testing
7th International Styrian Noise, Vibration & Harshness Congress, SAE Technical Paper
- 1994
Doctoral thesis
Ein Beitrag zur Detektion und Bewertung von kugelförmigen Einschlüssen mit holografischer Interferometrie
VDI-Verlag
Beyond these, more than 15 publications from the optical metrology years: holographic interferometry of adhesive bonds, fibre-reinforced components and pressure vessels, each coupled with finite element calculations, among them a chapter in the Handbuch Fertigungstechnologie Kleben.