HORIZON Intelligent cross-linked and flexible process chain
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1 Intelligent cross-linked and flexible process chain
2 Aachen University enjoys an outstanding reputation and stands for engineering Aachen University Established ,000 students 10,000 mechanical engineering students 50 % of the university has main focus on engineering disciplines Aachen University is ranking first in Germany concerning external funding Main building of RWTH Aachen University Laboratory for Machine Tools and Production Engineering WZL Major institute of RWTH Aachen Established employees m² office space and laboratories Main fields of research: factory planning, e-mobility, assembly organization, production engineering, manufacturing technology, research on tooling machines, quality management Institute building of WZL and PEM Chair of Production Engineering of E-Mobility Components (PEM) Institute of RWTH Aachen Established employees EUR 19 million are currently invested by RWTH Aachen into the PEM research field: e- mobility, ramp-up manufacturing, production engineering Page 2
3 WZL has long and intensive tradition in conducting successful research projects both as leader and participant Excerpt of previous research projects at WZL and PEM COLL-PLEXITY Collaborative Complexity Collaborations as complex systems (FP-6, 2.1 m): Development of a generic model of complexity as basis for a problem-to-system match framework for collaborative systems in production industry; Coordinator MPA Modular plant architecture (FP-5, 5.0 m): Development of a methodology for implementing changeable production structures by modular design; Coordinator VFF COSMOS Virtual Factory Framework (FP-7, 11.9 m): Improvement of planning processes in a factory lifecycle to implement the next generation Virtual Factory, constantly synchronized with the real one; Subproject task management responsibility Cost-driven Adaptive Factory based on Modular Self-Contained Factory (FP-7, 5.1 m); Work package responsibility intime In time delivery in non-hierarchical manufacturing networks for the machinery and equipment industry (FP-7, 4.6 m); Coordinator Page 3
4 Fields of interest for cooperation in Horizon 2020 We are looking for participation and cooperation possibilities to advance our research topics. In particular we are interested in the following sections of the Horizon 2020 research programme: Excellent Science WZL wants to connect and enhance its infrastructure in close collaboration with other partners Industrial Leadership Leadership in enabling and industrial technologies (e.g. factories of the future) Innovation in SMEs Societal challenges Smart, green and integrated transport Mobility for growth Green vehicles Science with and for Society If we could raise your interest in our fields of research and if you want to discuss possibilities for collaboration in research projects, we are looking forward to receive your request Calls of Interest (Excerpt) Factories of the Future FOF Factories of the Future FOF Deadline Page 4
5 Flexural force Process sensors Project proposal for FOF : Intelligent cross-linked and flexible process chain Variants, measured data Laserschneiden Biegen Laserschweißen Sheet metal Laser cutting Bending Laser welding Flexible manufactured body Page 5
6 Use case battery assembly: For each vehicle variant a convenient floor structure Flexible process chain for the body shop Mix of variants, e.g. high-voltage battery for BEV 1, BEV 2, HEV, PEV Plug connection Laser welding Laser beam Slot Lug Page 6
7 Further Potential of process: Tailored structures for lightweight design New freedoms in product design High strength joint High speed production (< 1 s for a joint replacing six spot welds) Process chain with only three process steps Demonstration structure, welding time ~30 sec Use case floor structure StreetScooter: 8 kg weight saving From 102 down to 55 bending operations From >1 h down to <10 min welding time Page 7
8 Our comprehensive infrastructure, research facilities and know-how in the field of e-mobility enables research on future transport solutions Competences for research on Smart, green and integrated transport focus on industrial-oriented research regarding the integrated product and process development in the field of e-mobility comprehensive experience and competences in the field of e-production due to various research and industry projects unique environment and infrastructure for creating innovations numerous research facilities modular and innovative technology platform streetscooter various labs for research on the manufacturing and assembling of electric vehicles and components Integration and testing environment for validation of single development steps Special mobility research facilities Technology platform: Various labs: DFA Demonstration Factory Aachen Centre for e-bike development: Page 8
9 The center for electric vehicle production establishes a cooperative platform for integral product & process development in networks Centre for electric vehicle production DFA Demonstration Factory Aachen The ZEP possesses holistic infrastructure and know-how for application-oriented research Page 9
10 As an integrating platform the elab conducts research on product design and production processes of the electric powertrain Profile Battery abuse center Engine- and powerelectronics-check, Mechanical shop floor (extract) Battery package assembly The elab offers the excellent infrastructure to Design process chains for the production of electric powertrain components Develop and advance innovative technologies plus testing Prototype production Joining process (extract) Partners Mixing and coating process Linear winding machine Battery cell assembly Page 10
11 The Ramp-up Factory enables to focus on optimization of producibility of products during the ramp-up phase 3D printer Revolving- and chassis-testbench Engine assembly (extract) Assembly (extract) Thermoforming Portal milling machine Profile Profound know-how of ramp-up time and cost optimisation plus risk management Focus on exploration of methods for production planning and control Real testing environment for new vehicle components regarding suitability for series production, safety and assemblability Climate chamber Bonding system Partners Pur-rim-plant Welding techniques Bending Page 11
12 The Demonstration Factory produces prototypes and small series in order to explore methods of production planning and control Profile Sheet metal forming Manual short run assembly car body welding line The Demonstration Factory offers the excellent infrastructure to Launch, examine and optimise an entire pilot series production Reproduce the supply chain as a whole and simulate the material flow Empirically collect, illustrate and analyse data concerning product, process and material flow Warehouse and logistics Automobile assembly DFA Demonstration Factory Aachen Page 12
13 StreetScooter and e.go are Spin-Offs of WZL and PEM and provide technology platforms for innovative research projects Profile Flexible technology platform based on a modular concept Versatile network of partners in both research and industry Real testing environment for development of electric vehicle components and processes Extensive knowledge and experience in small series production as well as ramp-up management Fast growing production volume with several hundreds of vehicles targeted this year Page 13
14 The Centre for e-bike development merges technical competences to master sectoral challenges Profile PRICES MARKET TECHNOLOGY Interdisciplinary extension of competences with high flexibility Adaptable technological platform and knowledge base for e-bikes Cross-linked research activities incorporating industry and customer needs REGULATIONS PRODUCTION Page 14
15 Contact Dr.-Ing. Peter Burggräf Chair of Production Management Werkzeugmaschinenlabor (WZL), RWTH Aachen Steinbachstraße 19 Germany Aachen ( / / * P.Burggraef@wzl.rwth-aachen.de Dr.-Ing. Christoph Deutskens, M.Eng. Dr.-Ing. Georg Bergweiler Chair of Production Engineering of E-Mobility Components (PEM), RWTH Aachen Steinbachstraße 19 Germany Aachen ( / / * C.Deutskens@pem.rwth-aachen.de Chair of Production Engineering of E-Mobility Components (PEM), RWTH Aachen Steinbachstraße 19 Germany Aachen ( / * G.Bergweiler@pem.rwth-aachen.de Page 15
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