AUTOMOBILE PRODUCTION INNOVATIVE … © Fraunhofer IPK Fraunhofer worldwide Representative / Marketing Office Dubai Bangalore Selangor Jakarta Beijing Seoul Tokyo Boston Plymouth East

1 © Fraunhofer IPK

Workshop Automotive Industry 22.08.2013 ITA - CCM

AUTOMOBILE PRODUCTION INNOVATIVE PRODUCTION TECHNOLOGY

M.Sc. David Carlos Domingos Technology development for sustainable automobile production

© Fraunhofer

The German Research Landscape

Applied Research

Fundamental Research

predominently institutional predominantly private

Characteristics of Research

Funding

Federal/ German Länder Institutes 0,9

HGF* 3,42

WGL* 1,42

Univer-sities 9,2

Industry

internal 46.91

external 10.91 AiF ~ 0,25

Fraunhofer* 1,82

MPG* 1,772

*overall budget in billion euros

HGF Hermann von Helmholtz-Gemeinschaft WGL Wissenschaftsgemeinschaft Gottfried Wilhelm Leibniz AiF Arbeitsgemeinschaft industrieller Forschungsvereinigungen MPG Max-Planck-Gesellschaft Source:

Stifterverband für die Deutsche Wissenschaft, Destatis, research organizations

1 estimation Wissenschaftsstatistik 2010, Stifterverband

2 2011

3 © Fraunhofer IPK

Fraunhofer is the largest organization for applied research in Europe

66 institutes and independent research units

The majority of the more than 22,000 staff are qualified scientists and engineers

An annual research volume of €2.0 billion, of which €1.6 billion is generated through contract research.

More than 70 percent of this research revenue derives from contracts with industry and from publicly financed research projects.

Almost 30 percent is contributed by the German federal government and the Länder governments in the form of institutional financing.

International collaboration through representative offices in Europe, the US, Asia and the Middle East

© Fraunhofer

Universities

perform excellent

scientific research

Research cycle

Innovation cycle

RTOs bridge the

innovation gap with

technological R&D

Innovative

companies create

new products

Intensive exchange with society

Societal challenge as future markets - being ready for global competition

Fraunhofer’s position in der German Innovation System

fundamental research challenge of efficient light emitting diodes

innovation of luminescence-converter by Fraunhofer: absorbs blue light and converts it in yellow light -> combination of blue and yellow appears white

successful commercialization of white light LED in lighting, car lighting etc by OSRAM

http://www.osram.de/osram_de/index.html

© Fraunhofer

Financing of research institutions 2011 in percent

0%

20%

40%

60%

80%

100%

Fraunhofer-Gesellschaft

Helmholtz-Gemeinschaft

Leibniz-Gemeinschaft Max-Planck-Gesellschaft

Industrial revenue

Revenue public sector

Basic funding

€1,85 billion3 €3,23 billion1 €1,29 billion1 €1,59 billion1, 2

1 source: Gemeinsame Wissenschaftskonferenz GWK, Pakt für Forschung und Innovation; Monitoring-Bericht 2012 2 Haushalt A: without MPI für Plasmaphysik 3 Revenues Contract Research

Total budget

6 © Fraunhofer IPK

Fraunhofer worldwide

Representative / Marketing Office

Dubai

Bangalore

Jakarta

Beijing Seoul

Tokyo

Boston

Plymouth

East Lansing San José

Newark Maryland

Cairo

Selangor

Santiago de Chile

Singapore

Cambridge

Brussels

Porto

Vienna

Bolzano Graz Budapest

Wrocław

Gothenburg

Thessaloniki

Sydney

London

Glasgow

Salvador

Sendai

Paris

Subsidiary

Center

Senior Advisor

Project Center / Strategic Cooperation

São Paulo Campinas

7 © Fraunhofer IPK


more than 22,000 staff

The Fraunhofer-Gesellschaft Main locations of the Fraunhofer Institutes and Research Institutions in Germany

8 © Fraunhofer IPK

7 Groups:

Information and Communication Technology

Life Sciences

Microelectronics

Light & Surfaces

Production

Materials and Components – MATERIALS

Defense and Security


more than 22,000 staff

The Profile of the Fraunhofer-Gesellschaft

9 © Fraunhofer IPK

Fraunhofer Alliances Adaptronics

Ambient Assisted Living AAL

Building Innovation

Digital Cinema

E-Government

Energy

Additive Manufacturing

Cloud Computing

AdvanCer

Nanotechnology

Simulation

Optic Surfaces

Photocatalysis

Polymer Surfaces POLO

Cleaning Technology

Water Systems (SysWasser)

Traffic and Transportation

Vision

Automobile Production

Lightweight Structures

Embedded Systems

Food Chain Management

Battery

10 © Fraunhofer IPK

Automation

Technology

Virtual Product

Creation

Corporate Management

Production Systems

Medical Technology

Assembly Technology and

Factory Management

Industrial Automation

Technology

Machine Tools and

Manufacturing Technology

Industrial Information

Technology

Quality Science

Joining and Coating

Technology

Quality Management

Joining and Coating

Technology


Prof. Dr.-Ing. J. Krüger

Prof. Dr.-Ing. R. Stark

Dr.-Ing. H. Kohl

Prof. Dr. h. c. Dr.-Ing.

E. Uhlmann

Prof. Dr.-Ing. E. Keeve

Prof. Dr.-Ing. G. Seliger

Prof. Dr.-Ing. J. Krüger

Prof. Dr. h. c. Dr.-Ing.

E. Uhlmann

Prof. Dr.-Ing. R. Stark

Prof. Dr.-Ing. R. Jochem

Provisional Head:

Prof. Dr.-Ing. R. Stark Prof. Dr.-Ing. M. Rethmeier

Prof. Dr.-Ing. R. Jochem


PTZ Berlin Two Institutes – For The Entire Manufacturing Process Chain

Managing

companies

Developing products

…with innovative

manufacturing technologies,

…and automated

methods

Guaranteeing quality

Manufacturing products…

Automation

Technology

Virtual Product

Creation

Corporate

Management

Production Systems

Assembly Technology and

Factory Management

Industrial Automation

Technology

Machine Tools and Manu-

facturing Technology

Industrial Information

Technology

Quality Science

Joining and Coating

Technology

Joining and Coating

Technology

Quality Management

…machines and

tools,


1986 IWF and IPK move into PTZ

> 640 employees

More than 90 test areas and 10 special laboratories on about 9 500 m²

Budget of 30,8 Mio. Euro in 2012

Spin-offs and start-ups by 12 % of former staff members

Production Technology Center Facts and Figures

© Fraunhofer IPK


Technology development for sustainable automobile production Agenda

I Megatrends determine the future

I Industrial trends und developments

I Technologies for automobile production




I Industrial trends and developments



Climate change and resource

scarcity

Demographic change

Penetration with new

technologies

Shortening and dynamizing of the product life

cycle

Globalization

Individuality of the markets

Learning society/

knowledge- society

Mobility

Megatrends determine the future

© Fraunhofer

Health and nutrition Affordable healthcare

Challenges – ”The Markets Beyond Tomorrow”

Safety and security Disaster prediction and management

Information and communication

Mobility and transportation Low-emission, reliable mobility in urban areas

Energy and living Low-loss generation, distribution and use of electricity

Production and environment Life-cycle production

Foto

s ©

Fra

un

ho

fer

© Fraunhofer

MOBILITY AND TRANSPORTATION

We conduct research in the following areas:

Personal mobility

Freight mobility

Lightweight construction systems

Road safety

Innov. vehicle technolo-gy and electromobility

Automotive innovation

Imag

es

© F

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nh

ofe

r; M

EV

© Fraunhofer

BEYOND TOMORROW PROJECTS Low-emission, reliable mobility in urban areas

Increasing population density

Inadequate development of transport infrastructure

Motorization in newly industrializing countries

Global increase in population

Increasing environmental pollution in cities

Integrated mobility (e.g. car sharing)

Traffic density

Cleaner cities

Demand for mobility

Urbanization

Sustainability

Global prosperity

Imag

es

© F

rau

nh

ofe

r; i

sto

ckp

ho

to

© Fraunhofer

PRODUCTION AND ENVIRONMENT

We conduct research in the following areas:

Production that saves energy & raw materials

Product development

Manufacturing technologies/methods

Measurement and test engineering

Automobile and plant engineering, robotics

Production processes

Materials and surfaces

Imag

es

© F

rau

nh

ofe

r; i

sto

ckp

ho

to

© Fraunhofer

BEYOND TOMORROW PROJECTS Life-cycle production

Resource scarcity in Germany

Global conflicts over access to rare earths

Reuse offers enormous potential for savings

Clean tech is gaining ground

Production and plant engineering are the backbones of German industry

Demand for raw materials

Production technology

Efficiency and productivity

Imag

es

© F

rau

nh

ofe

r; M

EV

;







Industrial trends and developments Introduction

»The demand for motor vehicles will not exceed one million – alone for the lack of available chauffeurs.« Gottlieb Daimler, 1901

42,3 mio. cars in Germany

(01.01.2011)

Benz patent-motorcar number 1 (1886)


Industrial trends and developments Politically motivated trends (EU)

Euronorm 5 and 6 for reducing emissions of motor vehicles

Emiss ion standard for the new car fleet to reduce CO2 emissions

Measures

Reducing weight and consumption

Shift of the operating point and friction reduction for efficient combustion

Exhaust gas recirculation

500

180 230

500

80

170

0

100

200

300

400

500

600

CO NOX HC + NOX

Po

llu

tan

em

issi

on

EURO 5

EURO 6

Euronorm 5 and 6 for cars

740

280 350

740

125 215

0

200

400

600

800

1000

CO NOX HC + NOXPo

llu

tan

t em

issi

on

EURO 5EURO 6

Euronorm 5 and 6 exemplarily for trucks of 2,5 t up to 7,5 t

mg/km

mg/km

NOx

NOx

HC + NOx

HC + NOx

Quelle

n: V

ero

rdnung (

EG

) N

r. 4

43/2

009,

Nr.

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007


Industrial trends and developments Politically motivated trends (EU)

Reduction of CO2-emission

Cost reduction of electric vehicles

Reducing petroleum-based fuels

Consolidation and expansion of the material properties including recycling

1 Mio. electric cars in Germany until 2020

Investment of 20 billion € per year for research and development by automotive industry

11,9

3,0 2,0 2,0 1,4 1,0 0,9 0

5

10

15

20

Pie

ce c

ou

nt

in m

illio

ns

Politically required number of electric cars (in mio.) in 2020

30.488

11.267

419 72 37 2 0

10.000

20.000

30.000

40.000

Car ownership in Germany after fuel type(in 1000; 01.01.2011)

Quelle

n: w

ww

.bundesr

egie

rung.d

e,

Sta

tist

iken

: w

ww

.sta

tist

a.d

e

Pie

ce c

ou

nt

in t

ho

usa

nd

s

Petrol Diesel LPG Natural Hybrid Electro Gas

China USA Japan France CAN GER Spain


Industrial trends and developments Automobile manufacturers

Lightweight

Downsizing Hybridization/ Electromobility

Fuels


Industrial trends and developments Lightweight

Substitution of metals by duro- and thermoplastics

Multimaterial concept

Use of structural components for load-oriented strength increase

Use of composite materials (CFRP) for structure, interior and exterior components

Reduction of wall thickness

Reduction of moving masses (connecting rods, rod bearings, pistons, piston pins, piston rings)

88 98 116 121 130

0

50

100

150

200

1980 1990 2000 2004 2010

Use

of

pla

stic

Use of plastic and composite materials per car in Germany

kg

Plastic components in a car

Quelle

n: A

uto

mo

tive

Outlo

ok 2

011,

lightw

eig

htd

esi

gn 0

4/1

1;

Sta

tist

iken

: w

ww

.sta

tist

a.d

e

Thermoplastics or polyurethane foam instrument panel,foam,column,lever,knobs

Thermosets tailgate

Thermosets reflectors

Thermosets wing

Thermosets window lifter Polyurethane foam seats

Elastomer bumper components

Thermosets cable railways, pump housing

Elastomer cable sheathing, seals

Thermoplastics bumper

Thermoplastics engine cover, oil filter, air filter

Thermosets hoods


Industrial trends and developments Downsizing

Emission and fuel saving by reduced displacement

Compensating the power loss by charging

Construction of smaller engines (2 and 3 cylinders are sought)

Cylinder shutdown in large motors (V8)

Use of turbochargers with variable turbine geometry for emission and consumption reduction

Operating principle of an exhaust turbocharger

Quelle

n: w

ww

.atz

onlin

e.d

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ww

.auto

mo

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pro

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n.d

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ww

w.a

mz.

de


Industrial trends and developments Fuels

Natural gas, biodiesel, bio-ethanol, LPG, GTL (gas-to-liquid), BTL (Biomass to Liquid)

Challenges

Engines for different fuels achieve worser emissions than conventional engines

Flex engines have increased corrosion of engine parts at high ethanol concentration

Increased wear especially on valves and valve seats

Quelle

: w

ww

.auto

bild

.de


Industrial trends and developments Hybridization / Electric mobility

Hybridization

micro hybrid

mild hybrid

full hybrid

range extender

Electromobility

Acceptance and willingness to buy vehicles with alternative drive is increasing

Dominance of internal combustion engines is declining

Great potential for the development of independent drive components and battery technology

57,6

20,2 14,3 5,5 2,4

0

20

40

60

80

100

Benzin Hybrid Diesel Elektro Gas

PK

W-A

bsa

tz 2

02

0

%

Prognostizierter PWK-Absatz im Jahr 2020 Quelle

n: w

ww

.atz

onlin

e.d

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ww

.auto

mo

bil-

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ww

w.a

mz.

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: w

ww

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a.d

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Technology development for sustainable automobile prodution Agenda



I Technologies for the automobile production


Lightweight

Downsizing Hybridization/ Electromobility

Fuels

Future concepts and technologies


Lightweight

Downsizing Hybridization / Electromobility

Fuels



Porsche Ceramic Composite Clutch Carrera GT

Future concepts and technologies: lightweight Development and design of lightweight structures

Reduction of the moving mass by guaranteeing at

least the same stiffness

Energy saving

Higher dynamics and accuracy of assembly

Ergonomic handling during installation

Intelligent use of materials leads to increase

energy efficiency

Lightweight construction allows greater range

Quel

le:

SGL

Car

bon,


Future concepts and technologies: lightweight Fiber reinforced plastics (FRP)

Reducing CO2 emissions and increasing the power

density as compared to aluminum and steel

Extension of the constructive possibilities, as up to

three times the specific strength compared to

aluminum alloys

Improved crash behavior through targeted

influencing the mechanical properties of the FRP-

component

Production of near net shape components possible

New solutions for simple and inexpensive

automated manufacturing processes necessary

17 16,1

10,2 13,2

15,9 17,1

0

4

8

12

16

20

2005 2007 2009 2011 2013 2015

lig

htw

eig

ht

veh

icle

s sa

les

fig

ure

s

year

Automobilbranche (US-Markt) Verkaufstrends

Plastic transmission crossmember with gearbox bearings in BMW 5er GT

Mio

Quel

le:

Schla

rb (

2007), C

om

posi

tes

Man

ufa

cturing (

2011)


Future concepts and technologies: lightweight Machinability of FRP

Complicated machining due to superabrasive

carbon fibers in association with high

temperature-sensitive adhesive polymer matrix

Problematic cooling lubrication in machining

process due to fluid intake and delamination

Delamination of the networks leads to large

tolerance deviations in manufacturing

Development of cutting tools

Development of new more reliable cutting

strategies for complex FRP structural components

Cutting edge milling tool for machining CFRP (left)

and for aluminum machining (right)

VW-XL1 – 1 liter car (Prototyp 2011) Quelle:

CVD diamond-coated cutting tool for CFRP processing

20 µm 20 µm

Quel

le:

htt

p://w

ww

.volk

swag

enag

.co

m


Future concepts and technologies: lightweight CO2- high pressure jets

Water jet technology has been continuously developed, but has several disadvantages

Complex micro filtration & treatment or disposal after processing

Parts cleaning after machining required

Development of a new procedure with high pressure jets of liquid carbon dioxide CO2

Liquid carbon dioxide as cutting medium

Advantages of both methods without the disadvantages of water jet technology

A method for separating, stripping, deburring and cleaning


Future concepts and technologies: lightweight Flexible robotic solutions increase productivity and quality

Complex body parts are difficult to access for

deburring and polishing processes

One approach is the use of flexible, robot-guided

procedures:

Adaptive deburring, polishing and finishing

processes

Robot-controlled submersible tumbling

A component recognition by 3D acquisition system

for an automated quality assurance.

Industrial deburring robot cell at the IPK


Future concepts and technologies: lightweight Aluminum parts milled by industrial robots

Robots used to machining aluminum process

A: face milling of thin surfaces

B: face milling of large surfaces

C: hole drilling and threading

Use of an integrated force and moment control in

order to maintain constant the milling forces

Robots for machining

A

B

C Quelle: Chevrolet Corvette 6.2L LT1


Future concepts and technologies: lightweight Automation solutions in the automotive sector

Control for Kobot system using the example of a

rear window assembly

Cooperation between man and machine:

autonomous and powerful torque guided motions

possible

Flexible automation that involves the people in

the process and thus leads to cost-effective

solutions

Optical assembly testing

Technical specification of assembly test systems in

gears manufacturing


Future concepts and technologies: lightweight High Speed Forming

Challenge: Conventional forming of magnesium

alloys only from about 220 ° C.

Solution: Magnetic pulse forming of

magnesium sheets at room temperature

Inductive heating and forming in one process

step

Forming of Mg-alloys at high strain rates

Challenge: welding of different materials

Solution: The magnetic pulse welding

Up to 90% energy saving compared with

conventional fusion welding processes

Formed Mg- sheet

flat coil

1,767e9

-2,884e8

Dru

ck

[P

a]

1,767e9

-2,884e8

Dru

ck

[P

a]

FEM-simulation of the welding process (joint zone)

Pre

ssu

re [

Pa]


Future concepts and technologies: lightweight Resistance spot welding of lightweight structures

Improvement of weldability for resistance spot

welding

Increased process safety in new materials

Optimization of the joints properties such as

fatigue strength and crash behavior


Future concepts and technologies: lightweight Arc welding of lightweight structures

Increase the weld strength, improve weldability

Reduce the hot cracking susceptibility by

selective grain refinement

Advantage of existing expertise:

Extension of the limits of use of high-

strength aluminium alloys

Cost reduction through effective joining

method



lightweight


Fuels


Future concepts and technologies: downsizing Generative processes

Laser-based, forming manufacturing process

Production of components directly from CAD data

and metal powder

Volume and not geometry-dependent costs

Economic production lot size to 1

Generation of components of difficult to machine

materials

Integration of various functions into one

component, thus avoiding assembly processes

Binding by locally melting the metal powder from

serial identic functional material


Future concepts and technologies: downsizing Selective Laser Melting

Poss ibilities

Large geometric freedom through layered

component structure

Strengths generated structures are very similar to

those of cast components

Reduction of the internal density of components

by up to 90% and the inertia by up to 30%

through use of lightweight structures

New parts of components out of TiAl6V4

TiAl6Nb7, INC. 718, Hastelloy X, Rene 80 can be

made by laser radiation



lightweight


Fuels


Bosch

IPK

Complex well geometries

Future concepts and technologies: Fuels Ablative method for manufacturing fuel injectors

injectors requirements

Hole diameter: <200 microns

Form accuracy: ± 1 micron

Borehole geometry: conical

Aspect ratio: ≤ 15


combined laser & EDM machining

Rapid production of complex shaped micro-

holes with high aspect ratios

Implementation by functional integration into

hybrid machine tool

Roughing by laser spiral drilling machining

Process simply by μEDM

hybrid machine

µEDM

LHD

IPK




Hybrid process allows the production of holes,

similar to those produced by EDM drilling process

in their individual quality

Reduction of processing time to 50%

Entry Exit Entry Exit20 µm 20 µm 60 µm 60 µm

Entry Exit Entry Exit20 µm 20 µm 60 µm 60 µm

Pilot hole produced by laser processing

IPK

IPK

Workpiece material :

1.5920 (thickness ts = 1 mm)

Geometry:

Through-bore

dB = 150 µm

pilot hole

dVB = 90 µm

machining process:

EDM and hybrid process

µEDM Hybrid process

0

8

16

24

s

40

pro

ce

ssin

g t

ime

tB

process

EDM

Laser

EDM



Lightweight


Fuels


Future trends and technologies: Electromobility Research and development, from idea to product

Experiments with electric delivery vehicles in

cooperation with DHL

Regional, national and European pilot projects to

determine the user requirements for electric

actuators within fleet tests

Interpretation of drive and control concepts

Development of production technology for the

manufacture of electric motors and battery

systems

Development of automation solutions


Field trials in Berlin, specializing in business services (KEP, store delivery) Research area: Steglitzer Schloßstraße as transport policy laboratory

Commercial Transport

Future trends and technologies: Electromobility Research and development, from idea to product


Future trends and technologies: Electromobility Requirements management, identification of user requirements

Development of a system for collecting

measurements data for

electrical Characteristics

dynamics and

Mobility behavior of different user groups (eg city

logistics, logistics service providers)


Future trends and technologies: Electromobility Drive and control concepts for urban commercial transport

On the basis of the measured data user-specific

drive concepts are designed, constructed and built

at the IPK

Development of control systems for parameter

control of E-drives as a function of dynamic load

and power conditions

Construction of a dynamometer

Felgenmotor


Werkzeuge Maschinen und -komponenten

Werkstoffe Fertigungs- verfahren

Prozessketten

Materials

› High strength

materials (Ni, Ti-based)

› Lightweight materials

(Mg, Al-alloy, foamed

metals)

› Composites (FRP-

reinforced ceramics,

MMC)

› Sintered materials

(ceramic, metal)

Tools

› Surface and coating

technologies

› Innovative cutting

materials

› Micro tools

› holistic approach to

design,

› manufacture and use

Manufacturing

processes

› High-speed machining

› High-performance

processing

› Ultra precision and

micro machining

› hybrid method

› Dry machining

› Rapid Prototyping and

Rapid Tooling

Process chains

Shorteing process chains

by:

› Substitution method

› hybrid method

› Near-net-shape

technologies

› integrated productand

development process

Areas of innovation in production technology Services of PTZ at a glance

Mashines and

-components

› Innovative

components

› adaptronic structures

› Seeing machine tools

› Rod and rope

kinematics

› Reconfigurable,

modular machines


Thanks for your attention!

Contact

David Carlos Domingos

Research assistant | Department Production Systems

Fraunhofer IPK | Pascalstraße 8-9 | 10587 Berlin

Phone: +49 30 / 3 90 06-413

+55 61 8347 7198

Email: [email protected]

Documents

AUTOMOBILE PRODUCTION INNOVATIVE … © Fraunhofer IPK Fraunhofer worldwide Representative / Marketing Office Dubai Bangalore Selangor Jakarta Beijing Seoul Tokyo Boston Plymouth East