Automotive Sector Vincent Jamier, PhD

Automotive Sector

Vincent Jamier, PhD

01 WHO ARE WE ? AND HOW TO COLLABORATE ?

02 R&D IN LEITAT - AUTOMOTIVE SECTOR – MATERIAL & COMPONENT

03 R&D IN LEITAT - AUTOMOTIVE SECTOR – PROCESS

04 ADVANCED TECHNICAL SERVICES

AGENDA

Growth

Sustainability

Internationalization(Chile)

01. WHO ARE WE ? AND HOW TO COLLABORATE ?Where are we located?

HEADQUARTER IN TERRASSA

4 sites Terrassa, Barcelona (2) & Vilanova del Camí

BCN 22@ -NANOTECH

HELIX & CLUSTER BUILDING - BIO

VILANOVA CAMÍ

http://www.google.es/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0CAcQjRw&url=http://www.ugt.cat/dues-sentencies-reconeixen-el-dret-dels-treballadors-del-parc-cientific-de-barcelona-a-cobrar-la-part-meritada-de-les-pagues-extres-2012-i-2013/&ei=BL9xVZGJFsbWU5iFgqAF&bvm=bv.95039771,d.d24&psig=AFQjCNFZf8ZudX1YBlf9le4DzFj9WQDqSg&ust=1433604218677248

http://www.google.es/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0CAcQjRw&url=http://www.ugt.cat/dues-sentencies-reconeixen-el-dret-dels-treballadors-del-parc-cientific-de-barcelona-a-cobrar-la-part-meritada-de-les-pagues-extres-2012-i-2013/&ei=BL9xVZGJFsbWU5iFgqAF&bvm=bv.95039771,d.d24&psig=AFQjCNFZf8ZudX1YBlf9le4DzFj9WQDqSg&ust=1433604218677248

http://www.google.es/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0CAcQjRw&url=http://www.poligonsdelsplans.cat/category/noticies/&ei=GstxVcWRFcG0UNjUgdgC&bvm=bv.95039771,d.d24&psig=AFQjCNFbauNidqrsVluqdDv1g-9goihOdQ&ust=1433607300763797

http://www.google.es/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0CAcQjRw&url=http://www.poligonsdelsplans.cat/category/noticies/&ei=GstxVcWRFcG0UNjUgdgC&bvm=bv.95039771,d.d24&psig=AFQjCNFbauNidqrsVluqdDv1g-9goihOdQ&ust=1433607300763797

R&D LEITAT:

• Applied research• Experimental

development• Support for

industrialization

01. WHO ARE WE ? AND HOW TO COLLABORATE ?Bridging R&D to Market

Our customers’ value: Quality, personal contact, clarity of resultsSociety value: Innovation, sustainability and environmental responsibility, market orientation Level of loyalty (future collaboration and recommendation) > 97%

+Corporate Social

Responsibility

275 handled Proposals

162 I+D+2i Projects on-going*

24 Led projects

300 Industrial projects

2.915 Advanced technology Solutions

Figures 2015

01. WHO ARE WE ? AND HOW TO COLLABORATE ?Results – Numbers

• R&D collaborative Projects

• R&D Subcontracting services

• Technology Transfer LEITAT Personnel in-company Innovation Centre Implantation I+D laboratory Implantation

• Strategic Partnership Opportunity LEITAT Chile Muscle Tech Network Centre for NanoSafety and Sustainability Packaging Cluster/ Barcelona Institute Packaging

01. WHO ARE WE ? AND HOW TO COLLABORATE ?How to collaborate? Flexibility as main business focus

http://www.ficosa.com/

http://www.ficosa.com/





BIOINVITRO

INDUSTRIAL BIOTECHNOLOGY

BIOMEDICINE

NANOSAFETY & NANOMEDICINE

NANOMATERIALS

SURFACE TREATMENTS

RENEWABLE ENERGY

NEW PRODUCTION PROCESSES

ADVANCED POLYMERS

ENVIRONMENTAL MANAGEMENT

FAST-MOVING CONSUMER GOODS

SMART SYSTEMS

ANALYTIC CHEMISTRY

TEXTILE TECHNOLOGIES

TRIBOLOGY & METAL PROCESSING

Technology services

02. R&D in LEITAT - AUTOMOTIVE SECTORResearch and Development lines

ReverseEngineering

Simu

lation

Mate

rials

Prototyping IntegrationDesignManufacturing

ProcessInspection / Validation

Mechanic Simulation

Finite Element Analysis (FEA)

Computational Fluid Dynamics (CFD)

Analytical Modeling

Nanomaterial & Adv. (bio)material

Light weight & smart (bio)composite

Smart Coating & Optimized Lubricant

Lithium & post-lithium battery

Structural and textile (Nano)fibres

Tribology & metal alloys

Mockups and conceptual

models. Rapid prototypes

through additive

manufacturing. Industrial prototypes.

Recovery and energy collection, Electrical

and thermal management of battery pack, Light electronics

and adv. communication

systems, Intelligent Systems for Security

Improvements, Thermoelectricity &

LEDs

3D laser scanning

Concept design, Ergonomy, Eco-

design, electric & mechanic design,

integration design, re-design & re-engineering

to improve efficiency & cost

of product

Conventional & Addtive

Manufacturing Automation & Adv. Robotic

Advanced Technology

Services5000 certifed

normes

02. R&D in LEITAT - AUTOMOTIVE SECTORLEITAT expertise within the value chain





11

02. R&D in LEITAT - AUTOMOTIVE SECTOR - MATERIAL & COMPONENT Reverse Engineering & Metrology

Metrology: Measurement of parts, approval of mold reports, etc .; Measurement and reporting based on CAD comparative method; Dimensional study for fault analysis, etc.

Reverse Engineering: Digitization of parts; Extraction of sets of points and curves; Modeling of surfaces, etc.

Design of tools: We offer our clients the possibility of designing and making measurements and fixing tools suitable for their dimensional controls; Identification of the needs for the construction of a design tool, etc.

Profilometer: To control common roughness parameters (Ra, Rz, Rq)

02. R&D in LEITAT - AUTOMOTIVE SECTOR - MATERIAL & COMPONENT Design

CAD – CAE – CAM & complex design simulation

Development of a high performance valve

FEAFinite Element Analysis

CFDComputational Fluid

Dynamics

ANALYTICAL MODELING

Static / Dynamic

Fatigue assessment

Non linearities

Implicit / Explicit

Structural / Thermal

Composites

Laminar / Turbulent

Fatigue assessment

Chemical Reactions

Heat Transfer

Multiphase / Multicomp

Porous Media

Numerical Models

Advanced Pre / Post

Heat Transfer

Composite Modeling

Mechanism Modeling

02. R&D in LEITAT - AUTOMOTIVE SECTOR - MATERIAL & COMPONENT Simulation

02. R&D in LEITAT - AUTOMOTIVE SECTOR - MATERIAL & COMPONENT Nanomaterial & Advanced Materials

Bulk materialsReinforced Light weight

Bio-source & Use of recycled materialScratch resistant

Auto-self repair scratch

Surface TreatmentPre-coating treatment

Texturization (metallization, etc.) Green & solvent-free painting

Smart coating(antimicrobial, heat diffusion, air purity enhancement,

high anti-adherence)

Bulk materialsPolymeric fibresScratch resistant

Auto-self repair scratchBio-source & Use of recycled material

Green Foam & Adhesive

Enhanced propertiesantimicrobial, anti-bug, flame retardant,

soil-release, UV-protection, fragrance release, heat diffusion, air purity

enhancement

ProcessesConventionnal & 3D kniting

Smart WindowElectrochromic devices

(organic polymer, metal oxide, electrowetting), Anti-soiling, Anti-

reflectance, Anti-icing

LEDOLED, AM-LED

Surface TreatmentTribology, Pre-treatment, Metal

processing Green & solvent-free painting

Smart coating(scratch resistance, auto-self

repairing, anti-soiling, heat diffusion, anti-corrosion, electro-

chromic/magneto-chromic)

Energy Harvesting & StorageFlexible PV,

thermoelectricity, battery integration

02. R&D in LEITAT - AUTOMOTIVE SECTOR - MATERIAL & COMPONENT Nanomaterial & Advanced Materials

02. R&D in LEITAT - AUTOMOTIVE SECTOR - MATERIAL & COMPONENTNanomaterial & Advanced Materials

Lubricant & Metal processingAbrasion, friction, erosion, corrosion optimization, Stability upon ageing ,

Optimizing the Formulation, Foaming tests

5S-standard laboratory

Energy Storage (EV + Stationary)

02. R&D in LEITAT - AUTOMOTIVE SECTOR - MATERIAL & COMPONENTElectronic & Smart Systems Integration

Emb

ed

de

d

Inte

llige

nce

Sensors

Battery

Energy Harvester

Communications

Smart Embeded devices

SENSOR NETWORKS - 5G oriented





19

ADDITIVE MANUFACTURINGCONVENTIONAL

MANUFACTURINGAUTOMATION &

ROBOTIC

Design and development of production tools. Simulation of processes.

Research, development and technology transfer of additive manufacturing applied to final production:

•with metals•with polymers•with ceramic

Design and construction of test benches.

Design and construction of experimental pilot plants.

Research and development of new robot functionalities, robotic cell safety, new collaborative robotics, quality control, service inspection and robotics.

Automation of work cells and processes.

Virtual factory.

03. R&D in LEITAT - AUTOMOTIVE SECTOR - PROCESS

20



ROBOTIC








Virtual factory.


Disseny

Maq

uin

ari

Mate

rials

Selecció del procés Fabricació AcabatsInspecció Validació

Aplicacions avantguarda

Design

Mach

ine

s

Mate

rials

Process selection Manufact.Post

processInspection / Validation

Cutting - edge Applications

ICT

& Facto

ry In

tegration

• New design tools,• Reverse Engineering• Modeling & Simulation• Generative algorithms• Structural Optimization

• Materials development: metals, polymers, ceramics, hybrids

• New processes

• Materials DB• Process capabilities DB

• Thermal treatments

• Coatings• Finishing• Polishing• Ancillary

equipment

• Geometry• Material

Properties• ND Assays

• Design of applications

• ...

Workforce trainingSustainability :

“People, Profit, Planet”Training CoursesDesign guidesInternships

• Life Cycle Assessment and Cost-Benefit Analysis

03. R&D in LEITAT - AUTOMOTIVE SECTOR - PROCESSAdditive Manufacturing

22

AM / 3DP HUB: Setting up an AM ecosystem

R+D Manufacturing:For design, industrialization &

production purposes

Training Economics

Design

Materials

Processes

Post-Processes

Validation / Certification

Cutting edge Applications

Industrial Sectors: Automotive, Machinery and Tooling, Energy, Aeronautical and Aerospace, Oil &Gas,

Health, Transport, Creative industries, Consumer goods…

AM

/ 3

DP

HU

BEq

uip

me

nt

and

Kn

ow

led

ge03. R&D in LEITAT - AUTOMOTIVE SECTOR - PROCESS

Additive Manufacturing

PROTOTYPES TOOLS, JIGS, FIXTURES...

FINAL PARTS

RESEARCH: new alloys,

new applications, post processes

finishing, coatings...

BENCHMARKING - SERVICES


24

TECHNOLOGIES and AM equipment available today:

Equipment Manufacturer Model

Selective Laser Melting

Renishaw AM250

Fused Deposition Modeling

Stratasys Dimension

Material extrusion RepRapBCN BCN3D+

Material extrusion Idem, modified by Leitat

Leitat ‘s special inks dispenser

Ancillary/support equipment: CNC milling machine, ovens, chillers, etc.

MATERIALS for AM available today:

Equipment Material Type

Selective Laser Melting Stainless steelMaraging steelAluminumTitanium

316I1.2709AlSi10MgTi6Al4V

Fused Deposition Modeling ABS -

Material extrusion ABS, PLA,PA -

Material extrusion Conductive Inks -

Technologies and AM equipment in the near future:

HP Multijet Fusion Open Platform


25



ROBOTIC








Virtual factory.


26Adapt from K. Bo Genefke, Danish Technological Institute, Centre for Robot Technology

Complejidad creciente

1

2

3

4

5

When:Need for new developmentsLack of knowledgeNew skills or functions

03. R&D in LEITAT - AUTOMOTIVE SECTOR - PROCESSRobotic implementation through LEITAT

Increasing complexity

Market solutions:

• Handling Robots

• No process

• A single robot

• Without external axes

Usually integration of the user or general robots integrators.

LEITAT advises in neutral search of market solutions and accompaniment of introduction of robotics in the company.

Genefke Scale©

03. R&D in LEITAT - AUTOMOTIVE SECTOR - PROCESSRobotic Level 1: Market solution

Market solutions tailored to a specific task:

• Known Process Robots

• Several robots without overlapping zones

• A single robot

• Few external axes or nonePerformed by general integrators of robots and integrators specializing in specific processes.

LEITAT advises on robotization of simple processes and existing technology to the company. Benchmarking of alternatives.

Genefke Scale©

03. R&D in LEITAT - AUTOMOTIVE SECTOR - PROCESSRobotic Level 2: Tailored market solution

Solutions that require to acquire new knowledge with projects of previous demonstration of the critical elements:

• The process is only part of the solution. Unknown.

• Requires simple sensor

• Several robots with overlapping zones

• Robots with standard robot control

• External axes

It is usually done by specialized and innovative integrators.

LEITAT can cooperate in critical parts and can perform pilots.

Benchmarking and testing of new processes in industrial laboratory

Genefke Scale©

03. R&D in LEITAT - AUTOMOTIVE SECTOR - PROCESSRobotic Level 3: Unknown partial process. Known integration

Genefke Scale©

Highly specialized and innovative integrators are needed.

LEITAT performs critical parts and technological demonstrators. Possible academic partner support.

Complex solutions that need to collaborate with specialized centers to create previous demonstrators:

• You can access public funding

• The process is complex and must be integrated into the solution

• Multiple sensors and unstructured environments

• Robots with external control and programming systems.

• External axes

03. R&D in LEITAT - AUTOMOTIVE SECTOR - PROCESSRobotic Level 4: Unknown process that requires novel integration

Genefke Scale©

Users / manufacturers only as specifiers. R&D project with risk.

LEITAT investigates and develops. Demonstrators and integration.

Academic partner for basic research

Unknown solutions that require development of basic and technological knowledge:

• There are no precedents

• Robots "programmed" in real time. Cognition.

• Robots in totally unstructured environments

• New types of sensors and their processing

03. R&D in LEITAT - AUTOMOTIVE SECTOR - PROCESSRobotic Level 5: Unknown process that requires new technology

Assessment on robotization of processes in the field of automotive:

•Welding dots, bow, laser•Assembling•Application of mastics•Paint application•Final Assembly•Loading / unloading of machines: injection, stamping•Systems of vision, localization, quality control•Dimensional control

03. R&D in LEITAT - AUTOMOTIVE SECTOR - PROCESSIntegration of robotic in Automotive





04. ADVANCED TECHNICAL SERVICESSummary

Characterization of materials: Physical, mechanical, thermal, chemical and microbiological.

Climatic aging -radiation-corrosion Study of defects in processing,

in products, diagnosis of failure and microscopic studies.

Verification of compliance with EN, ISO, UNE, DIN regulations specific to the automotive sector

(Renault (Self Validation tests), Ford, Nissan, VW).

Quality Control: • Product assurance• Process assurance• Supply Chain Management

Prototype Validation:• Materials• Finished products• Industrial processes

Areas of material characterization:• Area of Physical - mechanical test• Area of Material aging• Area of Chemical Tests - and analytical determinations• Area of Fire test • Area of Electrical tests-Determination of conductivity and resistivity• Area of Three-dimensional metrology • Area of Microscopy and colorimetry• Area of Experiments Fatigue.• Area of tests water analysis.• Preparation of ISO standard specimens.

Application of new technologies:• Plasma• Polymer extrusion

04. ADVANCED TECHNICAL SERVICESMaterial characterization

Department specialized in the development of tests and tests on mechanical and physicalproperties. In addition to the list below, the Physical-Mechanical Testing Laboratory offersthe possibility of performing tests and analyzes to measure according to each need.

• Mechanical resistances (traction, flexion and compression)

• Tests carried out at different temperatures (-40 to 250ºC)

• Brinell hardness, ball and Shore hardness

• Impact test:Charpy / Izod, with or without notchBall impact

• Resistances: peeling-adhesion

• Resistance to abrasion

• Resistance to fouling

• Scratching / marking

• Softening Temperature, (HDT, VICAT)

• Density

• Vertical and horizontal flammability (V0, V1, V2 and HB) (UL94)

• Fire classification (M0, M1, M2)

04. ADVANCED TECHNICAL SERVICESMaterial characterization - Physical-mechanical test

Specialized in the accelerated aging of materials and their behavior against environmental effects (radiation temperature, humidity) of materials, according to current regulations, specific regulations and / or according to internal procedures. The LEITAT Technology Center has a wide range of equipment for aging and its subsequent evaluation. There are four specific fields:

• Accelerated aging to light. (Xenon arch, UV lamp) & Solar simulation (MHG lamp)

• Aging in the open. (With measures of meteorological conditions)

• Climatic aging. (Temperature and humidity - large / medium volume chambers)

• Corrosion (Saline mist, cass test, automatic corrosion cycles)

For all of them, they have adequate equipment for their instrumental and visual assessment according to regulationsOptical properties:

• Color, coordinates

• Yellowing index

• Whiteness index

04. ADVANCED TECHNICAL SERVICESMaterial characterization - Material aging

• Transmission of light

• Brightness

• Other (adhesions)

Specialized in techniques of chemical analysis, according to current legislation, specific regulations and/or according to internal customized procedures.

Chemical composition

• Identification and characterization of polymers and additives

• Identification and characterization of loads and reinforcements

• Identification and characterization of VOCs and residual substances (VOCs, formaldehyde)

• Emission of carbon (automotive)

• Emission of formaldehyde (automotive)

• Fogging condensable components (automotive)

04. ADVANCED TECHNICAL SERVICESMaterial characterization - Chemical Tests and analytical determinations

Identification and characterization of thermoplastic and thermoset polymers

• Calorimetric characterization - crystallinity - melting temperature (DSC)

• Identification of metallic components by ICP

• Identification and characterization of additives (FTIR, Chromatography): Antioxidants, UV stabilizers, Plasticizers, Lubricants, anti-static, Flame retardants, etc.

• Identification and characterization of loads and reinforcements (FTIR, ashes):Fiberglass, talc, silica, calcium carbonate.

Techniques:FTIR (ATR) - Infrared Spectroscopy DSC - TGA - Differential Scanning Calorimetry and ThermogravimetryICP- Determination of metalsGC - Gas ChromatographyHPLS - Liquid Chromatography

Surface tension

Determination of thermal, rheological properties.

Index of Melt Flow Index

Viscosity in solution

Olfactory Sensory Analysis (Olor)

04. ADVANCED TECHNICAL SERVICESMaterial characterization - Chemical Tests and analytical determinations

Volumetric resistivity measurementMeasurement of surface resistance - Four probes method (Inert/Air atmosphere)

04. ADVANCED TECHNICAL SERVICESMaterial characterization - Electrical tests-Determination of conductivity and resistivity

Mechanical properties Scratching andabrasion, Cold brittleness, Shorehardness, Strain, compression anddelaminating, Bending (with cycles andtemperature) combined with PV tests

UNE-EN 61701-2000:Corrosion test, salty fogfor photovoltaic modules.

UNE-EN 61646-1997:Thin film photovoltaicmodule for terrestrialapplications. Validation ofthe design andqualification of PV type.

ISOS D, O, L, T & LT (1,2, 3): Testing organic solarcell devices and moduleswith respect to stabilityand operational lifetime.

Light induceddegradation test (LID):Test under request.Prototype test, pre-serialphase and fabricationstage.

Testing of materials and final products

UNE-EN 61215-2006:Photovoltaic module of c-Si for terrestrialapplications. Validation ofthe design andqualification of PV type.

Outdoor platform: PVtest with tracker andstatic facilities.

Dimensional metrology is one of the industrial processes for determining the quality andsupport of R&D tasks that is unknown to the majority of the population and without doubtwithout it there would not be many of the products and / or goods that Surround ineveryday life.

Laboratory• Metrology service in own laboratory• Parts metrology, approval reports for molds, dies• Measurement and graphical reports with comparative CAD method• Dimensional study for the analysis of assembly problems• Measurement of samples, statistical studies for process control• Automatic measuring programs for coordinate measuring machines

In-situ measurement• Provision of technicians and portable measuring equipment• Measurement and adjustment of assembly tools• Measurement of large parts and surfaces, comparative CAD• Verification and construction of machinery and devices• Verification and proper positioning of parts for assembly

04. ADVANCED TECHNICAL SERVICESMaterial characterization - Three-dimensional metrology

Reverse engineering

•Digitalization of parts

• Extraction of clouds of points and curves

• Surface modeling

• Verification of the model obtained by comparative CAD

Design of toolsWe give our clients the possibility to offer them the design and construction of a measurement tool or fixation appropriate to their dimensional controls

• Identification of the needs of realization of a tooling

• Design of the tooling

• Construction of the tools according to precision, delivery times, prices.

• Certification of tools

04. ADVANCED TECHNICAL SERVICESMaterial characterization - Three-dimensional metrology

Specialized in color measurements and studies of quality of polymer processing.

Measurements - resolution 1μm (Distances, angles, areas, depths, thicknesses)

Cross sections of fibers, threads, fabrics and plastic materials with coatings.

Identification of:• Fibers• Microcapsules• Contaminant

Photomacrography and photomicrography

Material Analysis• Injection defects in plastics - flows, voltages, vacuoles• Degradation of surfaces• Contaminant• Microscopic characterization• Degradation of textile fibers - thermal, chemical, mechanical• Defects of threads and fabrics

04. ADVANCED TECHNICAL SERVICESMaterial characterization - Microscopy and colorimetry

Mechanical fatigue testingDesign and construction of fatigue cycling equipmentCarrying out fatigue tests at different temperatures

Preparation of ISO standard specimens

By injection process.Dumbbell probes ISO 527 (type 1A) ,Prismatic ISO 178 and ISO 179

By mechanical cutting (NC)

04. ADVANCED TECHNICAL SERVICESMaterial characterization – Aging & Preparation of ISO standard specimens

LEITAT has the following management system certificates:Quality Management System (UNE EN ISO 9001: 2000 Standard)System of Environment Management (UNE EN ISO 14001: 2004)R&D&I Management System (UNE Standard 166002: 2006)Adhered to the Community Environmental Management and Audit Scheme (EMAS) Regulated by Regulation EC No 731/2001

Quality Management System (Standard UNE EN ISO / IEC 17025: 2005), for the following technical files:

Wool and Textile Products (18 / LE026)Fire behaviour (18 / LE274)Personal protective equipment (18 / LE705)

Other accreditations:OC-L / 023 - Inspection Body for EPIS CertificationRENAULTFIA (Gloves)FIA (Epis)Body of Control for Construction Materials

04. ADVANCED TECHNICAL SERVICESMaterial characterization - Accreditations

Vincent Jamier – [email protected] Project Manager

The multi-disciplinary expertise of LEITAT allow to cover the global value chain of Automotive sector.

Main strengths are based on: • Advanced material development & integration (from composite to energy)• 5G connected smart embedded devices• Additive Manufacturing Platform (metal & composite) •Robotization process (from current market assessment to human-robot collaboration implementation)• Certified body for the automotive sector

mailto:[email protected]

Documents

Automotive Sector Vincent Jamier, PhD