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
© 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
66 institutes and independent research units
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
66 institutes and independent research units
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
11 © Fraunhofer IPK
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
12 © Fraunhofer IPK
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,
13 © Fraunhofer IPK
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
14 © Fraunhofer IPK
Technology development for sustainable automobile production Agenda
I Megatrends determine the future
I Industrial trends und developments
I Technologies for automobile production
15 © Fraunhofer IPK
Technology development for sustainable automobile production Agenda
I Megatrends determine the future
I Industrial trends and developments
I Technologies for automobile production
16 © Fraunhofer IPK
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
rau
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
;
22 © Fraunhofer IPK
Technology development for sustainable automobile production Agenda
I Megatrends determine the future
I Industrial trends and developments
I Technologies for automobile production
23 © Fraunhofer IPK
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)
24 © Fraunhofer IPK
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.
715/2
007
25 © Fraunhofer IPK
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
26 © Fraunhofer IPK
Industrial trends and developments Automobile manufacturers
Lightweight
Downsizing Hybridization/ Electromobility
Fuels
27 © Fraunhofer IPK
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
28 © Fraunhofer IPK
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
e, w
ww
.auto
mo
bil-
pro
duktio
n.d
e,
ww
w.a
mz.
de
29 © Fraunhofer IPK
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
30 © Fraunhofer IPK
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
e, w
ww
.auto
mo
bil-
pro
duktio
n.d
e,
ww
w.a
mz.
de; Sta
tist
iken
: w
ww
.sta
tist
a.d
e
31 © Fraunhofer IPK
Technology development for sustainable automobile prodution Agenda
I Megatrends determine the future
I Industrial trends and developments
I Technologies for the automobile production
32 © Fraunhofer IPK
Lightweight
Downsizing Hybridization/ Electromobility
Fuels
Future concepts and technologies
33 © Fraunhofer IPK
Lightweight
Downsizing Hybridization / Electromobility
Fuels
Future concepts and technologies
34 © Fraunhofer IPK
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,
35 © Fraunhofer IPK
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)
36 © Fraunhofer IPK
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
37 © Fraunhofer IPK
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
38 © Fraunhofer IPK
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
39 © Fraunhofer 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
40 © Fraunhofer IPK
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
41 © Fraunhofer IPK
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]
42 © Fraunhofer IPK
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
43 © Fraunhofer IPK
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
44 © Fraunhofer IPK
Future concepts and technologies
lightweight
Downsizing Hybridization / Electromobility
Fuels
45 © Fraunhofer IPK
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
46 © Fraunhofer IPK
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
47 © Fraunhofer IPK
Future concepts and technologies
lightweight
Downsizing Hybridization / Electromobility
Fuels
48 © Fraunhofer IPK
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
49 © Fraunhofer IPK
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
Future concepts and technologies: Fuels Ablative method for manufacturing fuel injectors
50 © Fraunhofer IPK
Future concepts and technologies: Fuels Ablative method for manufacturing fuel injectors
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
51 © Fraunhofer IPK
Future concepts and technologies
Lightweight
Downsizing Hybridization / Electromobility
Fuels
52 © Fraunhofer IPK
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
53 © Fraunhofer IPK
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
54 © Fraunhofer IPK
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)
55 © Fraunhofer IPK
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
56 © Fraunhofer IPK
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
57 © Fraunhofer IPK
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]