Prof. Dr.-Ing. Prof. h.c. Klaus Dilger; Prof. Dr.-Ing. Christoph Herrmann

Digitalization and resource efficiency Open Hybrid LabFactory A unique platform for research, development, production and testing of hybrid components for the automotive industry Prof. Dr.-Ing. Prof. h.c. Klaus Dilger; Prof. Dr.-Ing. Christoph Herrmann

Agenda 1 2 3 Open Hybrid LabFactory Joint Collaboration with SIMTech Digitalization and Life Cycle Engineering 18.04.2018 Prof. Dr.-Ing. Klaus Dilger, Prof. Dr.-Ing. Christoph Herrmann TU Braunschweig, Open Hybrid LabFactory 2

Open Hybrid LabFactory Braunschweig - Research Region Braunschweig is one of Europe s most active research region in Europe Braunschweig is one of the top regions for innovation with the highest level of research and development expenditures in Europe (Eurostat, 2017). Braunschweig is ranked first in the nation for the number of inhabitants working in science with 7,33 % overall (Eurostat, 2017). 18.04.2018 Prof. Dr.-Ing. Klaus Dilger, Prof. Dr.-Ing. Christoph Herrmann TU Braunschweig, Open Hybrid LabFactory 4

Open Hybrid LabFactory BMBF - funding initiative ForschungsCampus In September 2012, 9 Research Campuses were selected out of ~ 90 valid applications Nine of them decided to start with a preparation phase of between six months and two years Eight of them are by now in the main phase with a BMBF support of 2 mill. EUR per year up to altogether 15 years All public funds must be matched at least with the same amount of private funds All partners must sign a cooperation agreement for at least five years Academic and industry partners should interact at eye level Open Hybrid LabFactory Wolfsburg Magdeburg Jena Aachen Mannheim Stuttgart Berlin picture: Prof. Knut Koschatzky, Fraunhofer ISI 18.04.2018 Prof. Dr.-Ing. Klaus Dilger, Prof. Dr.-Ing. Christoph Herrmann TU Braunschweig, Open Hybrid LabFactory 5

Open Hybrid LabFactory Future Material Concepts Time Hybrid Structures Hybrid Structures Hybrid Lightweight Design Quelle: SLC Multi Material Mix Optimized Fibre reinforced plastic designs Optimized Aluminium/Steel-Mix Today Carbonfibre reinforced plastics Aluminium Aluminium/ Steel Small volume Middle volume High volume Quantity Steel Source: Volkswagen AG 18.04.2018 Prof. Dr.-Ing. Klaus Dilger, Prof. Dr.-Ing. Christoph Herrmann TU Braunschweig, Open Hybrid LabFactory 6

Open Hybrid LabFactory The meaning behind the name Open Integration of the expertise of scientific and industrial research in an open factory Hybrid Democratized lightweight construction by the use of hybrid composite structures made of plastics, metal and load-path-optimized textile structures LabFactory Establishment of the world' s leading technology companies and top level research along the process chain in Wolfsburg 18.04.2018 Prof. Dr.-Ing. Klaus Dilger, Prof. Dr.-Ing. Christoph Herrmann TU Braunschweig, Open Hybrid LabFactory 7

Open Hybrid LabFactory Partner Structure Full members Public sector partners Project members New form of cooperation between academia and industry under one roof 18.04.2018 Prof. Dr.-Ing. Klaus Dilger, Prof. Dr.-Ing. Christoph Herrmann TU Braunschweig, Open Hybrid LabFactory 8

Open Hybrid LabFactory Research Fields Design and Simulation Fiber, Matrix, Textiles Component Production and Automation Quality and Testing Methods Environment and Recycling Interaction of Tools Alternative C- Fibers Additive Manufacturing Surface Characterization Life Cycle Thinking Material Characterization Near net shape textiles Simulation Optical NDT Methods Digital Factory Functional Integration New Matrix materials Mold-based Processes Adaptive Repair and Production Data Mining/ Big Data Boundary Layer Simulation Automated Process Chain Machining Aging Resource Efficiency Δ-α-safe Design Boundary Layer Technology Damage Analysis 18.04.2018 Prof. Dr.-Ing. Klaus Dilger, Prof. Dr.-Ing. Christoph Herrmann TU Braunschweig, Open Hybrid LabFactory 9

Open Hybrid LabFactory Technical Center Casting Technology Life Cycle Design & Engineering Lab Handling Technology Injection Moulding Technology Textile Rngineering Pressing Technique Analytics Technical Center Laboratories 18.04.2018 Prof. Dr.-Ing. Klaus Dilger, Prof. Dr.-Ing. Christoph Herrmann TU Braunschweig, Open Hybrid LabFactory 10

Open Hybrid LabFactory Hybrid Metal Forming Press Technical Specifications Multifunctional machine with a combination of high pressing force and high speed Pressing force up to 2.500 tons Closing speed up to 800 mm/s 18.04.2018 Prof. Dr.-Ing. Klaus Dilger, Prof. Dr.-Ing. Christoph Herrmann TU Braunschweig, Open Hybrid LabFactory 11

Open Hybrid LabFactory Hybrid Injection Moulding Machine Technical Specifications Hybrid injection moulding machine with horizontal mould opening plane (integrated production of plastic-metal light components Closing force up to 36,000 kn 18.04.2018 Prof. Dr.-Ing. Klaus Dilger, Prof. Dr.-Ing. Christoph Herrmann TU Braunschweig, Open Hybrid LabFactory 12

Open Hybrid LabFactory International Collaboration Germany (Europe) Asia-Pacific Established structures and actors in science and business Highly innovative large as well as small and medium-sized enterprises High production competence, focus: lightweight structures, integration of functions The world's largest exporter, especially in the field of production equipment High competence in large-scale automotive production Transnational value creation through new forms of cooperation Positioning the Open Hybrid LabFactory as a globally recognized competence center for lightweight manufacturing across the entire value chain Complementing the competency profile through complementary skills of the international partners Knowledge development based on modern communication channels down to the level of regional actors, in particular small and medium-sized enterprises Dynamic, fast developing science and business region High priority for promotion of education, research and innovation High technological competence in the production of materials and semi-finished products (fibers, plastics,...) Growth markets for consumer, durable and industrial goods; stable growth forecasts Established consumer goods industry, development of new industries, especially automotive and aviation 18.04.2018 Prof. Dr.-Ing. Klaus Dilger, Prof. Dr.-Ing. Christoph Herrmann TU Braunschweig, Open Hybrid LabFactory 13

Joint Collaboration with SIMTech A brief chronology New Joint Project (since Aug 2017) Seminar on Eco- Engineering (June 2002) Research Visit (May 2014) Research Visit (July 2015) Invited Lecture on Industrial Symbiosis (July 2016) 2002 2013 2014 2015 2016 2017 2018 Test bed platform for experimentation Learning environment platform for hands-on experience Invited Lecture (July 2013) Research Stay (Oct 2014) Urban Factories Lecture (Nov 2015) Collaboration on Learning/ Model Factories (since 2017) Master Class (Oct 2017) 18.04.2018 Prof. Dr.-Ing. Klaus Dilger, Prof. Dr.-Ing. Christoph Herrmann TU Braunschweig, Open Hybrid LabFactory 15

Joint Collaboration with SIMTech OHLF & SIMTech 1st day: Workshop OHLF delegation to Singapore (January 2018) 2nd day: Seminar Match Making between Singapore and Germany Discussion of joint research topics Development of joint project outlines Definition of joint (co-funded) projects 18.04.2018 Prof. Dr.-Ing. Klaus Dilger, Prof. Dr.-Ing. Christoph Herrmann TU Braunschweig, Open Hybrid LabFactory 16

Digitalization and Life Cycle Engineering Cyber Physical Production Systems (CPPS) Framework [I] Physical World Data gathering Data Treatment and Storage [II] Data Acquisition [III] Cyber World Research Fields Automatisation Industry 4.0- Interfaces Real time capability Dimensioning Process parameters [IV] Decision Support/Control Visualization Control Simulation Data Mining Contextsensitive methods toolbox Mixed Reality Visual Analytics Digitalization as a key to efficient production processes and operational excellence [OHLF 2018; IWF 2018] 18.04.2018 Prof. Dr.-Ing. Klaus Dilger, Prof. Dr.-Ing. Christoph Herrmann TU Braunschweig, Open Hybrid LabFactory 18

Digitalization and Life Cycle Engineering Potential Application Fields Potential application fields of CPPS Process control and optimization Machine control Quality management Maintenance Energy management Identification and modeling of influencing factors to optimize processes Understanding and control machine behavior Ensuring quality compliance through efficient checks and feedback Preventive avoidance of failure through prediction Ensuring energy efficiency by monitoring and recommendations 415 410 Measurement µ +σ -σ Detected Abnormal Change Energy in Wh 405 400 395 390 0 200 400 600 800 1000 1200 1400 1600 1800 2000 Time in Days Relationship between process parameters and resulting product qualities Automatic status detection and switch-off/ parameter adjustment Decision trees for product quality prediction by process parameters Trend analysis of selected state variables 3D emission monitoring for more energy-efficient TBS [IWF 2018] 18.04.2018 Prof. Dr.-Ing. Klaus Dilger, Prof. Dr.-Ing. Christoph Herrmann TU Braunschweig, Open Hybrid LabFactory 19

Digitalization and Life Cycle Engineering OHLF IT-infrastructure Applications Data usage Application: Monitoring Data mining & state visualisation Application: Life Cycle Assessment Sankey visualisation Vertical Scaling Application: X Data mining & state visualization Life Cycle Assessment Predictive Maintenance Data Storage Data layer Server NoSQL DB Preprocessing NoSQL DB Preprocessing SCADA Meta data Real time data storage Flexible data preparation (No SQL) Energy Data Data gathering Production Line Electrical energy flows Heat flows Cooling water flows Process and Machine Data Hybrid forming press Low pressure casting machine Low pressure casting machine Design and control parameter State variables 18.04.2018 Prof. Dr.-Ing. Klaus Dilger, Prof. Dr.-Ing. Christoph Herrmann TU Braunschweig, Open Hybrid LabFactory 20

Digitalization and Life Cycle Engineering Exemplary Application: Machine State Recognition for OEE Approximation Exemplary Application Supporting continuous improvement by automated calculation of key performance indicators (e.g. OEE) [sixsigmablackbelt.de] Good units Process rate OEE Overall Equipment Effectiveness Operating time Calendar hours (7 days * 24 hours) Scheduled hours Defects, rework Wasted performance Productivity OEE = Quality x x Unscheduled downtime Availability Productivity & Availability Scheduled downtime Machine State Recognition State Recognition Target: Approximated OEE Preliminary Assumption: No differentiation between availability and productivity Σ Σ Processing times Idle times 18.04.2018 Prof. Dr.-Ing. Klaus Dilger, Prof. Dr.-Ing. Christoph Herrmann TU Braunschweig, Open Hybrid LabFactory 21

Digitalization and Life Cycle Engineering Exemplary Application: Machine State Recognition for OEE Approximation Data gathering Data treatment and storage [II] Data Acquisition OHLF IT-infrastructure as data backbone 2,500 t hybrid forming press Extrusion of FRP rib structure on a hybridized demonstrator Machine state recognition [I] Physical World Siempelkamp OEE Data preparation [III] Cyber World Data Mining (Clustering) Application of data mining methods (e.g. k-means) on acquired process data [IV] Decision Support/Control Feedback and result visualization at Life Cycle Design & Engineering Lab 18.04.2018 Prof. Dr.-Ing. Klaus Dilger, Prof. Dr.-Ing. Christoph Herrmann TU Braunschweig, Open Hybrid LabFactory 22

Digitalization and Life Cycle Engineering Holistic Life Cycle Engineering Approach @ OHLF Selected Topics in Automotive Life Cycle Engineering With respect to Environmental Impacts & Cost System Level Time Horizon 2018 2030 Mobility System Private Car Car-Sharing Vehicle Level Drivetrain Vehicle size & function Component Level Materials Steel Al Mg FRP Functionality Substitution Funct.Integration 18.04.2018 Prof. Dr.-Ing. Klaus Dilger, Prof. Dr.-Ing. Christoph Herrmann TU Braunschweig, Open Hybrid LabFactory 23

Digitalization and Life Cycle Engineering Life Cycle Design & Engineering Lab 18.04.2018 Prof. Dr.-Ing. Klaus Dilger, Prof. Dr.-Ing. Christoph Herrmann TU Braunschweig, Open Hybrid LabFactory 24

Digitalization and Life Cycle Engineering Life Cycle Design & Engineering Lab 18.04.2018 Prof. Dr.-Ing. Klaus Dilger, Prof. Dr.-Ing. Christoph Herrmann TU Braunschweig, Open Hybrid LabFactory 25

Digitalization and Life Cycle Engineering LCDE_Lab: Environmental Break-Even for Material Substitution in Electric Vehicles (Example) Break-even of material substitution for electric vehicles Mag_min Magnesium CFRP_min Alu_Europe Aluminum HSS_min High-strength steel Share of lightweight materials Quelle: SLC Break-even [km] 800.000 700.000 600.000 500.000 400.000 300.000 200.000 100.000 GWP 1 kg material [kg CO2eq] 0 Aluminum 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 Electricity mix [gco2-eq/kwh] Singapore CFRP High-strength steel Europe Magnesium Reference steel High-strength steel Aluminum CFRP Magnesium 2.38 2.8 9.0 12.5 17.8 Substitution ratio - 0.9 0.55 0.47 0.44 erv (Wh/km/kg) 0.0369 [Egede 2016] 18.04.2018 Prof. Dr.-Ing. Klaus Dilger, Prof. Dr.-Ing. Christoph Herrmann TU Braunschweig, Open Hybrid LabFactory 26

Digitalization and Life Cycle Engineering LCDE_Lab: Using geographical visualization in Life Cycle Assessment LCA world map for selected countries; climate change Scenario "Commuter, "even use With ambient temperature and local electricity mix [Egede 2016;] 18.04.2018 Prof. Dr.-Ing. Klaus Dilger, Prof. Dr.-Ing. Christoph Herrmann TU Braunschweig, Open Hybrid LabFactory 27

Open Hybrid LabFactory Unique Competence Center for Manufacturing of Hybrid Structures Brings together leading partners from industry and academia Total Area 5215 m² Office (2.350 m²), Lab (400 m²) and Technical Center (2.100m²) 18.04.2018 Prof. Dr.-Ing. Klaus Dilger, Prof. Dr.-Ing. Christoph Herrmann TU Braunschweig, Open Hybrid LabFactory 29