DIRECT

Digitally supported production

Among other things, new, low-waste (target: max. 5% waste) lay-up processes for carbon fiber-based semi-finished products are used for this, as well as shape-adaptive tools whose geometry automatically adapts to a digital model. This allows the cost-intensive lightweight material CFRP to be used in a resource-saving manner. New components can be produced directly from the digital workspace without the need to manufacture component-specific molds. The specific goal here is the possibility of realizing a new component geometry within one day. The integration of various sensors into the production environment makes it possible to continuously monitor the status of the system and thus offer early intervention options.

Direct data analysis close to the data source (edge/fog computing), without time-consuming data transfers to the cloud, should be used to determine whether errors have occurred in the production process and whether they can be corrected directly. The ability of a complex production environment to react robustly to disruptions and thus always operate in an optimal range is also known as resilience. In the long term, a combination of digital production technology and form-adaptive, automated manufacturing processes can be expected to significantly reduce product costs by at least 50% for small to medium quantities. This enables the production of customized components, short-term adjustments to component geometry and the use of the lightweight material CFRP in a wide range of applications.

Leverage effect through linking with joint projects

The content of the project is closely linked to the ARENA2036 joint projects in order to create a leverage effect:

The Digital Fingerprint project aims to establish an open data architecture for components throughout their entire life cycle. DIREKT is linked to the project through the use of data semantics to process process- and product-specific component data.

The aim of the FlexCAR project is to develop an open vehicle platform. DIREKT wants to implement demonstrator components and thus forms the link to FlexCAR.

Fluid production aims to build a human-centered, cyber-physical production concept, DIREKT is linked to FluPro via intelligent and fluid resource modules.

International cooperation

Another focus of the InterSpiN funding initiative is the scientific exchange with the Australian Global Innovation Linkage at Swinburne University of Technology in Melbourne. This project deals with the topic of automated Industry 4.0 production of fiber composite components for large quantities. As part of the project, the new I4.0 Testlab - a facility for innovative research in the field of composite manufacturing - has been set up in collaboration with CSIRO (Australia's National Science Agency, Commonwealth Scientific and Industrial Research Organization) until mid-2021. In addition to the mutual exchange of information and project results, the existing international cooperation will be further intensified through the joint supervision of five doctoral students as part of the GIL project by Professor Fox (Swinburne University of Technology) and Prof. Dr.-Ing.

Expected results from DIREKT

Five specific expected results were defined for the focus project:

1. A virtual engineering environment for the flexible production system
2. System-capable learning production system for the resilient production of high-performance fiber composites
3. Three validated demonstrators
4. Economic efficiency, production concepts, strategies & scenarios of the future
5. Implementation strategies and application scenarios for flexible production systems

Key technologies in the DIREKT project

Reshaping

In manufacturing technology, the forming of carbon-based, textile semi-finished products, for example, is one of the most fundamental processes. In classic manual laminating, textiles such as woven or non-woven fabrics are manually inserted into the tool mold and adapted to the geometry. To increase the productivity of the forming process, there are increasingly automatic membrane or stamping processes to obtain the desired three-dimensional shape of the component.

Form-adaptive tool

Moulding tools for the production of fiber composite components can be associated with high costs. In particular, changes to the geometry of the tool, for example, are usually associated with a new design and procurement. By using a shape-adaptive tool based on DYNAPIXEL technology, it is possible to quickly adapt the mold geometry.

Screen printing technology

Screen printing is a proven process in the field of printing technology. Based on the starting material of a conductive silver printing paste, the cost-effective and reproducible production of sensors is being evaluated. The main focus is on integrating the sensors into the forming process for continuous data recording.

Edge Analytics

The production-related data analysis in the immediate vicinity of the production facility makes it possible to intervene in the manufacturing process of a component at an early stage. Data transmission from the front-end electronics to the evaluation of the process-related sensors is realized via the industrial communication standard IO-Link.