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© WZL/Fraunhofer IPT/KU Leuven
The European Manufacturing Industry Vision and challenges
Achieving Growth through Strategic Innovation
Fritz Klocke, Professor in Production Engineering, WZL-RWTH Aachen and Head of the Fraunhofer Institute for Production Technology (Germany)
Bert Lauwers, Professor in Production Engineering KU Leuven (Belgium)
Brussels; October 3rd
Seite 1© WZL/Fraunhofer IPT/KU Leuven
Outline
The EU Manufacturing Industry– Boundary Conditions– Markets beyond tomorrow
Actions taken – some initiatives – Factories of the Future (EFFRA)– Cluster of excellence on “Integrated Production”
Case studies– Energy– Mobility– Resource efficient Production– Life Science
Conclusion
Seite 2© WZL/Fraunhofer IPT/KU Leuven
Outline
The EU Manufacturing Industry– Boundary Conditions– Markets beyond tomorrow
Actions taken – some initiatives – Factories of the Future (EFFRA)– Cluster of excellence on “Integrated Production”
Case studies– Energy– Mobility– Resource efficient Production– Life Science
Conclusion
Seite 3© WZL/Fraunhofer IPT/KU Leuven
Environment, climate, recources
Economy growthwelfare
Individual and collective needs
Overall balance
Source: Acatech, oct. 2007
Industrial society in strained relations
Growth trough sustainable Innovation
Seite 4© WZL/Fraunhofer IPT/KU Leuven
Each Improvement inProducts
TechnologiesMachines
OrganisationManagement
which gains Acceptance
on the Market Place
might be called
INNOVATION
Source: J. Schumpeter: Theorie der wirtschaftlichen Entwicklung, 1911Joseph Schumpeter (1883 – 1950)
Innovation - what is it about?
Seite 5© WZL/Fraunhofer IPT/KU Leuven
Stratigic Dimension - Manufacturing Matters for Europe
66% of private R&D investment
20% of direct jobs and twice as many indirect jobs
Leading source of private R,D & I funding
Biggest purchaser of ICT in Europe
Part of a complex global economic system
Seite 6© WZL/Fraunhofer IPT/KU Leuven
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
Imag
es ©
Fra
unho
fer
Markets beyond tomorrow
Seite 7© WZL/Fraunhofer IPT/KU Leuven
Henry Ford"If you always do what you've always done, you'll always get what you've always got.“
Source: Library of Congress , Henry Ford
Einstein “We can never solve problems
by using the same kind of thinking we used when we created them”
Seite 8© WZL/Fraunhofer IPT/KU Leuven
Outline
The EU Manufacturing Industry– Boundary Conditions– Markets beyond tomorrow
Actions taken – some initiatives – Actions taken – some initiatives – Cluster of excellence on “Integrated Production”
Case studies– Energy– Mobility– Resource efficient Production– Life Science
Conclusion
Seite 9© WZL/Fraunhofer IPT/KU Leuven
The Public-Private Partnership (PPP)‘Factories of the Future’
European level PPPs in the area of R&D&I are a cooperation by the European Commission and private partners (small, medium & large industrial enterprises, research organisations & universities)
European Commission launched ‘Factories of the Future’ PPP as the biggest initiative of its type.
Aim to strengthen European industrial base, create sustainable industry & secure jobs in Europe
‘Factories of the Future’ promotes research through a Multi-Annual Strategic Roadmap
Roadmap means that research call topics are industry-relevant
61 projects launched to date, over double this will be launched between 2012 & 2013
Seite 10© WZL/Fraunhofer IPT/KU Leuven
Present ‘Factories of the Future’ Strategic RoadmapProject Examples
ICT-Enabled Intelligent ManufacturingHigh Productivity Manufacturing
New Materials in ManufacturingSustainable Manufacturing
ActionPlanTActionPlanT aims to develop a vision on the short, medium, and long term role of Information & Communication Technologies (ICTs) in the European manufacturing industry in order to ensure its sustainable competitiveness.
MEGaFiTThe primary goal of MEGaFiT is to develop and integrate all necessary technologies which create the basis to reduce the number of defects in the manufacturing of complex high-precision metal parts.
GrafolDeveloping the first roll-based chemical vapour deposition (CVD) machine for the mass production of few-layer graphene for transparent electrodes for LED and display applications.
EMC2EMC²-Factory will develop a radically new paradigm for cost-effective, highly productive, energy-efficient and sustainable production systems.
The present roadmap sub-domains with project examples:
Seite 11© WZL/Fraunhofer IPT/KU Leuven
The European Factories of the Future Research Association (EFFRA)
Industry-driven & 100% private European association
Explaining industry needs to public authorities (partner of the European Commission)
Created by MANUFUTURE ETP and industrial associations
Safeguarding industrial relevance of EU-projects within the ‘Factories of the Future’ programme
Creates consensus on common R&D priorities
Coordinates creation of strategic research roadmap
Working on new roadmap: ‘Factories of the Future 2020’
Promoting ‘Factories of the Future’
www.effra.eu
@EFFRA_Live
EFFRA.Live
Seite 12© WZL/Fraunhofer IPT/KU Leuven
Cybernetic perspectiveDeterministic perspective
Interconnected physical and mathematical model chains
Describe and predict complex behaviour
Mechanisms, rules and structures to operate and control complex production systems
Decision-making in an uncertain environment
Modelling
Excellence Cluster Production Technology for High Wage Countries“
Seite 13© WZL/Fraunhofer IPT/KU Leuven
Holistic Modelling ApproachModular Product and Modular Manufacturing Portfolio
Process model Hybrid process modeling
F(t)f
xd
Empirical models
FEM-model
Ther
mal
pro
cess
be
havi
our
Coupled multibody simulation
Thermal machine model
Temperature distribution
Process evaluation
Stability
Tolerances
Surfaces
∆total = ∆mech + ∆therm
Mec
h. p
roce
ss
beha
viou
r
Opt
imiz
ed
NC
-pro
gram
CAM Path optimization NC-simulation Default of set-pointsx = ... (t) a = ... (t)y = ... (t) b = ... (t)z = ... (t)
OK
Work piece model
Work piece model
Yes
No
∆therm
∆mech F(t)
T(t)
Seite 14© WZL/Fraunhofer IPT/KU Leuven
Multipurpose Technology Platforms
safety housing
robot withlaser heads
high-performancespindle
swivel rotary table
Source: Excellence Cluster, RWTh-Aachen, WZL (Multipurpose Machine) Prof. Brecher
Source: Fraunhofer IPT
Source: Alzmetall, Altenmarkt
Seite 15© WZL/Fraunhofer IPT/KU Leuven
KombiMaschWorking Chamber
Laser hardening
toolLaser
welding tool
Optical fiber
Process monitoring
sensorTool revolver
(cutting)
B-axis panning
head
Cutting Laser deposition welding Laser hardening
Source: AWK, Machine Tool Colloquium 2008
Seite 16© WZL/Fraunhofer IPT/KU Leuven
Complete Machining of Components with Optimized Surface LayersKombiMasch (Machine Tool Prototype), multipurpose machine
Turning/millingdrilling
Hardmachining
Laser depositionwelding
Laserhardening
Modular design of subsystems
Fully automated machining processes
User friendly appliance
Consistent CAx data in entire process
Award winning machine tool - most innovative product in the category »process combination«
Seite 17© WZL/Fraunhofer IPT/KU Leuven
Worldwide Production Networks - Cyber Physical Networks
Vision Fusion of real and virtual environment
Fully electronically integrated business processes, intercompany and across companies
Customer integration
Challenges High performance grits
Appropiate cloud technologies
IP issues
SecurityBildquellen: WZL, Siemens, BMBF
Virtual factory
VirtualCompony networks
VirtualCustomer integration
Cyber Physical Networks
Inter- and across companies
From the shop floorto top level management
Seite 18© WZL/Fraunhofer IPT/KU Leuven
Outline
The EU Manufacturing Industry– Boundary Conditions– Markets beyond tomorrow
Actions taken – some initiatives – Actions taken – some initiatives – Cluster of excellence on “Integrated Production”
Case studies– Energy– Mobility– Resource efficient Production– Life Science
Conclusion
Seite 19© WZL/Fraunhofer IPT/KU Leuven
EnergyWhat does the future hold? Existing Challenges
Major change in power generation (conversion)
Major change in energy distribution, networks
Major change in energy use (consumption)
Facing the Challenges through …
Solar power
Wind power
Tidal power (tidal range, water currents, waves,…)
Fossil fuels, biofuels and biomass
Nuclear power
Fuel cellsSource: REpower
Seite 20© WZL/Fraunhofer IPT/KU Leuven
Wind Power – Key Technologyfor Reduction of Greenhouse Gases
Source: BMU, ZSW-BW
emis
sion
of g
reen
hous
e ga
ses
[%]
(com
pare
d to
199
0)
year
100
80
60
40
20
1990 2020 2030 2040 2050
targets for reduction of greenhouse gases
-40%
-55%
-70%-80-95%
import of renewable energybiomass
geothermal energy
photovoltaic
wind power
hydro power year҅05 ҅10 ҅15 ҅20 ҅30 ҅40 ҅50
gros
s el
ectr
icity
gen
erat
ion
[100
0 G
Wh/
a] 800
600
400
200
gross electricity from renewable energies
gross consumptionof electricity
Seite 21© WZL/Fraunhofer IPT/KU Leuven
Increasing Request for Wind Turbines
10
20
30
40
50
60
2011 2012 2013 2014 2015 20160
new
inst
alla
tion
of w
ind
turb
ines
[GW
]
Area:Europe
Asia
America
Rest of world
+46%
Significant increase of new installations of wind energy plants in the future
Predicted New Installations of Wind Turbines till 2016
Source: BTM Consult
Seite 22© WZL/Fraunhofer IPT/KU Leuven
gearless wind turbine
Power Train Concepts
wind turbine with gearbox
Source: Schaeffler AG
mar
ket s
hare
[%]
0
20
40
60
80
100
gearbox
2009
2014
mar
ket s
hare
[%]
0
20
40
60
80
100
gearless
20092014
With gearbox …
High number of error sources due to high number of machine parts
Less electrical components due to gear box
Without gearbox …
Higher mass of housing (high amount of copper)
High amount of rare earths leads to severe increasing wind turbine prices
Seite 23© WZL/Fraunhofer IPT/KU Leuven
Definition of Large-Scale Parts
Diameter > 500 mm Weight > 30 kg Value of Part > 1,000 €
1,02,0
Dimensions of Large-Scale Parts
80 mm
Source: Liebherr
Source: Schaeffler Source: Liebherr-Verzahntechnik
3,04,05,06,07,0
0effe
ctiv
e ou
tput
[MW
]
1985 1990 1995 2000 2005 2008
20406080
100120140
0
roto
r dia
met
er [m
]effective outputrotor diameter
1 m1.5 MW
3.6 MW
6 MWsize development of
gears
Seite 24© WZL/Fraunhofer IPT/KU Leuven
High Demand on Gears Leads to Process Substitution– Generating Gear Grinding of Wind Turbine Gears
Workpiece Module mn 9.5 mm Number of teeth z 44 Tip diameter da 450 mm Face width b 225 mm Helix angle β 8° Stock ∆s 0.4 mm/flank
Process Time Grinding time: 23,2 min Dressing time per workpiece: 5,2 min Bottom to bottom time: 28,4 min
Source: Reishauer AG
Due to the high demand on gears and the small batch productionnew manufacturing processes are developed
Seite 25© WZL/Fraunhofer IPT/KU Leuven
Outline
The EU Manufacturing Industry– Boundary Conditions– Markets beyond tomorrow
Actions taken – some initiatives – Factories of the Future (EFFRA)– Cluster of excellence on “Integrated Production”
Case studies– Energy– Mobility– Recource efficient Production– Life Science
Conclusion
Seite 26© WZL/Fraunhofer IPT/KU Leuven
MobilityWhat does the future hold? Existing Challenges
Mobility of people and goods
Increasing traffic streams
Traffic technology uses around 30% of primary energy
Facing the Challenges through …
Combustion engines
Hybrid drives
Electric Mobility
Fuel cells
Lightweight concepts
Integrated traffic managementSource: RWE AG
Seite 27© WZL/Fraunhofer IPT/KU Leuven
Mobility drives Gear Technology
Quelle: Zukunftsinstitut
Wor
ld p
opul
atio
n[M
rd.]
6
4
2
1960 2000 year19800 C
ars
wor
ldw
ide
[Mrd
. km
]
40
30
20
10
01960 2000 year1980
Mobility
PKM = Passagierkilometer
1960: 3
1960: 3
1987: 5
1987: 5
2011: 7
2011: 7
1960: 5,5
1960: 5,5
1980: 17,4
1980: 17,4
2010: 43
2010: 43
People Growth
Seite 28© WZL/Fraunhofer IPT/KU Leuven
Investments in »Electric Mobility«
0
1000
2000
3000
4000
5000
21000
19000
20000
23000
22000in
vest
men
ts in
mill
ion
euro
s
Source: RWE AG, Koordinierungsstelle der Industrie 11/2010
Seite 29© WZL/Fraunhofer IPT/KU Leuven
Electric Mobility – Mechanical ComponentsHigh Speed Motor – High Torque Motor - Gear
Source: BMW, ZF; Cost structure: Research WZL of small cars with production costs around € 8.000
100%
Equipment
Propulsion
Body
Chassis
Others
Complete Vehicle
30-37%
22-24%
11-20%
9-12%
15-20%
Gears
Auxiliary Drives
Engine
Others
Propulsion
100%
Exhaust system8-11%
20-27%
18-22%
35-40%
7-9%
Con-rods
Camshaft
Crankshaft Engine block
Piston
Valves
Side shaft incl. synchronism
Differential
Clutch
Catalytic converterExhaust manifold
Muffler Incl. Tail pipe
Belt drive
Intake manifold
Engine electronicInjection system
Generator Cooling systemFuel tank
Oil and water pumps
Cost structure of a conventional vehicle
Seite 30© WZL/Fraunhofer IPT/KU Leuven
Innovative rolling process for the production of defined riblet structures on compressor blades
Sägezahn Riblets
Shotpeening
Ribletrolling
Source: Leistritz Turbomaschinen Technik, MTU, ThyssenKrupp
Functionality of riblets
Turbulentvortice
Large-eddy simulation (LES)
Shark skinwith riblets
Ma
Saw tooth riblets
Turbulent vortices are kept away from the enlarged surface of the riblet structure
Riblets can reduce wall friction of a turbulent flow up to 10%
Bulkforming
CastingMilling
Rawmaterial(TI6Al)
ECM
Milling
Seite 31© WZL/Fraunhofer IPT/KU Leuven
Reduction in weight – driven by new materials and design concepts
Fuel per passenger: 3.4 l / 100 km (Airbus A380)
Increasing air traffic
Highly efficient jet engines
Structure is load optimized and use of light weight materials
Materials
Source: Flight International, Reed Business Information, 2006
Layer designHoney comb structure
GFK
CFK
Aluminium
Glare (Glass-fibre reinforced Aluminium)
61% Alu20% CFK
3% GLARE2% GFK
10% Ti + Steel2% surface protection 2% miscellaneous
Seite 32© WZL/Fraunhofer IPT/KU Leuven
Spanten, Rippen, FußbodenträgerFahrwerksschächte
Share of titanium and composite materials (A350) is increasing
Door part: Titanium
Titanium in combination with CFKdue to chemical and mechanical compatibility
Source: Premium Aerotech
Door segment blue: titaniumgrey: CFPA350
Join the best suited materials together.
Role: Multi material design.
New tooling.
New production platforms.
Seite 33© WZL/Fraunhofer IPT/KU Leuven
Outline
The EU Manufacturing Industry– Boundary Conditions– Markets beyond tomorrow
Actions taken – some initiatives – Factories of the Future (EFFRA)– Cluster of excellence on “Integrated Production”
Case studies– Energy– Mobility– Resource efficient Production– Life Science
Conclusion
Seite 34© WZL/Fraunhofer IPT/KU Leuven
Resource Efficiency Dilemma
Pro
duct
ivity
Num
ber o
f Pro
duct
s
Use of Resources
today
objective
More Goods with less Resources
Seite 35© WZL/Fraunhofer IPT/KU Leuven
People do need fresh waterfertile soil, clean air and an
intact environment
This requiresClean water technologies
Saving and recycling of water inProduction
Environmentally friendly production
Fresh water for everybody might be the most important requirement
for the future
Water – an eminent resource in production
Seite 36© WZL/Fraunhofer IPT/KU Leuven
Quelle: Bundesumweltamt / Statistisches Bundesamt
Water – an eminent resource in production
Coolants in Cutting and Grinding
Cleaning
Solvents
Electrolytes
Dielectrics
Quenching
Heat converter
Seite 37© WZL/Fraunhofer IPT/KU Leuven
Waste water free electroplating
Chlorine free lubrication
Biodegradable dielectrics
Biodegradable cutting fluids
Dry cutting
People do need an intact environment
Seite 38© WZL/Fraunhofer IPT/KU Leuven
Chlorine free fineblanking
Objective
Development of chlorine free lubricants for shearing and fineblanking processes
Application of environmental friendly/biodegradable lubricants in combination with PVD tool coatings
Coatings
Wear
Model test Industrialapplication
Simulation
Lubricants
Develop-ment
Analysis
Test
Seite 39© WZL/Fraunhofer IPT/KU Leuven
Chlorine free fineblanking – Interdisciplinary Research
Results
Complete substitution of chlorine additives in fineblanking lubricants
Reduction of the process friction with the newly developed chlorine free ester lubricants compared to conventional lubricants on mineral oil basis
Enhanced tool life due to chemcal interaction of lubricant and workpiece surface
Coatings
Wear
Model test Industrialapplication
Simulation
Lubricants
Develop-ment
Analysis
Test
Seite 40© WZL/Fraunhofer IPT/KU Leuven
Dry cutting
New coatings and tool design
New machine designs
Minimal quantity lubrication (MQL)
Water – an eminent resource in production
Seite 41© WZL/Fraunhofer IPT/KU Leuven
Dry cutting in serial production
Source: Kennametal Hertel, Fürth
Work material: Ck45Tool: SE-Drill, two level twist drill
(Ti,Al)N-coatinghole diameter 10.6 / 12.5 mm
Cutting speed: vc = 71.5 m/min (level 1)vc = 89.4 m/min (level 2)
Feed: f = 0.3 mm
12,5
10,6
28,0
6,0
12 holes
0
500
1000
1500
2000
2500
3000
1080
2760
wet dry
Num
ber o
f hol
es
Seite 42© WZL/Fraunhofer IPT/KU Leuven
Conventional process chain
Forging
Soft turning,drilling, tappingwith coolinglubricant
Gear cuttingwith
lubricationCase hardening
GrindingWith
cooling lubricantGear lapping Screwing
Forging
Soft turning,drilling, tappingwith coolinglubricant
Gear cuttingwith
lubricationCase hardening
Grinding With
cooling lubricantGear lapping Screwing
Optimisation step1.
Hard turning
2. Optimisation step
Dry gearcutting
Wet machining:Cutting material: HSS Coating: TiN
Dry gearcutting
Eliminationlubrication/ yearca. 25.000 l
Dry machining:Cutting material: VHMCoating: TiAlN
New process parameters:Feed fCutting speed vc
3. Optimisation step 3.
Soft turningwith cooling
lubricantWelding
Soft turningwith cooling
lubricant
Elimination cooling lubricantSystem, consumption/ yearEnergy: 1,15 Mio. kWhMedium: 1052 m³Filter fleece: ca. 45 t
Screwing of crown wheel: - Process drilling and tapping- central cooling lubricant system
Welding of crown wheel: - Process Elimination of drilling and
tapping- Elimination of a central cooling
lubricant system
WeldingHard turning
Source: BMW
Technology Push – Bevel Gear ManufacturingEntire Process Chain – Technological Due Diligence
Seite 43© WZL/Fraunhofer IPT/KU Leuven
Component/productGrindingMilling
Anneal-ing Assembly
Support processes
FormingSemi-finishedpart/ material
Residual materialschips, effluent,
sludgeScrap
Emissionsheat, noise, vapours,exhalation, vibrations
Energy
Resource-efficient production – the production chain as a focus
SuppliesTools
Source: IWT Bremen, Kutz + Schulz, ThyssenKrupp, AWK 2008
Seite 44© WZL/Fraunhofer IPT/KU Leuven
Examplary forming tools in deep-drawing
Source: AUDI AG
Forming tool for front doors consists of– Upper part– Lower part– Die– Blank holder– Form block
Small additional parts suchs as screws and sliding elements are not part of the balance shell
Seite 45© WZL/Fraunhofer IPT/KU Leuven
Modelmaking
Coating
Casting
Fettling
Shot Peening
Quality Check
Machining
Build Up
Tryout
Pressing
Maintenance
End-of-Life
Foun
rdy
proc
esse
sM
achi
ning
and
build
upU
sage
Life Cycle phases of the forming tool The forming tool is formed with a
lost mould– Styrofoam model is milled into final
dimensions– Appliance of refractory coating – Casting
Machining is performed with different machines (small, medium, 5-axis)
During the life cycle a sample body part has been focused:front door of a common vehicle
End-of-life phase bases on predictions and assumptions
Seite 46© WZL/Fraunhofer IPT/KU Leuven
Standardization of different energy formsStandardization
…
Pressurized Air
Heating
Electr. Energy
Nm³ / part
kWh / part
kWh / part
t / part
MJ / part
MJ / part
MJ / part
MJ / part
Sha
res
of p
rimar
y E
nerg
y co
nsum
ptio
n /
MJ/
part
Consumption Primary energy
Seite 47© WZL/Fraunhofer IPT/KU Leuven
Production of the deep drawing tool
3%
58%
Tryout
19%
Build up
16%
Fettling & Shot peening1%
Casting
Coating
0%
Modelmaking2%
Machining
Main Consumers
Casting– Melting Energy and cradle-to-gate
material are the main consumers
Machining – Significant influence on the energy
consumption due to electrical energy
– Credit for scrap metal is included
Tryout– Tryout parts which are considered
as waste material have a significant influence on the consumption
– Credit for recycling of waste material is includedShares of primary energy consumption
Seite 48© WZL/Fraunhofer IPT/KU Leuven
Whole life cycle including usage and recycling
0,3%
Sha
res
of P
rimar
y E
nerg
y C
onsu
mpt
ion
Recycling Total
1,4%0,4%
1,8%
Usage
0,8%0,4%1,1%
Foundry Processes
1,5%100,0%
98,5%
96,7%
Mainte-nance
0,3%0,3% 0,3%
Tool manu-
facturing
96,7%
MaterialEnergy(Electrical, thermal)
No coil material (workpiece) included
The most impact is located during the usage phase
The primary energy consumption during pressing exceeds the primary energy for the manufacturing of the forming tool significantly
Seite 49© WZL/Fraunhofer IPT/KU Leuven
Design Optimization of Edge Geometry in Deep-DrawingGeometric Modeling in Tool Design
Structure Optimization
Objective: weight reduction with maximum stiffness
Principle: calculation of an optimized material distribution for preexisting load case
Design Optimization
Objective: homogenizing and reduction of loads
Principle: calculation of design optimization by iterative changing surface shape
Source: TOSCA Structure 7.1 Seminar, FE-Design GmbH
Seite 50© WZL/Fraunhofer IPT/KU Leuven
Structure Optimization of Tool SystemDefinition of an Optimization Model and Results
Structure optimization with TOSCA structure software
Definition of upper tool half as design area for structure optimization
Lower tool part was not changed
Optimization Strategy: keep stiffness constant
A stiffness satiation was reached after 14 iteration steps combined with a mass reduction of 40%
upper tool half
design areanot modifiable
not designable
0
1
2
3
0 2 4 6 8 10 12 1401020304050
stra
in e
nger
y U
[MJ]
iteration n [-]
mas
s re
duct
ion
mre
d[%
]
10.50
relative materialkey value vrel [-]
mass reduction
strainenergy
Source: Bäcker, V.: Numerical Tool Optimization in Deep Drawing, Dissertation WZL, RWTH Aachen, 2011
Seite 51© WZL/Fraunhofer IPT/KU Leuven
Efficiency Loss in Automobile Gearboxes –Gear Box in Use
3
2
4
1
1
4
4
1
1
3
3
Bearing friction– Type of bearing– Preload force
Oil flow – splashing- /delivering losses
– Body shape– Oil volume– Viscosity
Gear sliding– Sliding speed– Axle offset– Lubricating film– Topography– Surface structure
Friction of gasket– Type of gasket– Material– Surface structure
1
2
3
4
1 1
111
1 1
3 3
2
44
4
axle gear 92-98%
inline-shift gearbox96-99%
input shaft
gear wheel, gear 2 driven
shaft
countershaft, gear 1
reduction gear
Seite 52© WZL/Fraunhofer IPT/KU Leuven
Efficiency Loss in Automobile Gearboxes – Gear Box in Use –Power by the hour
3
2
4
1
1
4
4
1
1
3
3
Bearing friction– Type of bearing– Preload force
Oil flow – splashing- /delivering losses
– Body shape– Oil volume– Viscosity
Gear sliding– Sliding speed– Axle offset– Lubricating film– Topography– Surface structure
Friction of gasket– Type of gasket– Material– Surface structure
1
2
3
4
1 1
111
1 1
3 3
2
44
4
axle gear 92-98%
inline-shift gearbox96-99%
input shaft
gear wheel, gear 2 driven
shaft
countershaft, gear 1
reduction gear
Geared turbofanPower: 20 MW
Performance ratio: 98-99%Heat: 200 000 – 400 000 kW
Seite 53© WZL/Fraunhofer IPT/KU Leuven
Topics for an Energy Efficient Production Increase in process stability and quality (Zero Scrap
Production)
First part right
Material efficiency in mechanical manufacturing processes and systems
Energy efficiency in thermal und chemical manufacturing processes
Closed Resource loops for all Process chains and systems
Crosslink of resources in production systems
Lossless infrastructure use of productions facilities and fabrics
Development of methods for sustainable resources
Input
Prozess
Output
Inpu
t Process-step n
Information
Material
Energy
Out
putInformation
Material
Energy
Information
Material
Energy
Information
Material
Energy
Source: EFFPRO Study from the German Federal Ministry of Education and Research; Pictures: MEV publishing company
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Outline
The EU Manufacturing Industry– Boundary Conditions– Markets beyond tomorrow
Actions taken – some initiatives – Factories of the Future (EFFRA)– Cluster of excellence on “Integrated Production”
Case studies– Energy– Mobility– Resource efficient Production– Life Science
Conclusion
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Live science
Endemic diseases and customized solutions for an aging society are of top priority in national health
care systems
People do needindividual implants and limbs
pharmaceuticals and health care assistance
This requires interdisciplinarywork of biologists, medical doctors
and engineers
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Automation of biotechnological processes
Traditional laboratory processes are often characterized by a high degree of manual handling operations
Traditional laboratory processes require trained laboratory personnel
The automation– Increases throughput– Increases reproducibility and process stability– Enables continuous process monitoring
The challenge:– Modification of the established manual and laboratory
procedures for the special requirements of automation– Development of adapted process concepts– Integration of individual solutions into automated systems
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Cell isolation from human skin biopsiesRe-engineering of each step included in the laboratory process
Manual processing
fat separation (scalpel)
cutting of biopsy (scalpel)
incubation (dispase)
separation (tweezers)
grinding (scalpel)
incubation (trypsin/collagenase)
centrifugation
cell suspension (media)
Automated processing
filtration of epidermis
fat reduction (optional)
chopping of biopsy
incubation (dispase)
filtration of single cells
cell suspension (media)
incubation (trypsin/collagenase)
Fraunhofer IPT, Fraunhofer IPA, Fraunhofer IGB
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Cell isolation module Automated cell isolation from multilayered skin tissue Technical capabilities
– Isolation of keratinocytes and fibroblasts
– Automated handling solutions for tissue and cells
– Prevention of cross contamination
Methodology– Development of a combined
enzymatic and mechanical method for skin tissue dissociation
– Development of a multifunctional filtration pipette for tissue and cell handling
– Processing and validation of prototypes under sterile conditions
– Integration in tissue factory
Fraunhofer IPT, Fraunhofer IPA, Fraunhofer IGB
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Integrated metrology Cell proliferationMedia analysis
Cell counting deviceOCT-system
Metrology
Status cell culture Quality assurance
Dissolved oxygen
pH-value of the mediaOptical densityDetection of bacterial contaminations
Proliferation of cells
Cell status and cell concentrations
non-invasive analysis of skin test
Fraunhofer IPT, Fraunhofer IPA, Fraunhofer IGB
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Tissue factory 2011
Zellisolationsmodul
Zellexpansions -modul
Gewebe -aufbau -modul
Cell isolationmodule
Cell expansionmodul
Tissue cultivation module
--
Fraunhofer IPT, Fraunhofer IPA, Fraunhofer IGB
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Automated biotechnological processes - prerequisite for continous process monitoring
Minimization of rejections
Collection of critical process data
(variable cell growth,..)
early error recognition
(contaminations,..)
Quality control(non destructive)
Processoptimization
Quality, time, costs
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Limitations of tissue engineering processes/regenerative medicine High demand for pluripotent stem cells for research applications
Poor availability of appropriate donor tissues for research purpose
Liver tissue Kidney tissue Heart tissue Neuronal tissue …
Not enough (autologous) donor tissue/cell material available to cultivate tissue transplants
Specialized isolated cells are maturing during in vitrocultivation loss of specific cell functions
pluripotent stem cells (like embryonic stem cells) can be differentiated into all cell types and can self-renew to produce more stem cells
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Project Highlight » StemCellFactory «Objectives Automated cell isolation of mesenchymal stem cells from bone marrow
and fibroblasts from skin
Automation of a manually established process for the generation of induced pluripotent stem cells iPS
Automated differentiation of iPS into neuronal stem cells (and cardiac cells)
Methodology Re-engineering and optimization of each laboratory process to enable
complete process automation
Choice and integration of all necessary commercially available functional modules
Design and development of specific functional components and handling solutions
Development and integration of metrology for inline monitoring of all cell culture processes
Envisaged outcome Development of an fully automated, modular demonstrator for the
reproducible production of iPS derived cell products
iPS cell clone on feeder cells
CAD model of the StemCellFactory
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The problem of malaria infections in the world -Motivation for automated vaccine production
History of malaria infections Beginning of the 19th century: people thought that smelly
marshes are the cause of malaria 1880 researchers identified a parasite - which is transmitted by
infected mosquitos - as a trigger Middle of 20th century: malaria could be eleminated in many
contries
Status quo
Malaria is spreading to new regions of the globe and again in areas where it had been successfully suppressed
3,3 billion people are at risk, particularly in the tropics and sub-tropics
250 million cases of malaria annually
Every 45 sec. a child dies from malaria
Together with HIV/TB, malaria is the biggest hindrance to the development of the poorest countriesSource: World Malaria Report 2008. Geneva, World Health
Organization, 2008; 2006 data
Photo by CDC/James Gathany,http://www.who.int/features/factfiles/malaria/malaria_facts/en/
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Info from pathogen
Info from plant virus
Recombined
TransientGeneticVehicle
Sow seedsTreat seedlings Grow in greenhouse Harvest and disrupt leaves
Purify vaccine
Stabilize and package
Vaccines from Plants
Source: Fraunhofer IME
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Automated production of vaccines in tabacco plantsInfo from pathogen
Recombined
Sow seeds Treat seedlings Grow in greenhouse Harvest and disrupt leavesSource: Fraunhofer CMI, Fraunhofer IPT, Fraunhofer IME
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Lab on a chip for molecular diagnostics
Fluid dynamics
Low cost and manufacture
Integrated functions– Sample input– Mixers– Bacterial lysis– Nucleic acid isolation– PCR (thermal cycling)– Optical detection
Automated instrument
Demonstrated for bacteria
Extending to influenza (RNA virus) in human nasopharyngeal aspirates
Source: Sauer-Budge et al Lab Chip, 2009, 9, 2803 – 2810, Fraunhofer CMI, Boston
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Production technologyLab-on-a-Chip
Objective
Integration of PCR and fluorescence end-point detection for complete lab on a chip demonstration
Economic feasibility of end product
Methodology
Optimization of production processes to meet target costs
Design and development of tools for injection molding
Results
Ready-to-use prototype
New low cost lab on a chip technology in plastic has applications in research, point of care clinical diagnostics, food and agriculture industries
Demonstration of integrated lab-on-a-chip technology significantly improves attractiveness of technology to investors
PCR chamber
FluorescenceDetection
Mixers
DNA purification
Bacterialysis
Source: Fraunhofer CMI, Fraunhofer IPT
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Project examplesensitive lab-on-a-chip for detecting TB in urine
Rapid diagnostics for TB are sorely needed
Point-of-care in limited-resource settings require automation, sensitivity, low cost
Protein biomarkers– Sensitive point-of-care diagnostic detecting
TB antigen in urine
trDNA– Modified PCR of short fragments of DNA in
urine
Source: Fraunhofer CMI, Fraunhofer IPT
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Outline
The EU Manufacturing Industry– Boundary Conditions– Markets beyond tomorrow
Actions taken – some initiatives – Factories of the Future (EFFRA)– Cluster of excellence on “Integrated Production”
Case studies– Energy– Mobility– Resource efficient Production– Life Science
Conclusion
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Wait and hope!
Good things:Easy to be realized
Low budget required
DownsideBreak through inventions
happen rather seldom
Probability of success is low
Reserve the„right to play“
Sufficient investments to preserve the
competitiveness without an early determination of
further activities
Source: Courtney/ Kirkland/ Viguerie (HBR 6/97)
What willyou get?
Approach/ strategy to an innovation process
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Reqiurements
Critical brain powerto get the statistics aside
Synergy effects
Different disciplines
Science and industry
Trend analysesVisions and scenarios
define a Budgetinstall change processes
Go for it - change
What willyou get? Active creation
of the futurePlaying a leading role in
determining thecompetition rules in the sector
for example:- determine standards
- generate needs
Source: Courtney/ Kirkland/ Viguerie (HBR 6/97)
Approach/ strategy to an innovation process
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In a Nutshell
What is everything going to be about?
Inspiring and Education of the Young Generation.
It is our joint Future!
Everything is about people!
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It is not the strongest of the species, nor the most intelligent that survives.
It is the one that is the most adaptable to change.
*Regularly attributed to but not documented. Supposedly in the context of »Origin of Species« (1859)
Charles Robert Darwin* (1809-1882)
Source: academic.ru/pictures/dewiki/67/Charles_Darwin_aged_51.jpg
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Future developments have to be received as they evolve!
But we can do something,
that our future evolves as we feel like it!
Acc. to Curt Goetz, German author (1888 – 1960)
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Thank You very much for
Your kind attention!
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