AUTO IBN2 - Efficient assembly and innovative commissioning processes in the production of modern vehicles

In the ERDF-funded project, new human-robot-capable assembly processes for the automotive industry are being developed in cooperation with various partners.
ZeMA is a partner in the scientific community ‘Assembly, Handling and Industrial Robotics’. In addition, there are cooperation agreements with leading robot manufacturers such as Kuka, ABB and Bosch.

problem

In order to avoid a medium-term relocation of the vehicle final assembly due to the cost pressure from the high-wage location Saarland or Germany to countries with a low wage level, the cost-effectiveness of the vehicle final assembly must be increased. One way to do this is to increase the efficiency of assembly and testing processes in the automotive industry.

objective

The aim is to provide new impetus for efficient production processes by developing innovative start-up and assembly processes for motor vehicles. This offers the possibility to display or implement prototypical processes on the existing demonstrator depending on the application. The challenges and potentials of the construction of modern vehicles are addressed. At the same time, the project strengthens the competitiveness of German and locally based plant and equipment manufacturers. The steady increase in electronic components and the high number of mechatronic functions of vehicles tend to lead to increasing expenditure in vehicle disassembly and commissioning. In principle, the scope of work should not only be avoided, but the mechatronic capabilities of the motor vehicles should also be used for innovative and efficient process solutions. This should make work and process sequences more efficient. In addition, the structure of the assembly process for optimization is to be changed.

approach

The AutoIBN2 project is structured across disciplines and combines organizational as well as production-technical issues. The research focus of the project is the joint development of production strategies and technologies for cyber-physical production plants and efficient assembly processes. By means of smart equipment and intelligent methods, this is to be demonstrated using the example of vehicle disassembly, as well as its associated areas. For this purpose, the company is building on the latest developments in the field of vehicle technology, modern approaches in the field of computer science and also robot technology. This results in fundamentally new research approaches for increasing quality and securing efficient vehicle production at a high-wage location.
The project contains 5 work packages:

• Inline measurement: In-line measurement of the geometric travel axis by means of the developed wheel adaptation system and adjustment of the driver assistance systems in the assembly line

• Worker assistance systems for flow assembly: Innovative human-robot concepts for the automation of production and testing processes in the assembly line

• Virtual plant engineering: Methods and tools for the development, design and virtual commissioning of robust production plants

• Energy efficiency for the cyberphysical production network: Development of methods and applications for energy-efficient operation of production plants in different operating states

• Model and test factory environment: Expansion of the model factory at ZeMA to validate the research results in a real demonstrator

Results / Project status

The project was launched in mid-2015 and will run for at least 3.5 years. The work plan is structured in such a way that the contents of the work packages start in parallel and reach a common project status at the end of the project in the form of a development environment.

Recovery concept:

With the development environment created, processes are to be validated and continuation projects with industry and research services are to be made possible. In addition, the demonstrator and the research results are used to apply for and carry out further research projects. In addition, the equipment is used for teaching and further education measures.

Duration: 07.06.2015 - 31.12.2018

Funded by:

Use of AUTO IBN2
Category: Assembly systems

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