Automatically to the process chain: Like a 3D printer for car parts
Scientists at the University of Siegen are developing a new type of production cell for sheet metal components for vehicles. With the help of artificial intelligence and flexible manufacturing processes, special car body parts are to be produced profitably in small series.
Individualisation is a social megatrend that does not stop at the car industry: More and more vehicle models are available, more and more elements can be changed. From countless interior details to engine specifications and transmission type, customers can now customise their new car. Thousands of combinations are available for each model. This has a massive impact on production: suppliers have to produce components in many more variants than they did a few years ago – at the same time, the required quantities are falling. But how can companies still produce profitably in the face of these demands? Scientists at the University of Siegen are developing a new type of production cell for car body components: With the help of artificial intelligence and flexible manufacturing processes, individualised sheet metal components are to be produced profitably in it.
The aim of the project, called SkaLaB, is to profitably produce special sheet metal components in small series using artificial intelligence and flexible manufacturing processes. The project is funded by the Federal Ministry for Economic Affairs and Climate Protection with around 7.6 million euros and started in January 2023. The aim is to reduce the manufacturing costs for new geometrically different body variants and to make the production of the corresponding components attractive for medium-sized suppliers. The new manufacturing cell is designed to break up the traditional fixed manufacturing chain in car body construction by using a flexible manufacturing process. The sheet metal components are flexibly formed, welded and joined within the cell by mixing and recoupling previously separate work steps. The scientists want to investigate for which types of components this flexible production method works. The manufacturing cell will use state-of-the-art technology such as autonomous mobile robots, welding apparatus, presses and swivel bending machines. The process generator uses artificial intelligence to calculate how the component can be produced most cost-effectively in the cell. The manufacturing cell is not intended to replace skilled workers in production, but to work collaboratively with them. The project is a combination of research results and findings from the three Siegen chairs in the fields of artificial intelligence, the flexibilisation and digitalisation of production processes and 3D metal printing.
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