OEM&Lieferant Ausgabe 1/2018

100 So how can we solve the seeming contradic- tion between immature processes and the production based on these processes while converting the process into a mature pro- cess? One answer is the basic generic idea to equip the immature process with sensor and measuring technology as well as options to interfere. Another answer is the interdis- ciplinary cooperation between three strong institutes, the KIT’s Institute of Production Science (wbk) as well as Fraunhofer ICT and IOSB. They combine the specific competenc- es in materials, manufacturing and process as well as automation, sensor and informa- tion technology, which are necessary and sufficient to achieve the ambitious scientific objectives. Two challenging manufacturing processes, which are highly up to date and highly signif- icant for the industry in our county, serve as an example to demonstrate the benefit of the new proposed ICT-based methodology. In par- allel, two innovative manufacturing processes are to be created. On one side, manufacturing processes for lightweight components and on the other, a manufacturing process for the as- sembly of battery modules will be optimized for mass production. Lightweight construction is one of the most future-oriented technologies in vehicle and mechanical engineering. In this context, hy- brid lightweight construction is turning out to be the most prestigious discipline. It means the combination of various materials, which, taken together, show the best overall features for a given system, in line with the motto “the right material at the right place”. Among other things, the Karlsruhe Smart Factory, in cooperation with partners from industry, is designed to do fundamental and application-oriented research in the area of fiber composite-based hybrid lightweight engineering, particularly to get the required manufacturing processes ready for the mar- ket at an accelerated pace. The use of batteries based on Li-ion technol- ogy plays a significant role because no other storage technology has developed at a com- parable pace over the last 15 years. Today, the market of modern high-capacity batteries is dominated by Li-ion technology, which is likely to show even more significantly higher increases in capacity in the future. The maxi- mum theoretical energy density ranges from 2,600 Wh/kg (Li-S) to 11,100 Wh/kg (Li-O2). Thus, the theoretical values are within the same range as the energy density of fossil en- ergy sources. A promising field of application of modern high-capacity batteries is electro- mobility. However, the efficient and industrial mass production of battery systems requires new manufacturing processes and methods to be designed, which can quickly be imple- mented in industrial plants. This is another objective of the Karlsruhe Smart Factory. Simultaneously with the two sample fields of application, the two processes are designed to get productive in parallel with the develop- ment phase. In the context of ”Industrie 4.0“, the Karlsruhe Smart Factory, as a matter of course, addresses the complete networking of the manufacturing processes and the real- time processing and use of all available data relating to manufacturing processes and the design and (re-)structuring of lightweight and battery assembly. For the large number of innovative small and medium-sized enterprises in Baden-Württem- berg, the methodology to be developed at the Karlsruhe Smart Factory is a crucial factor for maintaining and enhancing their internation- al competitiveness. In the conflict between increasing individualization of production, a greater diversity of variants, new technologies and complex manufacturing processes, the Smart Factory can provide our enterprises with decisive advantages in global competi- tion. Of course, interested companies will be involved right from the start to ensure a tar- geted and quick transfer of the results. The infrastructure of the Smart Factory In cooperation with the federal state of Baden-Württemberg and the KIT, a plot of land on the eastern campus of the KIT was selected as the location for the Karlsruhe Smart Factory. The main building will take the form of an L, which can be extended step by step so it can take the shape of a comb. The building of the Smart Factory will con- sist of two components: one part for the KIT and one for Fraunhofer. Nevertheless, the two parts of the building are connected by a prestigious linear lobby. The KIT’s part of the building will contain lightweight engineering including all the required machinery and equipment. To achieve a higher density, the part of the building that belongs to Fraun- hofer will consist of two floors: The first floor has been designed for lightweight engineer- ing and emobility, the second for research related to Industrie 4.0. The building and its equipment are flexible or adaptive enough to allow for a simple reorganization or re- placement of the manufacturing processes. There will also be room for exhibitions and presentations. The planned meeting and seminar rooms will be used for training ses- sions, including hands-on training. The trans- fer of technology to the regional enterprise clusters is a reality even today and will be expanded through the Smart Factory. n Websites Fraunhofer IOSB www.mes.fraunhofer.de Karlsruhe Institute of Technology (KIT) www.forschungsfabrik-ka.de/ servlet/is/65033/ The WebLog for the Industry 4.0 community www.industrie40.blog Dr.-Ing. Olaf Sauer Deputy Head of the Institute Digital BusinessCard