[Due to the increasing size of the archives, each topic page now contains only the prior 365 days of content. Access to older stories is now solely through the Monthly Archive pages or the site search function.]
GM earns EPA ENERGY STAR Award for Environmental Leadership; energy use per vehicle in manufacturing down 10% YoY
April 12, 2017
General Motors earned a 2017 EPA ENERGY STAR Partner of the Year — Sustained Excellence award for continued leadership in protecting the environment through superior energy efficiency. GM’s commitment to reducing energy intensity saved $73 million in energy costs last year and avoided 388,000 metric tons of carbon emissions, equivalent to the electricity use of 57,000 US homes.
In the US, GM reduced energy use at its manufacturing facilities by 10% on a per-vehicle basis in 2016 compared to the previous year. Additional achievements include:
Toyota invests $1.33B in Kentucky plant to introduce TNGA; 2018 Camry to be 1st TNGA car made in US
April 10, 2017
Toyota Motor is making a $1.33-billion investment in Toyota Motor Manufacturing, Kentucky, Inc. (TMMK); the plant will be Toyota’s first in North America to begin producing vehicles using Toyota New Global Architecture (TNGA). (Earlier post.) In 2015, Toyota announced it was investing $1 billion in a new TNGA plant in Guanajuato, Mexico—the first designed from the ground up with TNGA production engineering technologies. The Guanajuato plant will begin producing the Corolla with Model Year 2020. (Earlier post.)
The TMMK-produced Camry, from the 2018 model year, will become the first Toyota vehicle made in the US fully to incorporate the new vehicle development and production technology.
Next-gen Audi A8 introduces new four-material space frame; light weight and rigid
April 06, 2017
For the next generation of the Audi A8, an intelligent mix of four materials—aluminum, steel, magnesium and carbon fiber-reinforced polymer (CFRP)—is being used for the first time in the weight-bearing body structure—more materials than in any of the brand’s previous production models.
The resulting low weight and impressive rigidity—the upcoming flagship’s torsional rigidity surpasses the predecessor model’s rigidity value by up to 24%—from the multi-material construction of the Audi Space Frame (ASF) offer greater performance, efficiency and safety.
Porsche and Audi to work on shared vehicle architecture; electrification, autonomy, digitization
April 05, 2017
Within the Volkswagen Group, Porsche AG and AUDI AG now plan to cooperate more closely on future vehicle architectures, with a particular focus on electrification, digitization and autonomous driving.
Brands within the Volkswagen Group have been rolling out modular component matrices, or assembly toolkits, for their light-duty vehicles over the past few years. Until recently, the four main modular toolkits (modularen Baukästen) of the Group were: the MQB (transverse, driven by the Volkswagen brand); the MLB (longitudinal, driven by the Audi brand); the MSB (standard drive, driven by Porsche); and the NSF (New Small Family). (Earlier post.)
For Greener Manufacturing, Think IAQ
April 03, 2017
by Craig Widtfeldt, RoboVent
The next generation of cars will be cleaner and greener than ever—but a lot of the manufacturing processes that go into them are still pretty dirty. From the frame to the muffler, automotive manufacturing still involves welding, cutting, grinding and machining. These processes can create problems for indoor air quality (IAQ) and hurt your sustainability metrics.
The Problem with Particulates. Welding, cutting, grinding and machining all create particulates with varying levels of toxicity. These particulates have serious health impacts if not controlled in the factory environment. If they are vented to the outdoors, there are also environmental issues to consider. Controlling toxic particulates from manufacturing processes is one of the most important things auto manufacturers can do to improve their sustainability and protect their workers.
Ford investing $1.2B in 3 Michigan plants; focus on trucks, SUVs, big data & mobility services
March 28, 2017
Ford Motor Company is investing $1.2 billion in three Michigan manufacturing facilities to strengthen its leadership in trucks and SUVs and support the company’s expansion to an auto and mobility company.
Ford is investing $850 million in Michigan Assembly Plant to retool the plant to build the all-new Ford Ranger and Ford Bronco. Employees at Michigan Assembly Plant will begin building Ranger at the end of 2018 and Bronco in 2020.
Dürr now supports bodies up to 8m long with Ecopaint RoDip rotational dip process
March 21, 2017
Dürr has expanded the capability of its Ecopaint RoDip rotational dip process to handle vehicle bodies up to eight meters in length for the first time. Dürr will be installing this technology in the new Mercedes-Benz Vans factory in North Charleston, SC. It will form part of a complete paint shop being built by Dürr on behalf of Mercedes Benz Vans.
RoDip comes in two versions, RoDip M and RoDip E. RoDip E has an electrically driven transport unit on one side of the tank comprising both transport and rotation drives. RoDip E is very flexible and can be programmed with body-related dipping curves. RoDip M uses two mechanical chain drives, one on each side of the tank. The Ecopaint RoDip E version will be used in the Mercedes-Benz Vans paint shop.
Novelis enters supply agreement with NIO to provide aluminum solutions for next-gen EVs
March 16, 2017
Novelis, the world leader in aluminum rolling and recycling, has expanded its automotive supply capabilities by signing an agreement with EV company NIO (earlier post), to provide innovative aluminum solutions for its fleet of smart, high-performance, premium electric vehicles. NIO will use Novelis Advanz aluminum alloys to create a wide range of structural components and parts for its aluminum-intensive NIO electric SUV models to be launched over the next five years.
The NIO partnership marks Novelis’ first major commitment in the premium electric vehicle space. Supply for NIO will come from Novelis’ Changzhou plant, China’s first facility dedicated to manufacturing heat-treated automotive sheet. The plant is an example of Novelis’ long-term commitment and capability to supply product in Asia for auto manufacturers based in that region and globally.
IACMI launches project to optimize resins and sizings for vinyl ester / carbon fiber composites; targeting automotive adoption
March 13, 2017
The Institute for Advanced Composites Manufacturing Innovation (IACMI), a Manufacturing USA institute driven by the University of Tennessee, Knoxville and the US Department of Energy, in partnership with Ashland, Zoltek, Michelman, University of Dayton Research Institute (UDRI), JobsOhio, and Michigan State University (MSU) has launched a project focused on the optimization of vinyl ester resins and fiber sizings for the fabrication of carbon fiber composites.
The effort will identify styrene-free prepreg formulations with longer room temperature shelf life, shorter cycle times, and reduced cost. Advancements in these areas will increase productivity, decrease scrap and material costs, and enable adoption into the automotive industry.
ORNL, HTS International to collaborate on manufacturing research; conformal cooling
March 11, 2017
HTS International Corporation and the Department of Energy’s Oak Ridge National Laboratory (ORNL) have signed an agreement to explore potential collaborations in advanced manufacturing research such as in conformal cooling. (Conformal cooling refers to the use of a cooling passageway which conforms to the shape or profile of a mold core or cavity to perform rapid, uniform cooling in injection molding or blow moulding.)
The memorandum of understanding follows HTS’s recent decision to locate its headquarters and production operations in a Knox County business park adjacent to DOE’s Manufacturing Demonstration Facility at ORNL. The lab’s expertise and unique facilities in materials science, metallurgy and advanced manufacturing attracted the attention of HTS’s leadership during a 2015 visit to Tennessee.
Ford testing 3D printing of large-scale parts using Stratasys Infinite Build 3D printer
March 09, 2017
Ford Motor Company is exploring how large-scale one-piece auto parts, such as spoilers, could be printed for prototyping and future production vehicles, as the first automaker to pilot the Stratasys Infinite Build 3D printer.
Audi wins VDA Logistics Award for automated vehicle transport
February 22, 2017
Audi has won the Logistics Award for 2017 from the German Association of the Automotive Industry (VDA) in recognition of its FTS driverless vehicle transport system. The autonomously operating system has been in production operation at the Ingolstadt site since the beginning of the year. The parking robot, RAY, from Serva Transport Systems, sorts up to 2,000 cars per day for loading onto railway freight cars. (Earlier post.) This application is the only one of its kind to date in the automotive industry.
There are now twelve parking robots in use at Audi’s main plant in Ingolstadt. They autonomously transport Audi models after production for railway loading. For this, one of the roughly six meter long and three meter wide robots uses laser sensors to determine the position and dimensions of a car and adjusts itself accordingly. Then the robot carefully lifts the car up to ten centimeters.
Government of Canada awards $18.2M for aluminum autoparts and better Li-ion battery management
February 17, 2017
The Government of Canada is awarding a total of $18.2 million to two companies that have developed innovations with the potential to make cars lighter, more fuel efficient and, in the case of electric cars, better performing due to a longer battery life.
Astrex Inc. of Lakeshore will receive a repayable contribution of up to $17 million from the Federal Economic Development Agency’s (FedDev Ontario) Advanced Manufacturing Fund. The investment will enable Astrex, a manufacturer of auto parts, to establish a facility that produces lightweight, high-strength aluminum components. The parts manufactured at this plant will reduce fuel consumption and lower carbon emissions.
Siemens reports successful full load tests of additively manufactured CM247 gas turbine blades
February 07, 2017
Siemens has achieved a breakthrough by finishing its first full load engine tests for gas turbine blades completely produced using Additive Manufacturing (AM) technology. The company successfully validated multiple AM printed turbine blades with a conventional blade design at full engine conditions—the components were tested at 13,000 revolutions per minute and temperatures beyond 1,250 degrees Celsius.
Furthermore, Siemens tested a new blade design with a completely revised and improved internal cooling geometry manufactured using the AM technology. The project team used blades manufactured at its 3D printing facility at Materials Solutions, in Worcester, UK. Siemens acquired a majority stake (85%) in Materials Solutions in August 2016. (The remaining 15% is held by the founder, Carl Brancher.)
Mercedes-Benz Sindelfingen to produce EQ brand EVs
February 01, 2017
The Mercedes-Benz Sindelfingen plant will produce electric vehicles in the new electric EQ brand (earlier post), according to an agreement the company and works council have signed after intensive negotiations. Mercedes-Benz earlier announced that its Bremen plant will build the first production EQ model by the end of this decade. (Earlier post.)
The new generation of electric vehicles will be based on a scalable architecture developed specifically for battery-electric models; it is suitable for all model series as well as sub-models, such as SUVs, saloons and coupés. Wheelbase and track are variable.
GM and Honda to establish industry-first $85M joint fuel cell system manufacturing operation in Michigan
January 30, 2017
General Motors and Honda are establishing the auto industry’s first manufacturing joint venture—Fuel Cell System Manufacturing, LLC, FCSM)—to mass-produce an advanced hydrogen fuel cell system that will be used in future products from each company. Over the past three years, GM and Honda have been collaborating on next-generation fuel cell and hydrogen storage systems, aiming at commercialization in the 2020 time frame. (Earlier post.)
The co-developed new generation stack builds on the compact size and high-performance of Honda’s current generation stack in the Clarity (earlier post) by achieving significant cost reductions. FCSM will operate within GM’s existing battery pack manufacturing facility site in Brownstown, Michigan, south of Detroit. Mass production of fuel cell systems is expected to begin around 2020 and create nearly 100 new jobs. The companies are making equal investments totaling $85 million in the joint venture.
Audi and EOS start development partnership focused on holistic approach for metal-based additive manufacturing
January 25, 2017
Audi AG has started a development partnership with EOS, a global provider of high-end Additive Manufacturing (AM) solutions. The EOS consulting division “Additive Minds" is supporting Audi in the holistic implementation of this industrial 3D printing technology and the development of a corresponding 3D printing center in Ingolstadt.
Audi recognized early on the potential of additive manufacturing for the automotive industry, and now promotes the application of the technology, working closely with EOS. For Audi, toolmaking and the casting technical center for planning are leading applications. Industrial 3D printing is first being applied to equipment and prototype building at Audi, as well as motor sports, where the technology is already in use today.
FLAC project seeks 40-80% weight reduction in automotive components through 3D printing
January 22, 2017
Engineers at The University of Nottingham are developing lightweight automotive components using new additive manufacturing processes to boost vehicle fuel efficiency, while cutting noise and CO2 emissions as part of the Functional Lattices for Automotive Components (FLAC) project. FLAC aims to achieve significant weight reductions in mass (40-80%) and optimized thermo-mechanical performance in new vehicle components.
The Nottingham team will construct components using selective laser melting (SLM). SLM uses a 3-Dimensional Computer Aided Design (CAD) model to digitally reproduce the object in a number of layers. Each layer is sequentially recreated by melting sections of a bed of aluminium alloy powder using a laser beam. Layer by layer, the melted particles fuse and solidify to form novel structures that can be made up from complex lattices to provide a light-weight component. SLM helps increase functionality and lower the number of separate components in production. This significant mass saving cuts component costs and increases overall vehicle efficiency.
Ford adding hybrid F-150 & Mustang, PHEV Transit, new BEV SUV by 2020; $700M for Flat Rock for EV production; cancels $1.6B Mexico plant
January 03, 2017
Ford detailed seven of the 13 new global electrified vehicles it plans to introduce in the next five years, including hybrid versions of the iconic F-150 pickup and Mustang in the US, a plug-in hybrid (PHEV) Transit Custom van in Europe and a fully electric SUV with an expected range of at least 300 miles (483 km) for customers globally.
The automaker also announced plans to invest $700 million to expand its Flat Rock Assembly Plant in Michigan into a factory that will build high-tech autonomous and electric vehicles along with the Mustang and Lincoln Continental. The moves are part of a $4.5 billion investment in electrified vehicles by 2020.
DOE awarding $12.9M to 6 pilot- and demonstration-scale projects for manufacturing biofuels, bioproducts, and biopower
December 29, 2016
The US Department of Energy (DOE) has selected six projects—entitled, “Project Definition for Pilot- and Demonstration-Scale Manufacturing of Biofuels, Bioproducts, and Biopower”—-for up to $12.9 million in federal funding. These projects, required to share the cost at a minimum of 50%, will develop and execute plans for the manufacturing of advanced or cellulosic biofuels, bioproducts, refinery-compatible intermediates, and/or biopower in a domestic pilot- or demonstration-scale integrated biorefinery.
The projects will be evaluated in two phases. Award recipients will design and plan their facilities in Phase 1. In order to continue to Phase 2, projects will be evaluated on Phase 1 progress, as well as the ability to secure the required 50% cost share funding for Phase 2. DOE anticipates Phase 2 awards to be made in fiscal year 2018 to construct and operate the pilot- or demonstration-scale facility. Projects could receive additional federal funds of up to $15 million for pilot-scale facilities or $45 million for demonstration-scale facilities.
Audi developing modular assembly principle as successor to production line; Győr testing for 2018 e-tron electric motor production
December 19, 2016
Audi is developing a new modular assembly principle intended as the enabler of the post-production line assembly era. Modular assembly—intended to address the need for growing complexity and flexibility in production—breaks up the traditional fixed-rhythm production line into individual process steps.
In the latest issue of Audi Encounter, Fabian Rusitschka, managing partner of Ingolstadt-based startup arculus GmbH, Audi’s partner in developing this concept, noted that while the current A3/Q2 production line has around 160 process steps, modular assembly turns that into roughly 200 spatially distinct stations manned by one or two people. The processes each have different timing, and are flexible. Audi anticipates modular assembly will deliver productivity benefits of at least 20%. While development of the principle is ongoing, Audi has begun to use modular assembly in developing the production process for the electric motor for the 2018 e-tron SUV (C-BEV) (earlier post).
Continental producing 48V hybrid drives at Nuremberg plant; in use in Renault diesels by end of year
December 16, 2016
Continental’s new 48V hybrid drives are making their first appearance in series production vehicles. (Earlier post.) Manufactured at Continental’s Nuremberg plant, these first series-production 48V hybrid drives will be applied in “Hybrid Assist” diesel variants of both the new Renault Scénic and Grand Scénic models from the end of this year.
Just three years after the start of the project, the Nuremberg location developed a modular manufacturing concept that it uses to manufacture efficiently and in line with the cost structures of the volume market. To do so, the supplier invested around €15 million (US$15.7 million) in new production equipment. Using the currently installed equipment, up to 200,000 vehicles can be furnished with 48-volt drives.
ITM Power to launch 100 MW electrolyzer plant designs at Hannover Messe 2017
December 13, 2016
ITM Power will showcase a series of large scale electrolyzer configurations up to 100MW in size at Hannover Messe 2017 (24 - 28 April). This is in response to utility and oil and gas industry demand for larger scale industrial installations.
ITM Power has sold a number of MW-scale plants over the last year and is now responding to enquires for much larger plant for bus and heavy goods vehicle refueling stations in the to 10MW range and, increasingly, industrial applications ranging from power-to-gas, refineries and steel-making in the 10MW to 100MW range.
CMU study suggests difficulties in reaching targeted low price points for Li-ion batteries
December 11, 2016
A new study by a team at Carnegie Mellon University examining the costs for varied cell dimensions, electrode thicknesses, chemistries, and production volumes of cylindrical and prismatic Li-ion batteries finds that although further cost savings are possible from increasing cell dimensions and electrode thicknesses, economies of scale have already been reached, and future cost reductions from increased production volumes are likely to be minimal.
Their findings suggest that prismatic cells, which are able to further capitalize on the cost reduction from larger formats, can offer further reductions than those possible for cylindrical cells. However, none of these changes are sufficient to reach the DOE energy storage target of $125 kWh by 2020, the study found. Even in the most optimistic scenario, when the cells are the largest (20720), electrodes the thickest (100 mm), and the production volume is 8 GWh per year, the cost per kWh for LMO cells is well above the DOE target. NCA cells are $206 kWh-1 and NMC cells are $180 kWh-1. Their paper is published in the Journal of Power Sources.
Nissan introduces driverless towing system at Oppama Plant using modified LEAF
December 05, 2016
Nissan Motor has introduced Intelligent Vehicle Towing (IVT), a fully automated vehicle towing system, at its Oppama Plant. The IVT system uses a modified Nissan LEAF autonomously to tow trollies carrying finished vehicles between designated loading and unloading points at the plant.
Unlike conventional automatic guided vehicle systems for transporting parts, which often require the installation of rails or extensive use of magnetic tape, this system does not need any special infrastructure to operate. This new project, which utilizes mapping and communication technologies to link an intelligent and all-electric car to infrastructure, is a step towards the realization of Nissan Intelligent Integration, a component of Nissan’s Intelligent Mobility vision.
BMW Group expands BMW i Ventures role with new €500M fund; widened scope of investment, greater independence
December 01, 2016
The BMW Group is expanding the remit of its BMW i Ventures venture capital unit and creating a new fund of up to €500 million (US$531 million) over ten years to support it. The new fund will allow BMW i Ventures to make investments in a wider range of areas, such as autonomous driving and digitalization, and to secure continued access to the technologies of the future.
BMW i Ventures’ previous focus on mobility services and electro-mobility will be expanded to cover the BMW Group’s full innovation spectrum in all areas of Strategy Number ONE > NEXT, even those outside of the traditional automotive value chain. Future topics for exploration will focus on “Enabling Technology and Digital Vehicle Technology”, “Mobility and Digital Services”, “Customer Experience” and “Advanced Production Technology”.
Daimler/Secar CRP hybrid struts receive AVK Innovation AWARD; intelligent material mix allows large-scale production
As part of a development project, researchers at Daimler AG and the Austrian CRP (carbon fiber reinforced plastics) applications specialist Secar Technologie GmbH have developed an innovative new CRP composite pultrusion process enabling carbon fibers and metal to be pultruded in profile form in larger volumes.
Pultrusion is a continuous molding process in which reinforcing fibers are saturated with a liquid polymer resin and then carefully formed and pulled through a heated die to form a part. Pultrusion results in straight constant cross section parts of virtually any shippable length.
Audi deploying smart glove Mark from ProGlove in logistics department at Ingolstadt
November 29, 2016
Audi has begun using smart gloves from Munich-based startup ProGlove in its international logistics department at the Audi plant in Ingolstadt, where the group handles the worldwide dispatch of car components.
The glove—named “Mark”—has an embedded barcode scanner on its back; employees trigger the scanning function by pressing the thumb and first finger together. As a result, the users have both hands free and can work more ergonomically, without needing to pick up and put down a conventional barcode scanner. After a four week pilot phase, Audi employees are now using ten of these wearables in five positions in the Ingolstadt plant.
BMW, Dürr, BASF integrated paint process cuts 12 kt CO2 annually
November 23, 2016
The BMW Group saves 12,000 tons of CO2 annually during automotive production at its Munich plant by eliminating one step from the paint process. In other words, compared to a conventionally coated vehicle, a car coated with the shortened process can drive the first 420 kilometers with a net zero carbon footprint. In addition, the process saves as much energy as the amount needed by 250,000 Munich residents to wash one load of laundry every week.
These are the findings of a new TÜV-certified study conducted by the BMW Group together with the mechanical and plant engineering firm Dürr and BASF’s coatings experts.
Volkswagen investing €3.5B in German plants for e-mobility and digitalization; MEB production, pilot plant for batteries and modules
November 18, 2016
Volkswagen will invest €3.5-billion (US$3.7-billion) investment in the future-oriented areas of e-mobility and digitalization for its German plants. As part of an agreement with its General Works Council (i.e., labor), the Board of Management announced that the Volkswagen brand’s German plants will develop and produce electric vehicles and components based on the Modular Electric Drive Kit (MEB). (Earlier post.)
The MEB is the foundation for an entirely new generation of long-range battery-electric vehicles that will be connected, autonomous, open and priced for the volume market as required by Volkswagen’s positioning. The first production MEB vehicle, a version of the I.D. concept shown this year at the Paris show (earlier post), will—with a range of up to 373 miles and a market introduction in 2020—be priced approximately at the level of a diesel Golf, before any subsidies.
Dürr introduces new generation of painting robots with greater kinematic freedom; Industry 4.0
November 11, 2016
Dürr has introduced its next-generation of painting robot: the new Ecopaint Robot. With its greater kinematic freedom, the EcoRP E043i model with its seven-axis kinematic system enlarges the work zone and can eliminate the need for a linear displacement rail. This can significantly reduce investment and maintenance costs in the paint booth. Another newly developed product, the EcoRCMP2 robot control, is a key module of the Smart Factory.
Conventionally, paint robots are usually equipped with six axes. A displacement rail in the booth wall ensures that the robot can move parallel with the car body in the paint booth and thereby reach all car body areas. The new Dürr robot has now been equipped with a seventh rotatory axis. This significantly increases flexibility and versatility,said Dr. Hans Schumacher, President and CEO of Dürr Systems AG.
Borgward to build manufacturing facility in Bremen; all-electric-drive Borgward BX7 first model; Industry 4.0
October 27, 2016
Borgward Group AG, the reincarnation of the German automaker that ceased operations in 1961 (earlier post), will be returning to Bremen and building a production facility there. Bremen was the former home of Borgward, and the German automotive company produced around 1.2 million Borgward, Lloyd, and Goliath brand vehicles here from the 1920s until it ceased operations.
In accordance with Borgward’s announcement that it will begin sales in Europe with electric SUVs, the first model to be produced in Bremen will be a Borgward BX7 with an all-electric drive system. (Earlier post.) The company also plans to manufacture electric and plug-in-hybrid versions of the BX5 series and other models. Construction of the new manufacturing facility is scheduled to begin in early 2017. Production will be launched at the plant a year later, in 2018.
Columbia team develops new prelithiation method to increase Li-ion battery energy density by 10-30%
October 24, 2016
A team at Columbia University, with colleagues from Institute Recherche d’Hydro-Québec (IREQ), has developed a new pre-lithiation method to increase the energy density of lithium (Li-ion) batteries by utilizing a trilayer structure that is stable even in ambient air. This makes the battery both longer lasting and cheaper to manufacture. The work, which may improve the energy density of lithium batteries by 10-30%, is published in the ACS journal Nano Letters.
Li-ion batteries are produced in a discharged state; however, a considerable amount of active Li+ ions are lost during the initial charge due to the formation of the solid electrolyte interphase (SEI) on the anode surface. This results in a low initial coulombic efficiency and lowers the energy density of full cells. This step is even more critical in nanostructured anodes with high specific capacity, such as Si and Sn, due to their high surface area and large volume change.
CarboSax: new joint venture for more sustainable carbon fiber production forms in Germany
October 13, 2016
PD Glasseiden, a Germany-based producer of fiberglass; European Carbon Fiber GmbH; and the ForschungsCampus Open Hybrid LabFactory e.V., established under the auspices of the Lower Saxony Research Centre for Vehicle Technology at the TU Braunschweig and Volkswagen AG have formed a joint venture—CarboSax GmbH—to pursue developing, manufacturing and distributing more sustainable carbon fibers in Germany.
In the first step at a location in Chemnitz, Saxony, CarboSax will build a pilot line for the sustainable production of carbon fibers. The objective of this carbon fiber pilot line production is a significant reduction in production costs by 30% over currently available commercial carbon fibers. This cost reduction is required to further enable the use of carbon fiber in mass production in the automotive industry, mechanical engineering and wind power. An equal objective is a reduction of at least 50% in CO2 emissions from carbon fiber production.
FANUC to build factory of the future using NVIDIA AI platform; self-teaching robots in the FIELD system
October 05, 2016
NVIDIA and FANUC Corporation are collaborating to implement artificial intelligence on the FANUC Intelligent Edge Link and Drive (FIELD) system to increase robotics productivity and bring new capabilities to automated factories worldwide.
Adding AI to the FIELD system will give robots the ability to teach themselves to do tasks faster and more efficiently. By learning together, what used to take a single robot 8 hours can now be done by eight robots in an hour.
Schaeffler and IBM sign Watson IoT partnership; Industry 4.0
October 04, 2016
Leading automotive and industrial supplier Schaeffler has signed a multi-year strategic partnership agreement with IBM to accelerate the digital transformation of its entire operations and customer solutions using Watson’s cognitive intelligence and insight from billions of sensors that make up the Internet of Things (IoT).
Schaeffler manufactures millions of precision-engineered products that help to keep the world’s machines moving—from those that go into automotive clutch systems, to those in hybrid engines and the huge industrial bearings used in wind turbines. Through the agreement, Schaeffler will tap IBM’s cloud-based Watson IoT technologies to help transform every aspect of its business from product development, through to manufacturing and its supply chain, sales and aftersales service.
Audi opens €1B San José Chiapa plant in Mexico; 1st on N.A. continent; Smart Factory
October 02, 2016
Audi is further expanding its worldwide production network with the opening of the company’s first automobile plant on the North American continent. This will be the first time the company has produced a model for the global market at a location outside of the European continent.
Audi will produce the new generation of the Audi Q5 for the world market in San José Chiapa in Mexico’s federal state of Puebla. The €1-billion plant has an annual production capacity of approximately 150,000 premium SUVs. By the end of the year, a total of 4,200 jobs will be created locally at Audi México.
New Audi paintshop at Ingolstadt; heating energy & water per car down by 20%, CO2 by 30%, VOCs by 90%; bell-bell
September 22, 2016
Audi has put a new topcoat paint shop into operation at its plant in Ingolstadt. The new paint shop incorporates technologies such as air recirculation, dry separation and exhaust air cleaning that enable a significant reduction in the use of resources. Heating energy and water consumption per car are reduced by 20%. Air recirculation also helps to reduce CO₂‑emissions per painted car by 30%, while the cleaning of exhaust air reduces emissions of volatile organic compounds (VOCs) by 90%.
The new topcoat point line‑in the north of the plant site also introduces state‑of‑the‑art painting technology at Audi: paint‑application equipment with robot technology and electrostatic high‑speed rotation spray guns carry out the “bell‑bell” painting process fully automatically.
GM commits to 100% renewable energy by 2050
September 15, 2016
General Motors plans to generate or source all electrical power for its 350 operations in 59 countries with 100% renewable energy—such as wind, sun and landfill gas—by 2050.
This new renewable energy goal, along with the pursuit of electrified vehicles and efficient manufacturing, is part of the company’s overall approach to strengthening its business, improving communities and addressing climate change. GM is also joining RE100, a global collaborative initiative of businesses committed to 100 percent renewable electricity, working to increase demand for clean power.
Kiel nanoscale-sculpturing makes metal surfaces strong, resistant, and multifunctional; multi-material joining
September 08, 2016
Researchers at the University of Kiel (Germany) have developed a new process—which they call “nanoscale-sculpturing”—for the surface preparation of metals.
Nanoscale-sculpturing, which is based on knowledge from semiconductor etching, turns surfaces of everyday metals into their most stable configuration, but leaves the bulk properties unaffected. Thus, nanoscale-sculpturing ensures stronger, reliable joints to nearly all materials, reduces corrosion vastly, and generates a multitude of multifunctional surface properties. An open-access paper on their work is published in the RSC journal Nanoscale Horizons.
Stratasys demonstrates next-gen 3D printing for aerospace and automotive manufacturing; partnering with Ford
September 06, 2016
Stratasys Ltd., the 3D printing and additive manufacturing solutions company, will preview demonstrations of next-generation manufacturing technologies at IMTS 2016 (International Manufacturing Technology Show, 12-17 September) as part of its SHAPING WHAT’S NEXT vision for manufacturing.
The Stratasys Infinite-Build 3D Demonstrator is designed to address the requirements of aerospace, automotive and other industries for large lightweight, thermoplastic parts with repeatable mechanical properties. The Infinite-Build 3D Demonstrator features a novel approach to Fused Deposition Modeling (FDM) extrusion that increases throughput and repeatability.
DOE HPC4Mfg program funds 13 projects to advance US manufacturing; welding, Li-S batteries among projects
August 31, 2016
A US Department of Energy (DOE) program designed to spur the use of high performance supercomputers to advance US manufacturing has funded 13 new industry projects for a total of $3.8 million. Among the projects selected are one by GM and EPRI of California to improve welding techniques for automobile manufacturing and power plant builds in partnership with Oak Ridge National Laboratory (ORNL).
Another one of the 13 projects is led by Sepion Technologies, which will partner with LBNL to make new membranes to increase the lifetime of Li-S batteries for hybrid airplanes.
AK Steel introduces NEXMET family of next generation high strength steels for automotive lightweighting
August 22, 2016
AK Steel launched NEXMET, an new family of high strength steels for use in automotive lightweighting applications. These products are specifically designed to assist automotive original equipment manufacturers (OEMs) in meeting 2025 US Corporate Average Fuel Economy (CAFE) targets.
AK Steel’s NEXMET family of products will offer high strength, greater ductility (elongation), and improved formability solutions for a range of needs for structural and exterior automotive body lightweighting uses.
ExxonMobil & Georgia Tech CMS membrane brings advantages of reverse osmosis separations to hydrocarbon mixtures; potential significant cuts in chemical manufacturing energy use & emissions
August 19, 2016
Scientists from ExxonMobil and the Georgia Institute of Technology have developed new free-standing carbon molecular sieve (CMS) membrane technology that could significantly reduce the amount of energy and emissions associated with manufacturing plastics. Results of the research were published in Science. Using a molecular-level filter, the new process employs a form of reverse osmosis to separate para-xylene, a chemical building block for polyester and plastics, from complex hydrocarbon mixtures. The current commercial-scale process used around the world relies on energy and heat to separate those molecules.
Reverse-osmosis membranes are already widely used to desalinate seawater, consuming a fraction of the energy required by thermally driven processes. The new organic solvent reverse osmosis process is believed to be the first use of reverse osmosis with carbon membranes to separate liquid hydrocarbons.
DOE to award up to $137M for SuperTruck II, Vehicle Technology Office programs
August 16, 2016
The US Department of Energy (DOE) will invest up to $137 million in two programs, subject to appropriations, to develop next-generation technologies that will support industry in going beyond the newly announced Phase II standard for medium- and heavy-duty vehicles (earlier post) and also accelerating technology advances for passenger cars and light trucks.
One initiative, SuperTruck II (earlier post), will award $80 million to four projects to develop and to demonstrate cost-effective technologies that more than double the freight efficiency of Class 8 trucks. Through the other initiative, the Office of Energy Efficiency and Renewable Energy Vehicle Technologies Office Program Wide Funding Opportunity Announcement (earlier post)selections, 35 new projects will receive $57 million to develop and deploy a wide array of cutting-edge vehicle technologies, including advanced batteries and electric drive systems, to reduce carbon emissions and petroleum consumption in passenger cars and light trucks.
CALSTART white paper shows nationwide tech supplier industry ready to support more efficient heavy-duty trucks and buses
August 12, 2016
A new high-level white-paper from clean transportation industry group CALSTART shows that US companies that develop and manufacture high-efficiency, low-carbon technologies for heavy-duty vehicles are ready to support more efficient trucks and buses.
In a first attempt to gauge the scope of the United States’ high-efficiency technology supplier sector for heavy-duty trucks and buses, CALSTART conducted an initial scan of businesses and identified and mapped 255 companies. The firms range from vehicle manufacturers to component suppliers to technology developers, and operate from 535 facilities in 40 states, impacting 80% of the nation.
Researchers gain better insight into transformation of steel; managing nucleation could limit need for alloying elements
August 10, 2016
Researchers at TU Delft have shed new light on the process of nucleation in the polymorphic transformation of solid materials—specifically, steel. Polymorphism is the ability of a solid material to exist in more than one phase or crystal structure. Polymorphism may occur in metals, alloys, ceramics, minerals, polymers, and pharmaceutical substances.
In an open access paper published in Nature’s Scientific Reports, the team presented in-situ three-dimensional x-ray diffraction (3DXRD) microscopy measurements of the ferrite (α) to austenite (γ) transformation in steel during heating, which the team performed at the European Synchrotron Radiation Facility.
Ford’s new Dagenham Diesel EcoBlue engine production line reduces energy and water use by more than 50%
August 04, 2016
The new Ford EcoBlue diesel engine production line at Dagenham Engine Plant will reduce water and energy consumption by more than 50%. Dagenham Engine Plant is Ford’s largest diesel engine production facility globally, and produced the first EcoBlue diesel engine (earlier post) in April this year. Water usage per engine will be among the lowest at any Ford manufacturing facility worldwide, delivering an anticipated annual saving of 17.5 million liters of water compared with 2011—enough to fill seven Olympic-size swimming pools.
The reduction in the volume of coolant pumped around the facility also helps to significantly reduce energy usage. Three smaller coolant systems require around 70% less energy, and contribute to reducing energy use per engine from 188 kWh in 2011 to 92 kWh in 2016—the energy saved is roughly enough to power an average house for a week.
SMDI releases steel roadmap for automotive; Gen3 AHSS
August 02, 2016
Over the past 10 years, new steel innovations have reduced automotive component and sub-system mass by nearly 25%; some studies have shown mass savings up to 29% versus traditional mild steel benchmarks. The Steel Market Development Institute (SMDI)—a business unit of the American Iron and Steel Institute (AISI)—has now released its 2016 Steel Industry Technology Roadmap for Automotive.
The roadmap outlines the long-term technology needs to support future automotive material selection decisions with advanced high-strength steel (AHSS) including, optimized design, fuel economy, strength and durability, environmental performance and value.
EIA projects energy intensity of US steel production to drop 27% by 2040
July 29, 2016
Steel production is energy-intensive; in 2015, the steel industry accounted for 1.5% of all industrial shipments in the US but 6.1% of industrial delivered energy consumption. The US Energy Information Administration’s (EIA) Annual Energy Outlook 2016 (AEO2016) Reference case projects that energy use in the steel industry will further increase by 11% over 2015–2040.
Over the same period, however, the AEO2016 projects in its Reference case a 27% drop in the steel industry’s energy intensity, compared with an 18% reduction in total industrial energy intensity. Several alternative cases examine drivers for further energy intensity reductions in the steel industry.
Study: Overall automotive aluminum recycling rate above 90%
New research from the Worcester Polytechnic Institute’s (WPI) Center for Resource Recovery and Recycling calculated an overall recycling rate of 91% for automotive aluminum. The peer-reviewed study, funded by the Aluminum Association, examines how much aluminum used in the United States’ light-duty automotive sector is recovered and recycled from vehicles at end of life.
The new study, Automotive Aluminum Recycling at End of Life: A Grave-to-Gate Analysis, details a “grave-to-gate” analysis, which spans the moment an automobile becomes obsolete to the moment the aluminum metal units are completely recycled and enter back into life as input material for new applications, including vehicles. Researchers attribute automotive aluminum’s high recycling rate to the metal’s economic value, citing the “concerted effort to recover this valuable lightweight commodity from end-of-life vehicles.”
BMW provides some insight into Dingolfing eDrive competence center; motors, battery packs and more
During its Innovation Days 2016 event in Munich, the BMW Group provided some insight into its Dingolfing competence center for the manufacture of electric drive systems (eDrive). Dingolfing supplies the high-voltage batteries and other chassis and powertrain components for BMW i models and the BMW Group’s plug-in hybrid models—current (earlier post) and future.
Beginning with the launch of the first BMW i production models, the Dingolfing plant has produced high-voltage batteries and other powertrain and chassis components for these vehicles. Prior to that, the plant had supplied high-voltage batteries for the BMW Active E; BMW 3 Series ActiveHybrid; BMW 5 Series ActiveHybrid; and BMW 7 Series ActiveHybrid. Now, with the market launch of the first plug-in hybrid versions of the BMW core-brand models—for which the plant supplies the rear-mounted electric motors and all high-voltage battery packs—production of BMW eDrive components in Dingolfing is scaling up once again.
BMW introducing fully-automated, optical measuring cell in pilot plant; digitalization for production
July 28, 2016
The BMW Group has introduced a fully-automated, optical measuring cell in its pilot plant in Munich. Freely moving robot arms use sensors to create a three-dimensional image of an entire vehicle and generate a 3D data model from the data captured, with an accuracy of less than 100 µm. This allows barely visible deviations to be identified at an early stage.
The optical measuring cell is deployed at the interface between development and series production. It forms part of the BMW Group’s digitalization strategy for production and supports the high quality standards for production of premium vehicles. The next generation of the BMW 5 Series Sedan will be the first to benefit from this new technology.
BMW Group expands use of additive manufacturing processes in series production; planar technologies
July 13, 2016
The BMW Group has been using components from 3D printers in series production since 2012; more than 10,000 additively-manufactured parts are built into the Rolls-Royce Phantom. The Additive Manufacturing Center at the company’s Research and Innovation Centre (FIZ) has also been using these forming processes to produce parts for the new Rolls-Royce Dawn since the beginning of the year.
The BMW Group is steadily pursuing the evolution and use of advanced additive-manufacturing methods, and says it will continue to expand the application of 3D printing in the future. Planar 3D printing technologies will enable much faster production times and more economical production.
Volkswagen brand says it has met 2018 Think Blue. Factory. environmental targets; environmental compatibility of car production improved by 25%
July 09, 2016
The Volkswagen brand announced that it has reached the self-defined sustainability target for production set out in Think Blue. Factory. for 2018. (Earlier post.) At the brand’s production facilities throughout the world, vehicles and components are now manufactured in a way which is 25% more environmentally compatible than five years ago.
Taking the average of the five agreed environmental indicators for the Volkswagen brand, environmental impact has been reduced by 25.3%, with energy consumption down by 24.7%; CO2 emissions by 29.1%, waste production by as much as 46.5%; water consumption by 18.2%; and solvent emissions by 8.2% between 2010 and the end of 2015. These figures are determined per vehicle or component produced.
Porsche opens new plant for eight-cylinder engines; digitalization and data management; V8s for all VW Group brands
July 08, 2016
Porsche has officially dedicated a new engine plant for eight-cylinder engines. The factory at the main site in Stuttgart-Zuffenhausen works with state-of-the-art production methods, leveraging digitalization and data management. At full plant utilization produces around 200 eight-cylinder V-engines daily. The sports car manufacturer has invested nearly €80 million in the new production facility.
Porsche’s new engine plant will also contribute towards synergies within the Volkswagen Group. Plans call for producing the eight-cylinder V-engines for all Group brands in Stuttgart-Zuffenhausen from this point forward.
Renault-Nissan Alliance delivers €4.3B synergy target early; autonomous drive and connectivity expected to deliver major savings
July 06, 2016
Renault-Nissan Alliance generated €4.3 billion (US$4.8 billion) in synergies in 2015, one year ahead of schedule and an increase of 13% from 2014. Purchasing, engineering and manufacturing were the main contributors.
The Common Module Family and cross-production continue to reduce costs, while the development of technologies including autonomous drive and vehicle connectivity is expected to generate major savings moving forward. With the convergence, the Alliance expects to generate at least €5.5 billion (US$6.1 billion) in synergies in 2018
DOE to award up to $70M for Manufacturing Institute focused on reuse, recycling and remanufacturing
June 27, 2016
The US Department of Energy (DOE) will award up to $70 million for a new Clean Energy Manufacturing Innovation Institute focused on improving technologies and processes to achieve cost parity of recycled and waste materials with primary feedstocks, while improving material efficiency in manufacturing processes.
The new funding opportunity—(DE-FOA-0001594) “Reducing EMbodied energy And Decreasing Emissions (REMADE) in Materials Manufacturing— will support the REMADE in America Institute. The REMADE institute will enable the development and widespread deployment of key industrial platform technologies that will significantly reduce life-cycle energy consumption and carbon emissions associated with industrial-scale materials production and processing by creating new technologies for reuse, recycling, and remanufacturing of materials.
Lamborghini inaugurates new Advanced Composite Structures Laboratory carbon fiber research center in Seattle
June 21, 2016
Automobili Lamborghini celebrated the grand opening of its new Seattle-based carbon fiber research facility, the Advanced Composite Structures Laboratory (ACSL). Operating as an entity outside of the company's headquarters in Sant’Agata Bolognese, the ACSL is responsible for unlocking new potential in carbon fiber.
Seattle is a strategic location for the ACSL, particularly because of its collaboration with Boeing in working toward carbon fiber innovations that are beneficial in both automotive and aerospace applications. The grand opening of the new ACSL also marks the 30th anniversary of Lamborghini’s use of carbon fiber reinforced polymer in its vehicles.
LA-based SMLC to lead new DOE Smart Manufacturing Innovation Institute; ~$800M for 5 new hub competitions
At an event in Washington, President Obama announced that the Smart Manufacturing Leadership Coalition (SMLC) will lead the new Smart Manufacturing Innovation Institute, in partnership with the Department of Energy. The winning coalition, headquartered in Los Angeles, California brings together a consortium of nearly 200 partners from across academia, industry, and non-profits to spur advances in smart sensors and digital process controls that can significantly improve the efficiency of US advanced manufacturing.
The Smart Manufacturing Innovation Institute is the ninth manufacturing hub awarded by the Obama Administration. The President also announced the launch of five new manufacturing hub competitions, which will invest nearly $800 million in combined federal and non-federal resources to support transformative manufacturing technologies from collaborative robotics to biofabrication of cells and tissues, to revolutionizing the ways materials can be reused and recycled.
New aluminum-cerium alloys could boost rare earth production; improved energy efficiency of engines
June 03, 2016
Researchers at the Department of Energy’s Oak Ridge National Laboratory (ORNL) and partners Lawrence Livermore National Laboratory (LLNL) and Eck Industries have developed aluminum-cerium (Al-Ce) alloys that are both easier to work with and more heat tolerant than existing products.
ORNL scientists Zach Sims, Michael McGuire and Orlando Rios, along with colleagues from Eck, LLNL and Ames Laboratory in Iowa, discuss the technical and economic possibilities for aluminum–cerium alloys in an article in JOM, a publication of the Minerals, Metals & Materials Society. The alloys have the potential to jump-start US production of rare earth elements, the researchers suggested.
RoMulus project: developing intelligent multi-sensor systems for Industry 4.0
May 29, 2016
The RoMulus (Robust multi-sensor technology for status monitoring in Industry 4.0 applications) research project project sponsored by the German Federal Ministry of Education and Research (BMBF) is focused on simplifying and accelerating the development and use of intelligent multi-sensor systems for Industry 4.0——the digitalization of production processes based on devices autonomously communicating with each other along the value chain. (Earlier post.)
Multi-sensor systems are key components for the success of Industry 4.0 applications. They record, process, and transmit a number of measurement parameters, such as pressure, acceleration, and temperature, all in a highly compact space. Machines are not the only ones to receive such sensors; workpieces are also increasingly being fitted with the intelligent sensor systems so that each product can provide its blueprint and report its manufacturing status. Based on this information, production is largely able to organize and monitor itself.
NIST, partners create new international standard to improve sustainable manufacturing
May 27, 2016
A public-private team led by the National Institute of Standards and Technology (NIST) has created a new international standard that can “map” the critically important environmental aspects of manufacturing processes, leading to significant improvements in sustainability while keeping a product’s life cycle low cost and efficient.
ASTM member Kevin Lyons, group leader, National Institute of Standards and Technology, notes that the new standard (ASTM E3012-16, Guide for Characterizing Environmental Aspects of Manufacturing Process) provides structure and formalism to ensure consistency in characterizing sustainable manufacturing processes. From there, computers can provide information and analytics on production and performance. Lyons explains that using the standard will help business transition into science-based modeling, decision-making, and production.
Novelis commissions $120M finishing line for automotive aluminum sheet; importance of the closed-loop recycling program
May 26, 2016
Novelis, the world leader in aluminum rolling and recycling, celebrated the commissioning of its third CASH (Continuous Annealing Solution Heat) treatment finishing line for aluminum automotive sheet in Oswego, NY. Installed to support the production of stronger, lighter and safer vehicles, the $120-million CASH 3 line expands the company’s production to supply aluminum sheet for the body and cargo box of Ford’s 2017 F-150 SuperDuty pickups. The CASH 1 and 2 lines supply aluminum for Ford’s F-150. With the addition of the third CASH line in Oswego, Novelis has furthered its position as the leading automotive aluminum sheet supplier in North America.
The commissioning of the CASH 3 line also marks the expansion of the benchmark closed-loop recycling program—developed by Novelis, Ford and Penske—which processes roughly 25 million pounds of automotive aluminum scrap per month—more than enough to build 30,000 F-150 bodies. (Earlier post.) Recycled aluminum, which requires significantly less energy and water, avoids 95% of the greenhouse gas emissions associated with primary aluminum production.
PSA Group outlines powertrain production strategy: gasoline PHEVs, EVs and next-gen diesel and gasoline engines
May 25, 2016
As part of the energy transition process and in line with the technological offensive spelled out in its Push to Pass strategic plan (earlier post), PSA Group will focus on diversifying its offerings with plug-in hybrid gasoline systems and next-generation electric powertrains. The latter will be used in particular to equip e-CMP, its future electric platform developed in partnership with Dongfeng Motors. (Earlier post.) At the same time, the Group will continue to develop next-generation internal combustion engines, both gasoline and diesel.
For strategic reasons, PSA Group will manufacture the main electric powertrain components in France, signalling its determination to develop high-tech operations in profitable niche markets. The electric powertrain will be produced at the Trémery/Metz centre of excellence, while the gear systems will be manufactured at the Valenciennes plant.
Amprius demonstrates new tool for roll-to-roll manufacturing of high-energy batteries with Si nanowire anodes
May 24, 2016
Amprius, a manufacturer of high-energy lithium-ion batteries using silicon nanowire anodes (earlier post), has demonstrated a novel tool for high-volume manufacturing. The new tool, a first-of-its-kind system for inline, continuous, and roll-to-roll production of three-dimensional silicon nanowire anodes, will enable Amprius to scale manufacturing and deliver lightweight and long-lasting batteries for unmanned vehicles, wearable technologies, and electric vehicles.
Amprius developed its new tool in partnership with Meyer Burger (Netherlands) B.V., a world leader in high-throughput deposition systems and processes. The tool uses a multi-step, Chemical Vapor Deposition (CVD) process to produce Amprius’ silicon nanowire anodes. Amprius will unveil its new manufacturing tool to a select group of industry partners on 29 June 2016, at a Meyer Burger facility in the Netherlands.
ORNL team develops laser process for lower cost, more robust joining of carbon fiber and aluminum
May 20, 2016
Researchers led by a team from Oak Ridge National Laboratory (ORNL) have developed a new laser process that could make joining carbon fiber composites and aluminum for lightweight cars and other multi-material high-end products less expensive—as well as making the joints more robust.
The process would replace the practice of preparing the surface of the materials by hand using abrasive pads, grit blasting and environmentally harmful solvents. Using a laser to remove layers of material from surfaces prior to bonding improves the performance of the joints and provides a path toward automation for high-volume use.
Max Planck, MIT researchers develop new strategy for high-entropy alloys; overcoming the strength/ductility tradeoff
May 19, 2016
Researchers at the Max Planck Institute in Dusseldorf, Germany, and MIT have developed a novel strategy to design nanostructured, bulk high-entropy alloys (HEAs) (earlier post) with multiple compositionally equivalent high-entropy phases. The new approach is described in a paper this week in the journal Nature.
The result, says C. Cem Tasan, the Thomas B. King Career Development Professor of Metallurgy in MIT’s Department of Materials Science and Engineering, also challenges the conventional wisdom that improving the strength of a metal alloy is always a tradeoff that results in a loss of ductility.
Volkswagen takes stake in German Research Center for Artificial Intelligence (DFKI); autonomous driving and the digital factory
May 14, 2016
Volkswagen is taking a stake in the German Research Center for Artificial Intelligence (DFKI), the world’s largest non-profit scientific institution specializing in artificial intelligence (AI). By acquiring participating in DFKI, the Volkswagen Group is reinforcing its research activities in the field of future-oriented digital technologies.
In addition to research in artificial intelligence, DFKI specializes in the fields of robotics, Industry 4.0 and driver assistance systems. In a joint project, Volkswagen and DFKI have started further to develop the software framework ROCK (Robotics Construction Kit) to allow direct, close cooperation between human beings and robots. The system was presented in a near-production scenario at the Volkswagen AG IT Symposium 2016.
ORNL exclusively licenses plasma processing technology for carbon fiber production to RMX Technologies; 75% less energy, 20% lower cost
May 13, 2016
RMX Technologies and the Department of Energy’s Oak Ridge National Laboratory have signed an exclusive licensing agreement for a new technology that significantly reduces the time and energy needed in the production of carbon fiber. Combing these benefits with a low-cost precursor currently in development, the result can be a carbon fiber product that is 40% less expensive to manufacture than current commercial products.
The ORNL/RMX plasma processing technology is a new approach to the oxidation stage of carbon fiber production in which polymer materials are oxidized (or stabilized) before carbonization. During oxidation, the thermoplastic precursor is converted to a thermoset material that can no longer be melted. Oxidation is the most time-consuming phase of the multistep carbon fiber conversion process.
Hemming of thin-gauge AHSS achieves 30% weight savings
May 12, 2016
Hemming is a forming operation which is used in the automotive industry to join two sheet metal panels together. During the process, the flange of the outer panel is bent over the inner one. It is commonly used to assemble the outer parts of a car, such as doors, hoods, trunk leads and fenders. The accuracy of the hemming operation is very important as it affects the surface appearance and thus influences surface quality
Novelis supplying aluminum for Cadillac CT6 in N America and China
May 10, 2016
Aluminum rolling and recycling leader Novelis announced that its aluminum is used in the new 2016 Cadillac CT6 body. The new mixed material vehicle construction featured in the Cadillac CT6 represents a first of its kind for General Motors (GM) in North America and China. (Earlier post.)
In North America, Novelis’ plant in Kingston, ON will supply GM’s Detroit-Hamtramck plant in Detroit, Michigan. Novelis’ plant in Changzhou, China will supply GM’s Shanghai plant, which will produce the CT6 manufactured locally in China.
PARC, ORNL and Ford collaborate on high-energy, high-power battery production for EVs using CoEx printing
April 28, 2016
PARC, a Xerox company, is collaborating with Oak Ridge National Laboratory (ORNL) and Ford Motor Company in a DOE-funded project that will use PARC’s novel CoEx printing technology (earlier post) to fabricate thick, higher energy and higher power battery electrodes with the end goal of enabling longer range and low cost electric vehicles.
The goal of the project—“Co-Extrusion (CoEx) for Cost Reduction of Advanced High-Energy-and-Power Battery Electrode Manufacturing”—is to demonstrate pilot-scale, electric vehicle (EV) pouch cells with a 20% improvement in gravimetric energy density (Wh/kg), and a 30% reduction in $/kWh costs.
Honda introduces new automotive assembly line system: Assembly Revolution Cell Line; first implementation in Thailand
April 21, 2016
Honda Motor Co. has deployed the first mass-production automobile assembly line with a main line that incorporates a flowing cell production system. Honda has named this the Assembly Revolution Cell (ARC) Line and introduced it in Honda’s new Prachinburi Plant in Thailand that became operational in March 2016.
The newly-developed ARC Line differs significantly from a conventional line production system and was developed by incorporating flowing cell production-style production units in the main line. In production on a conventional line—the foundation of automobile production to date—each line worker (production associate) takes charge of a single process and installs parts to vehicle bodies flowing on a conveyor. In cell production, by contrast, one production associate takes charge of a broader range of production processes and installs multiple parts.
Volkswagen plant in Wolfsburg opens competence center for manufacturing technology and innovation for new production technologies
Volkswagen has opened a competence center for technology and innovation and its Wolfsburg plant. Volkswagen employees will develop and test new production technologies on-site in the center’s near-production environment.
The innovation center has six sections: digital way; human-machine interaction (HMI); material flow and material handling; body construction; assembly; and ergonomics. Going forward, experts will be able to test their developments in continuous operation for a three- to six-month period and at the same time train employees on site in how to use the new technologies.
Ford launches 10-year project to transform Dearborn campus; sustainability in the built environment; Living Building Challenge
April 12, 2016
Ford Motor Company unveiled its plans to transform its Dearborn facilities into a modern, green and high-tech campus to foster innovation and help drive the company’s transition to an auto and a mobility company. The 10-year transformation of the company’s more than 60-year-old Dearborn facilities will colocate 30,000 employees from 70 buildings today into primarily two locations—a product campus and a world headquarters campus. More than 7.5 million square feet of work space will be rebuilt and upgraded into even more technology-enabled and connected facilities.
The transformation will integrate sustainability and innovation throughout the built environment, including a new Sustainability Showcase building on the product campus, which will aim to meet Living Building Challenge standards, the highest level of sustainability certification today. To be certified under the Challenge, projects must meet a series of ambitious performance requirements over a minimum of 12 months of continuous occupancy. Among the key criteria is that 100% of the building’s energy needs on a net annual basis must be supplied by on-site renewable energy. No combustion is allowed.