3DProCar

3DProCar - Flexible process chains for thermoplastic FKV components with complex geometry manufactured in one piece

3DProCar

Web technology and automotive technology, how do they go together? This age-old manufacturing technology and modern vehicle construction are combined in a highly innovative research project. Plastic and carbon fibers are preformed with innovative textile and weaving technology and then the finished body component is manufactured in an automated process.

In this context, the 3DProCar project contributes to the development of flexible process chains for thermoplastic, components made of fiber-reinforced plastics with complex geometry in one piece. The overall goal of the collaborative project is the simulation-based development of these complex process chains.

IBG Technology Hansestadt Lübeck GmbH is involved as an active partner in the subproject for the design, construction, and implementation of an automated preforming process for a new type of hybrid semi-finished products with “locally different levels of stiffnesses.” The development, technological implementation, and validation of a fully automated preforming and consolidation process for new hybrid semi-finished products with locally different levels of stiffness is carried out there. Preforming solutions by means of cooperating robot systems for the realization of complex forming processes are researched, developed, and validated for this purpose. The focus of the preforming system is on the fully automatic pickup, transport, possible manipulation (especially in the area of incorporated ribs), and the targeted storage of the semi-finished product, as well as a targeted draping process which implements the data of an offline simulation.

3DProCar Robot preforming complex
3DProCar Robot preforming complex

A second focus is the development and validation of the quality-assured, highly flexible consolidation process. The fact that this process no longer adversely affects component draping is of particular importance. No form of processing may change the draping. The removal of the finished component from the consolidation tool is also being worked out as part of this development.

The joint project is actively carried out by 12 partners from science and industry. The partners of the IBG subproject include Daimler AG, Dynamore GmbH, IDEA GmbH, and the Institute for Lightweight Engineering and Polymer Technology of the Dresden University of Technology.

Funding:

This research and development project is funded by the Federal Ministry of Education and Research (BMBF) as part of the framework concept “Innovations for the Production, Services, and Work of Tomorrow” and the Energy and Climate Fund. It is supervised by the Project Management Agency Karlsruhe (PTKA).

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Optimisation of production processes in all sectors

Automation and Robotics as instruments for increasing the efficiency of industrial production processes are designed and developed by the IBG / Goeke Technology Group, under the guiding principle "Transformation of human genius into technical perfection". Technology solutions and high technology systems are designed for the individual requirements of our global clients and all sectors, from our main headquarters in Neuenrade, Dortmund.

Automotive solutions, robotics-based solutions and other technology systems from the IBG / Goeke Technology Group are best-in-the-class industry technologies. We achieve this top level in industrial technology through close interlinking of decades of experience as engineers with science and research. We ensure that our know-how in the automotive and robotics fields, as well as our technology service, benefits from optimisation of industrial processes, but without losing sight at the person at the centre of it all – learn more about our social engagement here.

  • Automation of complex manufacturing and assembly systems
  • Configuration of special systems
  • Development and construction of customer-specific special machines