azl – aachen center · aachen center for integrative lightweight production – azl 4 equipment...
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AZL – Aachen Center for Integrative Lightweight Production
Prof. Dr. Christian Brecher
Prof. Dr. Christian Hopmann
Dr. Michael Emonts
Dr. Kai Fischer
Dr. Michael Effing
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1Aachen Center for Integrative Lightweight Production – AZL www.azl.rwth-aachen.de
New RWTH Aachen Campus2 areas with 800.000 m²
Emphasis on production technology: – 62 professorships– 11.350 students, 2.600 employees
RWTH Aachen is the European Center forProduction Technology
Area 1: Melaten
Area 2: West
RWTH Aachen260 research institutes
482 professorships
4.500 scientists
40.358 students
2 clusters of excellence:– “Integrative Production Technology for High-
Wage Countries” – “Tailor-made Fuels form Biomass”
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2Aachen Center for Integrative Lightweight Production – AZL www.azl.rwth-aachen.de
Development of student numbers of Faculty ofMechanical Engineering at RWTH Aachen
Ges
amtz
ahl S
tudi
eren
de
num
bern
ewen
scrip
tions
0
500
1000
1500
2000
2500
3000
0
2.000
4.000
6.000
8.000
10.000
12.00084
/85
85/8
686
/87
87/8
888
/89
89/9
090
/91
91/9
292
/93
93/9
494
/95
95/9
696
/97
97/9
898
/99
99/0
000
/01
01/0
202
/03
03/0
404
/05
05/0
606
/07
07/0
808
/09
09/1
010
/11
11/1
212
/13
13/1
411
.350
Gesamtanzahl Studierende (WS) incl. Wirtsch. Ing.
Anzahl Studierende 1. Semester (WS)2.680
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3Aachen Center for Integrative Lightweight Production – AZL www.azl.rwth-aachen.de
Composite Competences along the Value Chain are present at the new RWTH Campus
Textiles (ITA)Plastics and Composites (IKV)Production Technology (WZL, IPT, ILT, ISF)Quality Assurance (WZL)Lightweight Design (ilb)Automotive (ika)
8 InstitutesMore than 750 scientistsMore than 1.100 student workers
Composite Competences and Cooperation since more than 25 years
1987 2014
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4Aachen Center for Integrative Lightweight Production – AZL www.azl.rwth-aachen.de
Equipment available at the RWTH-Institutes (selection)
Mechanical testing (static, crash, fatigue)
Testing lab for fibres, textiles and preforms
Textile machines „from fibres to preforms“
Pultrusion- and filament winding equipment
RTM-systems, presses and autoclaves
Moulding machines for thermoplastic composites
Injection moulding machines
Prototype workshops
Machinery for manufacturing of pilot applications
Servo-hydraulic testing lab (incl. climate control)
Modular stiffness- and acoustic testing facilities
Impact testing
Crash facility for vehicle and component tests
Simulationhard and -software for simulation of complete vehicle models(u.a. 106 CPU Linux Cluster for managing confidential data:div. Solver, e.g. Abaqus explicit/implicit, LS-Dyna, ANSYS, PAMFORM, PAMCRASH and Fluent)
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5Aachen Center for Integrative Lightweight Production – AZL www.azl.rwth-aachen.de
The AZL is designed as the Integrative Solution Provider
All required competences along the value chain are present at the new campusIntegrative and interdisciplinary approach along the value chain
All competences availableat the RWTH Aachen Campus
Industrial Partners
Material supplierManufacturing equipment supplier Molder Tier 1/2 OEM
∑ 750 scientists working on production technologies, lightweight materials and lightweight applications
Cooperation
Materials
Molder
Manuf. Equipm. Supplier
Tier 1 / 2
OEM
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6Aachen Center for Integrative Lightweight Production – AZL www.azl.rwth-aachen.de
AZL – Addressed Branches and ProductsLight weight design for
Aerospace– Structural parts
Wind energy– Blades– Power train (gear housing, gear wheels , hollow shafts)– Nacelle and tower
Automotive industry– Bodywork– Structural parts– Power train (gear housing, shafts and gear wheels)
Transportation (Trucks, ships, trains, busses)– gear housing
(light weight design, reduction of noise emissions)– Structural parts
Sport and leisure industry– Sports equipment
Machine tools– Structural parts
(light weight design, stiffness, corrosion resistance)
Plant construction– Composite vessels and tubes
Chemical and food industry– Composite vessels and tubes
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7Aachen Center for Integrative Lightweight Production – AZL www.azl.rwth-aachen.de
AZL Market and Technology StudyKick-Off Meeting with Participants
Start of project: March 2013, duration: 12 months
International industrial consortium with 34 companies– 15 Material Suppliers – 6 OEM – 7 Tier 1/ Tier 2 – 6 Equipment Provider
Kick-Off Meeting: Feb. 06th 2013in Aachen:
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8Aachen Center for Integrative Lightweight Production – AZL www.azl.rwth-aachen.de
»Worldwide Market Study for Lightweight Applications«Current Status and Outlook
»Level 0« - MarketsDefinition of 5 target markets/ industries
»Level 1« - Market SegmentsDerivation of 47 market segmentsSelection of 13 attractive key segments based on pilotstudies (performed by Steering Comittee)
»Level 2« - Technology TreesDerivation of ~450 attractive components/ applications within the key segments
Pre-evaluation based on basic technology and marketcriteria, confirmed by expert interviewsSelection of 50 Highlight components
»Level 3« - Detailed Market Studies48 technology analyses including market size anddevelopment, technological maturity, competitors etc.
Selection of 12 Highlight components
»Level 4« - Business Cases12 detailed business cases including comprehensiveprofitability and technology analyses
Prioritization of components and enablingtechnologiesGoal of the 3. Report Meeting Workshop
- Task already accomplishedLevel 0Level 3 - Task still to be performed
Stag
e 2
Stag
e 1
Definition of relevant„trend markets“
Distribution into„segments“
Systematic searchbased on specificsearch parameters
Identification ofpotential enablers
Identification ofattractive
applications
Structuring ofMarkets/ technology
fields
Derivation based on current or expectedcapabilities
Systematic approach:
Definition ofstudy scope
Stag
e 3
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9Aachen Center for Integrative Lightweight Production – AZL www.azl.rwth-aachen.de
Exemplary ProceedingStage 1 – Pilot Study
Market SegmentationStructured overview on market segments, structureand overall market volume
Segment AnalysisOverview on high level chances, risks
Technology and market trends
Segement Evaluation High level aggregation of market and technologyintelligence
Selection of most promising segments based on expert knowledge (interviews) and appraisal of thesteering committee
2 31
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10Aachen Center for Integrative Lightweight Production – AZL www.azl.rwth-aachen.de
Exemplary ProceedingStage 1 – Pilot Study
Segment Sub-structureOverview on technology fields within the marketsegment at hand
Detailed Segment AnalysisDerivation of major challenges within these sub-segments in order to enable a focussed selectionof growing or developing marketsegments
»Technology Tree«Market requirement-based breakdown of relevant sub-segments into systems and components
Criteria-based selection of applications/ components (advantages during product usage, advantagesfor production, subjective »product experience«)
2 31
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11Aachen Center for Integrative Lightweight Production – AZL www.azl.rwth-aachen.de
Exemplary ProceedingStage 2 – Detailed Analysis
Value-Chain Overviewconnected and/or synergetic technologies withinthe value-chain of the component at hand
Visualization and quantification of added valuesteps
48 Detailed Technology and Market AnalysesDetailed Aggregation of relevant technology- andmarket-related information
Executive Summary for quick evaluation
2 31
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12Aachen Center for Integrative Lightweight Production – AZL www.azl.rwth-aachen.de
Exemplary ProceedingStage 3 – Business Cases
Application/ Component SelectionCriteria-based portfolio analysis of remainingapplications and components
Final selection of 12 most promising highlightapplications
12 Business Case AnalysesHighly detailed calculation of business cases for theselected highlight applications/ components
Derivation of relevant required technologies, materialsand/or services to address these highlights
Selection of most attractive components for furtherconsortial projects and implementation
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13Aachen Center for Integrative Lightweight Production – AZL www.azl.rwth-aachen.de
Integrative Production Technology and Material Science
Multi-Material-SystemsAutomation of Lightweight ProductionLight weight and recycling suited product development, manufacture, assembly, planning and quality assuranceMore efficient methods for processing, machining, assembly and recycling
Holistic consideration of light weight design operationsServices across branches, products and materials
Integrative Approach
Growing Industrial Demand
Production pre-
arrangements ManufactureAssembly/handling
Product development
Advance development Operation
Disassembly/
recycling
Production systems Plastics
Metals
Process technologies
Production and recycling managementProduction quality
FRP
FRP Composites
Business quality
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14Aachen Center for Integrative Lightweight Production – AZL www.azl.rwth-aachen.de
Cluster „Integrative Production Technology“ (Home of AZL)
Pic
ture
s: C
apric
orn
Dev
elop
men
t, H
enn
Arc
hite
kten
New Building complex of the new Cluster “Integrative Production Technology” at RWTH Aachen University:
25.000 m² Machinery Hall and Office Buildingsfor AZL, WBA and E-Lab
Infrastructure for additional 800 Scientists
3.000 m² for shops, gastronomy, service
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15Aachen Center for Integrative Lightweight Production – AZL www.azl.rwth-aachen.de
Cluster „Integrative Production Technology“ Home of AZL – Impressions
Source: Capricorn Development, Henn Architekten
25.000 m² Machinery Hall and Office Buildings for AZL, WBA and E-Lab
Infrastructure for additional 800 Scientists
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16Aachen Center for Integrative Lightweight Production – AZL www.azl.rwth-aachen.de
New AZL Equipment (Examples) in Addition tothe Existing Equipment of the Partner Institutes
Composite Press System– Table Size: 1,8 m x 2,8 m– Tonnage: 1.800 to
Handling Systems– Loading of press system– Handling of semi-finished
products– Handling and processing of parts– Integrated quality assurance
systems
Large-Scale ProductionSystems for– Injection molding– Compression molding– Thermoforming– Combined processing
15 m
6 m
Multifunctional Composite Press
Handling System(Process Preparation)
Handling System(Part Handling, Finishing)
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17Aachen Center for Integrative Lightweight Production – AZL www.azl.rwth-aachen.de
AZL Infrastructure and Services
AZL Development Centercompletion in 2014
Office building
Machinery hall
Staffing: – Scientists– Technicians– Designers
Founded in 2012
Full Scale Production Equipment for:Thermoplastic systemsThermoset systemsMultimaterial systems
Composite AcademyEducation for industrial staff– Technicians, lab workers, engineers, managersSeminarsSales and Marketing Excellence
Consultancy ServicesMarket studiesTechnology transferBenchmarkingInnovation management
S E
R V
I C
E S
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18Aachen Center for Integrative Lightweight Production – AZL www.azl.rwth-aachen.de
Production management
Produktions-vorbereitung Fertigung Montage/
HandhabungProdukt-
entwicklungVor-
entwicklung BetriebDe-
Montage/Recycling
Produktions-vorbereitung Fertigung Montage/
HandhabungProdukt-
entwicklungVor-
entwicklung BetriebDe-Montage/
Recycling
production -pre-arrangements
manufacture assembly/handling
product -development
pre development operation disassembly/
recycling
Integrative Strategic Research Topics
Efficient recycling processes
Production management for light weight components
Monitoring and optimization of quality
More efficient production systems and processes, new joining methods
New composites (organic, non-organic) and light weight structures
Design and simulation tools for light weight components
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19Aachen Center for Integrative Lightweight Production – AZL www.azl.rwth-aachen.de
Campus Melaten of RWTH Aachen University –Next location for your development site?
+5 anonymous
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20Aachen Center for Integrative Lightweight Production – AZL www.azl.rwth-aachen.de
Campus Project of RWTH - One of the largestEuropean research landscapes
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21Aachen Center for Integrative Lightweight Production – AZL www.azl.rwth-aachen.de
Campus Project of RWTH - One of the largestEuropean research landscapes
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22Aachen Center for Integrative Lightweight Production – AZL www.azl.rwth-aachen.de
Contact for further Information
Dr. Michael EmontsCEO AZL RWTH,Managing Director AZL Aachen GmbH
Tel.: +49 241/ 8904-150
Email: [email protected]
Dr. Kai FischerDivisional Director AZL RWTH: Production Technology Composites,Managing Director AZL Aachen GmbH
Tel.: +49 241/ 80-23884
Email: [email protected]
Dr. Michael EffingSenior Advisor AZL Aachen GmbH
Tel.: +49 241/ 80-23887
Email: [email protected]
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Partner Model of AZL Aachen GmbH
Introduction of Services and Partner Model in the Field of Lightweight Production
Dr. Michael Emonts
Dr. Kai Fischer
Dr. Michael Effing
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24AZL Aachen GmbH – Excellence in Lightweight Production
Partner of AZL –Excellence in Lightweight Production
Mission of AZL Aachen GmbH:
■ Industrial R&D-services in cooperationwith research institutes
■ Workshops and seminars forindustrial employees
■ Networking: Lightweight activities ofresearch institutes, associations andcompanies
■ Support of RWTH research instituteswith invest, infrastructure, services
Be part of the AZL Aachen Network
Exclusive Partner Labels:
Mission of AZL RWTH:
■ Research
− Production technology for themass production of lightweightcomponents
− Process chains for the massproduction of composite-basedmulti-material systems
■ Education
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25AZL Aachen GmbH – Excellence in Lightweight Production
Partner of AZL –Excellence in Lightweight Production
Partnership
Status Usage of label „OFFICIAL / FOUNDING*PARTNER“ for your public relations
Definition and discussion of pre-competitive projects and cooperations
Discussion of strategies of AZL
Lightweight activities of RWTH Aachen research institutes, associations and companies
Networking with other industrial Partners of AZL Aachen GmbH
Research consulting/ project definition
Setup of consortia for industrial research projects and for joint research projects with public funding
Identification of public fundings for individual research demands
-
Annual Partner Meeting
Networking
Initialization andCoordination ofResearch Projects
Additional Marketing
Usage of label „PREMIUM PARTNER“ for your public relations
Definition and discussion of pre-competitive projects and cooperations
Discussion of strategies of AZL
Lightweight activities of RWTH Aachen research institutes, associations and companies
Networking with other industrial Partners of AZL Aachen GmbH
Research consulting/ project definition
Setup of consortia for industrial research projects and for joint research projects with public funding
Identification of public fundings for individual research demands
Extended public relations (Internet, Publications, Presentations, etc.)
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26AZL Aachen GmbH – Excellence in Lightweight Production
Partner of AZL –Excellence in Lightweight Production
Public Relations
Usage of exclusivepartner label
Usage of label „OFFICIAL PARTNER“ for your public relations like letter paper, website, presentations, print media, etc.
Listing as “OFFICIAL Partner” with company logo and explanation of portfolio to acquire new customers and development partners (max. 700 digits)
Listing of your company in the showcase of AZL Aachen GmbH as “OFFICIAL Partner” with company logo and trade name in the building of the new Cluster “Integrative Production Technology
Setup of publications, presentations, newsletter, partner meeting related to your innovative products
Listing on the website
Listing in the showcase
Usage of PR activities
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27AZL Aachen GmbH – Excellence in Lightweight Production
Partner of AZL –Excellence in Lightweight Production
Public Relations
Usage of exclusivepartner label
Usage of label „OFFICIAL PARTNER“ for your public relations like letter paper, website, presentations, print media, etc.
Listing as “OFFICIAL Partner” with company logo and explanation of portfolio to acquire new customers and development partners (max. 700 digits)
Listing of your company in the showcase of AZL Aachen GmbH as “OFFICIAL Partner” with company logo and trade name in the building of the new Cluster “Integrative Production Technology
Setup of publications, presentations, newsletter, partner meeting related to your innovative products
Listing on the website
Listing in the showcase
Usage of PR activities
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28AZL Aachen GmbH – Excellence in Lightweight Production
Partner of AZL –Excellence in Lightweight Production
Public Relations
Usage of exclusivepartner label
Usage of label „OFFICIAL PARTNER“ for your public relations like letter paper, website, presentations, print media, etc.
Listing as “OFFICIAL Partner” with company logo and explanation of portfolio to acquire new customers and development partners (max. 700 digits)
Listing of your company in the showcase of AZL Aachen GmbH as “OFFICIAL Partner” with company logo and trade name in the building of the new Cluster “Integrative Production Technology
Setup of publications, presentations, newsletter, partner meeting related to your innovative products
Listing on the website
Listing in the showcase
Usage of PR activities
Composites Europe 2013, Stuttgart
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29AZL Aachen GmbH – Excellence in Lightweight Production
Partner of AZL –Excellence in Lightweight Production
Human Resources Marketing
Contact to junioremployees
Highly qualified staff is educated within lectures and practical research at RWTH Aachen within the field of materials science and lightweight production
Publication of jobs for internships and employment
Direct contact via employees of AZL Aachen
Placement of job offers viaWebsitePrint media
Comfortable recruiting section for specialists (technicians, student workers, graduates)
3 months duration after publishing
Printed job offers are published in the showcase withinin the building of the new Cluster “Integrative Production Technology”
Usage of different media
Recruting section of AZL Aachen website
Publishing in Showcase
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30AZL Aachen GmbH – Excellence in Lightweight Production
Partner of AZL –Excellence in Lightweight Production
Industrial R&D Consulting
Setup of consortia forjoint research projects
Identification of potential partnersIndustrial companiesResearch Institutions
Consulting on focusing research topics
Consulting how to use AZL infrastructure as technology platform
Risk-reduction by identification of available public funding possibilities for your demand
BMBF, BMWI, EU, Cross-Border Fundings, etc.
Usage of the expertise of AZL Aachen to focus research topics
Direct contact via the AZL Aachen network partners to setup consortia for public funded projects
Possibility to use AZL infrastructure as technology platform for
Identification of publicfundings
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31AZL Aachen GmbH – Excellence in Lightweight Production
Partner of AZL –Excellence in Lightweight Production
Industrial R&D Consulting
WorkshopsFree participation in workshops to define cost-shared pre-competitive projects
Thermoplastic Tapes - Material and Processing Benchmark (May 15th 2014)
New Designs for Low-Cost and Energy-Efficient Double-Belt Presses for Continuous Composite Manufacturing (May 15th 2014)
High-speed RTM matrices (May 27th 2014)
Back-moulding of thermoplastic tailored preforms (June 05th 2014)
Scheduled after annual partner meeting 2014:Quality control and -management for highly integrated process chains
Individualized production for high-volume markets
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32AZL Aachen GmbH – Excellence in Lightweight Production
Partner of AZL –Excellence in Lightweight Production
Face-to-Face Networking
Annual Partner Meeting Platform to initialize projects within the network of AZL Aachen partners
Pre-competitive R&D projectsCooperation
Presentation of innovative R&D projects
Discussion of the AZL Aachen strategy, update on new equipment and services
Strengthen the network between AZL Aachen partners and the lightweight activities of the RWTH Campus
Dates:July 03 2014July 02 2015
Participation of 3 employees included
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33AZL Aachen GmbH – Excellence in Lightweight Production
Campus Melaten of RWTH Aachen University – Next location for your development site?
+5 anonymous
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34AZL Aachen GmbH – Excellence in Lightweight Production
Partner of AZL –Excellence in Lightweight Production
Contributions for a 2-year-partnership (2014, 2015) Number of Employees
< 2525 - 250250 - 500
> 500
*Annual contribution with commitment for a 2 year partnership (2014, 2015)
Anual Contribution*
2.000,- €5.000,- €7.500,- €
10.000,- €
Anual Contribution*
25.000,- €
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35AZL Aachen GmbH – Excellence in Lightweight Production
Contact for further Information
Dr. Michael EmontsCEO AZL RWTH,Managing Director AZL Aachen GmbH
Tel.: +49 241/ 8904-150
Email: [email protected]
Dr. Kai FischerDivisional Director AZL RWTH: Production Technology Composites,Managing Director AZL Aachen GmbH
Tel.: +49 241/ 80-23884
Email: [email protected]
Dr. Michael EffingSenior Advisor AZL Aachen GmbH
Tel.: +49 241/ 80-23887
Email: [email protected]