Resource-Efficient Process Chains for the Production of High-Performance Powertrain Components in the Automotive Industry

Publikation: Beitrag in Buch/Bericht/Sammelwerk/KonferenzbandAufsatz in KonferenzbandForschungPeer-Review

Autoren

  • Berend Denkena
  • Benjamin Bergmann
  • Marcel Wichmann
  • Miriam Handrup
  • Daniel Katzsch
  • Philipp Pillkahn
  • Leon Reuter
  • Christopher Schmidt
  • Frederik Stelljes
Forschungs-netzwerk anzeigen

Details

OriginalspracheEnglisch
Titel des SammelwerksManufacturing Driving Circular Economy - Proceedings of the 18th Global Conference on Sustainable Manufacturing
Herausgeber/-innenHolger Kohl, Günther Seliger, Franz Dietrich
Herausgeber (Verlag)Springer Science and Business Media Deutschland GmbH
Seiten410-418
Seitenumfang9
ISBN (elektronisch)978-3-031-28839-5
ISBN (Print)9783031288388
PublikationsstatusVeröffentlicht - 26 Apr. 2023
Veranstaltung18th Global Conference on Sustainable Manufacturing, GCSM 2022 - Berlin, Deutschland
Dauer: 5 Okt. 20227 Okt. 2022

Publikationsreihe

NameLecture Notes in Mechanical Engineering
ISSN (Print)2195-4356
ISSN (elektronisch)2195-4364

Abstract

This paper focuses on process chains for power train components of passenger cars and heavy duty vehicles. In the project “Powertrain 2025” particular attention is being paid to increase the resource efficiency of the manufacturing process chains and reduce energy demand during service life. In detail cylinder liners are equipped with an adapted geometry and topography which reduces friction losses. Process chains for chassis components are investigated and optimized in order to increase the resource efficiency during manufacturing, service life and maintenance. In addition, process chains for the manufacturing of drive shafts are adjusted. By eliminating hard machining, energy is saved and friction losses are reduced by laser machining of microstructures. Furthermore, micro dimples are applied in vane pumps, which leads to a tribological improvement and thus enhances their friction behaviour. Moreover, a system architecture for process planning is developed and ecologically optimized process parameters are calculated. For a final consideration, a calculation software is developed which enables to calculate the main energy consumption of the manufacturing processes and the carbon footprint for the expected service life. A weight reduction of the powertrain components of 4.5 kg per vehicle and a potential annual energy saving of 13,073 MWh is obtained.

Zitieren

Resource-Efficient Process Chains for the Production of High-Performance Powertrain Components in the Automotive Industry. / Denkena, Berend; Bergmann, Benjamin; Wichmann, Marcel et al.
Manufacturing Driving Circular Economy - Proceedings of the 18th Global Conference on Sustainable Manufacturing. Hrsg. / Holger Kohl; Günther Seliger; Franz Dietrich. Springer Science and Business Media Deutschland GmbH, 2023. S. 410-418 (Lecture Notes in Mechanical Engineering).

Publikation: Beitrag in Buch/Bericht/Sammelwerk/KonferenzbandAufsatz in KonferenzbandForschungPeer-Review

Denkena, B, Bergmann, B, Wichmann, M, Handrup, M, Katzsch, D, Pillkahn, P, Reuter, L, Schmidt, C & Stelljes, F 2023, Resource-Efficient Process Chains for the Production of High-Performance Powertrain Components in the Automotive Industry. in H Kohl, G Seliger & F Dietrich (Hrsg.), Manufacturing Driving Circular Economy - Proceedings of the 18th Global Conference on Sustainable Manufacturing. Lecture Notes in Mechanical Engineering, Springer Science and Business Media Deutschland GmbH, S. 410-418, 18th Global Conference on Sustainable Manufacturing, GCSM 2022, Berlin, Deutschland, 5 Okt. 2022. https://doi.org/10.1007/978-3-031-28839-5_46
Denkena, B., Bergmann, B., Wichmann, M., Handrup, M., Katzsch, D., Pillkahn, P., Reuter, L., Schmidt, C., & Stelljes, F. (2023). Resource-Efficient Process Chains for the Production of High-Performance Powertrain Components in the Automotive Industry. In H. Kohl, G. Seliger, & F. Dietrich (Hrsg.), Manufacturing Driving Circular Economy - Proceedings of the 18th Global Conference on Sustainable Manufacturing (S. 410-418). (Lecture Notes in Mechanical Engineering). Springer Science and Business Media Deutschland GmbH. https://doi.org/10.1007/978-3-031-28839-5_46
Denkena B, Bergmann B, Wichmann M, Handrup M, Katzsch D, Pillkahn P et al. Resource-Efficient Process Chains for the Production of High-Performance Powertrain Components in the Automotive Industry. in Kohl H, Seliger G, Dietrich F, Hrsg., Manufacturing Driving Circular Economy - Proceedings of the 18th Global Conference on Sustainable Manufacturing. Springer Science and Business Media Deutschland GmbH. 2023. S. 410-418. (Lecture Notes in Mechanical Engineering). doi: 10.1007/978-3-031-28839-5_46
Denkena, Berend ; Bergmann, Benjamin ; Wichmann, Marcel et al. / Resource-Efficient Process Chains for the Production of High-Performance Powertrain Components in the Automotive Industry. Manufacturing Driving Circular Economy - Proceedings of the 18th Global Conference on Sustainable Manufacturing. Hrsg. / Holger Kohl ; Günther Seliger ; Franz Dietrich. Springer Science and Business Media Deutschland GmbH, 2023. S. 410-418 (Lecture Notes in Mechanical Engineering).
Download
@inproceedings{ef9068b2f358447886b7c456c035b573,
title = "Resource-Efficient Process Chains for the Production of High-Performance Powertrain Components in the Automotive Industry",
abstract = "This paper focuses on process chains for power train components of passenger cars and heavy duty vehicles. In the project “Powertrain 2025” particular attention is being paid to increase the resource efficiency of the manufacturing process chains and reduce energy demand during service life. In detail cylinder liners are equipped with an adapted geometry and topography which reduces friction losses. Process chains for chassis components are investigated and optimized in order to increase the resource efficiency during manufacturing, service life and maintenance. In addition, process chains for the manufacturing of drive shafts are adjusted. By eliminating hard machining, energy is saved and friction losses are reduced by laser machining of microstructures. Furthermore, micro dimples are applied in vane pumps, which leads to a tribological improvement and thus enhances their friction behaviour. Moreover, a system architecture for process planning is developed and ecologically optimized process parameters are calculated. For a final consideration, a calculation software is developed which enables to calculate the main energy consumption of the manufacturing processes and the carbon footprint for the expected service life. A weight reduction of the powertrain components of 4.5 kg per vehicle and a potential annual energy saving of 13,073 MWh is obtained.",
keywords = "Automotive Industry, Process Chains, Resource Efficiency",
author = "Berend Denkena and Benjamin Bergmann and Marcel Wichmann and Miriam Handrup and Daniel Katzsch and Philipp Pillkahn and Leon Reuter and Christopher Schmidt and Frederik Stelljes",
note = "Funding Information: In this paper process chains for machining and manufacturing cylinder liners, casting molds, drive shafts and vane pumps were investigated and optimized. A method for energy-efficient production planning and a virtual demonstrator for visualization and output of the results were developed. These enable the process chains to be planned, controlled and monitored in terms of resource efficiency. In the project “Powertrain 2025 -Energy-efficient process chains for the production of a friction-, weight-and service life-optimized powertrain”, funded by the Federal Ministry for Economic Affairs and Climate Action, significant energy-saving potential was identified both in the production phase and in the service life phase of powertrain components. The research results and measures presented resulted in a weight reduction of the powertrain components of 4.5 kg per vehicle and a potential annual energy saving of 13,073 MWh.; 18th Global Conference on Sustainable Manufacturing, GCSM 2022 ; Conference date: 05-10-2022 Through 07-10-2022",
year = "2023",
month = apr,
day = "26",
doi = "10.1007/978-3-031-28839-5_46",
language = "English",
isbn = "9783031288388",
series = "Lecture Notes in Mechanical Engineering",
publisher = "Springer Science and Business Media Deutschland GmbH",
pages = "410--418",
editor = "Holger Kohl and G{\"u}nther Seliger and Franz Dietrich",
booktitle = "Manufacturing Driving Circular Economy - Proceedings of the 18th Global Conference on Sustainable Manufacturing",
address = "Germany",

}

Download

TY - GEN

T1 - Resource-Efficient Process Chains for the Production of High-Performance Powertrain Components in the Automotive Industry

AU - Denkena, Berend

AU - Bergmann, Benjamin

AU - Wichmann, Marcel

AU - Handrup, Miriam

AU - Katzsch, Daniel

AU - Pillkahn, Philipp

AU - Reuter, Leon

AU - Schmidt, Christopher

AU - Stelljes, Frederik

N1 - Funding Information: In this paper process chains for machining and manufacturing cylinder liners, casting molds, drive shafts and vane pumps were investigated and optimized. A method for energy-efficient production planning and a virtual demonstrator for visualization and output of the results were developed. These enable the process chains to be planned, controlled and monitored in terms of resource efficiency. In the project “Powertrain 2025 -Energy-efficient process chains for the production of a friction-, weight-and service life-optimized powertrain”, funded by the Federal Ministry for Economic Affairs and Climate Action, significant energy-saving potential was identified both in the production phase and in the service life phase of powertrain components. The research results and measures presented resulted in a weight reduction of the powertrain components of 4.5 kg per vehicle and a potential annual energy saving of 13,073 MWh.

PY - 2023/4/26

Y1 - 2023/4/26

N2 - This paper focuses on process chains for power train components of passenger cars and heavy duty vehicles. In the project “Powertrain 2025” particular attention is being paid to increase the resource efficiency of the manufacturing process chains and reduce energy demand during service life. In detail cylinder liners are equipped with an adapted geometry and topography which reduces friction losses. Process chains for chassis components are investigated and optimized in order to increase the resource efficiency during manufacturing, service life and maintenance. In addition, process chains for the manufacturing of drive shafts are adjusted. By eliminating hard machining, energy is saved and friction losses are reduced by laser machining of microstructures. Furthermore, micro dimples are applied in vane pumps, which leads to a tribological improvement and thus enhances their friction behaviour. Moreover, a system architecture for process planning is developed and ecologically optimized process parameters are calculated. For a final consideration, a calculation software is developed which enables to calculate the main energy consumption of the manufacturing processes and the carbon footprint for the expected service life. A weight reduction of the powertrain components of 4.5 kg per vehicle and a potential annual energy saving of 13,073 MWh is obtained.

AB - This paper focuses on process chains for power train components of passenger cars and heavy duty vehicles. In the project “Powertrain 2025” particular attention is being paid to increase the resource efficiency of the manufacturing process chains and reduce energy demand during service life. In detail cylinder liners are equipped with an adapted geometry and topography which reduces friction losses. Process chains for chassis components are investigated and optimized in order to increase the resource efficiency during manufacturing, service life and maintenance. In addition, process chains for the manufacturing of drive shafts are adjusted. By eliminating hard machining, energy is saved and friction losses are reduced by laser machining of microstructures. Furthermore, micro dimples are applied in vane pumps, which leads to a tribological improvement and thus enhances their friction behaviour. Moreover, a system architecture for process planning is developed and ecologically optimized process parameters are calculated. For a final consideration, a calculation software is developed which enables to calculate the main energy consumption of the manufacturing processes and the carbon footprint for the expected service life. A weight reduction of the powertrain components of 4.5 kg per vehicle and a potential annual energy saving of 13,073 MWh is obtained.

KW - Automotive Industry

KW - Process Chains

KW - Resource Efficiency

UR - http://www.scopus.com/inward/record.url?scp=85161406864&partnerID=8YFLogxK

U2 - 10.1007/978-3-031-28839-5_46

DO - 10.1007/978-3-031-28839-5_46

M3 - Conference contribution

AN - SCOPUS:85161406864

SN - 9783031288388

T3 - Lecture Notes in Mechanical Engineering

SP - 410

EP - 418

BT - Manufacturing Driving Circular Economy - Proceedings of the 18th Global Conference on Sustainable Manufacturing

A2 - Kohl, Holger

A2 - Seliger, Günther

A2 - Dietrich, Franz

PB - Springer Science and Business Media Deutschland GmbH

T2 - 18th Global Conference on Sustainable Manufacturing, GCSM 2022

Y2 - 5 October 2022 through 7 October 2022

ER -