Main Competence Areas
Production Systems

The Main Competence Areas consider both similar and complementary services offered by Fraunhofer IPK in Berlin as well as by CCM-ITA in São José dos Campos.

Both CCM and IPK currently offer a large number of products/services in their portfolios.

 

Networking of production facilities - Industrie 4.0
AMELI 4.0

Condition Monitoring in Industrie 4.0

Industrie 4.0

Flexible Transparent Manufacturing

Energy demand monitoring

Reduction of energy consumption, increase of productivity and costs saving

Machine learning for intelligent production
Cockpit 4.0

Semantic product data for engineering

Industrie 4.0

Flexible Transparent Manufacturing

Additive Manufacturing 4.0

Mobile App for Quality Assurance

ReLkat

Reinforcement learning for complex automation technology applications

Spot Welding Process

Development of AI models with data responses from resistance welding process

Precision manufacturing

Application Center for Micro-Production Technology

Production technologies including machine tools or parts
Precision manufacturing

Application Center for Micro-Production Technology

Systems for microproduction technology
Process Chains for Micro-Production

Manufacturing high-precision components with micro-features

Microstructured dental implants

Laser surface structuring to reduce bacterial adhesion

Robot assisted manufacturing - e.g. milling or grinding
Industrial robots as machine-tools

Flexibility, precision and automation with industrial robots

VISION

Performance and efficiency of industrial robots

AGE Project – Automation of the Construction and Installation of Large Scale Industrial Reservoirs

Development of a high innovative process through automatic align with industrial robots using a programming called cooperative movement

AME Project – Automation of Aircraft Structural Assembly

Development of an automatic process for robotic assembly of aircraft structures and a cooperative robotic system for drilling and inserting fasteners for aeronautical fuselages

AME_ASA Project – Automation of Aircraft Wings Structural Assembly

Development of robotic systems and end effectors applied in industrial robots to execute the tasks necessary to manufacturing aircraft wings

EFIP-EFORB – Devices for Aircraft Structures Assembly

Development of end-effectors to complement the necessary tasks for the automation of aircraft structural assembly

EXOBOT – Mobile Robotic Force Amplification System

Development of a force amplification system to handle large pipes

Condition monitoring, predictive maintenance
AMELI 4.0

Condition Monitoring in Industrie 4.0

Lifecycle Monitoring with the Digital Twin

IoT-based services for industrial production

MobiKAM

Measuring and testing with mobile cameras

Energy demand monitoring

Reduction of energy consumption, increase of productivity and costs saving

Monitoring and Analysis

Intelligent solutions for Predictive Maintenance

Processing strategies, machine tools, tools and devices
Industrie 4.0

Flexible Transparent Manufacturing

High performance production

Development, deployment and adaptation of production and manufacturing technologies

CMC-Finishing

Machining of complex free-form surfaces on Ceramic Matrix Composite

Advanced ceramics for deep sea applications

Development of technologies and strategies for the finishing high-performance ceramics

Evaluation of the cast iron Drilling process

Evaluation of the drilling process, regarding machinability of the cast iron, using minimum quantities of lubricant (MQL) and flood rating

Machinability of commercial steels and new alloys

Evaluation of the influence of the company’s commercial steel alloy modifications, compared to the material’s machinability with the addition of alloy elements

Machinability Evaluation of Three Similar Medium-Carbon Alloys

Evaluation of the differences between both alloys in what concern the machinability, specially the chips characteristics

Evaluation of Nbc Tools

Evaluation of the efficacy of the tools made with niobium carbide as their substrate

Analysis of the valve seat machining process

Evaluation of the influence of material and cutting parameters in the machinability of guide seats

EFIP-EFORB – Devices for Aircraft Structures Assembly

EFIP-EFORB – Devices for Aircraft Structures Assembly Development of end-effectors to complement the necessary tasks for the automation of aircraft structural assembly

Numerical simulation of manufacturing processes
Numerical simulation of additive processes

Optimizing heat flows and reducing dimensional deviations

DRS – Design for residual stress in gear manufacturing chain

Develop a predictive model for RS in gears induced by the interaction between manufacturing processes

Repair and cleaning technologies – e.g. blasting technologies
Clean Process

Dry and residue-free in-process cleaning of aluminum cast parts

Maintenance, repair and overhaul in energy and transport

Development of resource-saving and energy-efficient MRO processes and technologies

MRO innovation field - Cleaning

Removal of surface impurities and reduction of downtimes

MRO innovation field - Repairing

Increasing the degree of automation and flexibility in repair and maintenance

Dry and residue-free machining technologies

Pre-treatment, cleaning, cutting and decoating with CO2 technologies

FERA Feasibility Study - Tools and Gears Repaired Additively

This feasibility study aimed to explore the challenges of additive manufacturing application for gear teeth repair and the evolution to a robust design

Cutting fluids
Cutting Fluid Analysis to Aerospace Industry

Evaluation of the cutting fluids that could be used by the company and its suppliers in Aerospace Industry

Gears and powertrain technologies / surface engineering, especially ceramic parts
Assessment of the Manufacturing Chain on the Fatigue Behavior of PM Gears

Identification of the fatigue behavior of gears subjected to an alternative powder metallurgy manufacturing chain, recording them by using an S-n curve

Development of the Powder Metallurgy chain for High Performance Automotive Gears

Application of the "integrated product development" method to the design of the powertrain components manufacturing chain

Optimization of the screw connection for closing a planetary gear unit

Analyze the interaction between surfaces and their connection to the state of finishing in order to optimize the screw connection used to close a planetary gear unit

Investigation of the effect of microalloy elements in special steels on the durability of gears

Analyze the interaction between surfaces and their connection to the state of finishing in order to optimize the screw connection used to close a planetary gear unit

High-performance laser and arc welding methods
Laser beam and hybrid welding

Process development, parameters determination and technical & economic assessment

Submerged arc welding with multi-wire welding system

Welding of longitudinal seams in large-diameter pipe production

Welding of thick sections (20 mm – 450 mm) with laser-hybrid or submerged arc welding
Laser beam and hybrid welding

Process development, parameters determination and technical & economic assessment

Resistance spot welding of Advanced High Strength Steels (AHSS) – understanding & avoiding Liquid Metal Embrittlement (LME)
Thin sheet welding in car body construction

Resistance spot welding of steel and aluminum sheets with a thickness of approximately three millimeters

Resistance spot welding of high-strength steel sheets

Influence of surface coatings on liquid metal embrittlement

Optimization of the welding sequence on complex assemblies

Reducing distortions through process simulation

Integrity of Advanced High-Strength

Research to investigate the influence of the welding parameters on the integrity of AHSS weld spots and to understand how significant is the effect of a processing chain on the integrity when compared to the “as-welded” condition

Effect of Welding Parameter on the Mechanical and Metallurgical

Identification of the welding parameters’ influence on the properties of dissimilar TWIP - Aluminum Killed Drawing Quality (AKDQ) steel RSW joint

Numerical simulation of welding processes
Optimization of the welding sequence on complex assemblies

Reducing distortions through process simulation

Additive Manufacturing processes for innovative materials based on laser metal deposition
Combined process chain based on L-PBF and L-DED

Increased functionality for additively manufactured components

Sensors in additively manufactured components

Process for embedding sensors & actuators in additive components

System technology for laser beam repair welding

Continuous quality control during laser cladding

AM Gears – Additive manufacturing of metalpolymer gears for automotive transmissions

Development of metal-polymer composite gears manufactured by additive manufacturing

FERA Feasibility Study - Tools and Gears Repaired Additively

This feasibility study aimed to explore the challenges of additive manufacturing application for gear teeth repair and the evolution to a robust design