High Efficiency Manufacturing

FPC@ITA’s develops solutions for the design and management of manufacturing companies – such as organizational and business models, business processes and process organization. In this context we deal with corporate strategies and their planning, knowledge management and benchmarking, process control and information transfer. For many companies enquiries with stricter requirements for technology and quantity are now part of everyday life. How long does it take your production department to adapt efficiently and reliably to such a situation? We develop solutions to flexibly coordinate model-based production technologies and factory management systems

Energy efficiency strategy for manufacturing processes and production chain

©Fraunhofer IPK ©CCM-ITA

EnEffReg

Holistic efficiency control for production systems

ENERPRO

Energy efficiency measures for production systems

Energy performance analysis of spot welding process

Analysis of energy consumption and quality aspects of spot welding process by statistical approach

Residual stresses heterogeneity assessment of high performance powder metallurgy gears

Comprehension of the residual stress state of gears manufactured by powder metallurgy

DRS – Design for residual stress in gear manufacturing chain

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

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

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

Increase of production efficiency via DA/ML

©Fraunhofer IPK ©CCM-ITA

Cockpit 4.0

Semantic product data for engineering

Additive Manufacturing 4.0

Mobile App for Quality Assurance

Spot Welding Process

Development of AI models with data responses from resistance welding process

TDO 4.0 - New Die Tryout Concept

Development of online monitoring tools to diminish manual interventions during the tryout stage of sheet metal forming dies

Efficient engineering conception through Integrated Product Development (IPD)

©Fraunhofer IPK ©CCM-ITA

PDM/PLM Competence Center

Efficient introduction of PDM/PLM for product data integration and transparent processes

Development of analysis tools for mechanical vehicle systems

Development of tools for analysis of vehicular mechanical systems for gears and crankshafts

Ball Rod - Development of a Rolling Contact Fatigue Test Bench

Planning the revitalization and optimization of a bench for performing rolling contact fatigue tests with the "ball-rod" concept

Development of a horizontal shaft rotor and verticalized power transmission system focused on downtime and maintenance cost reduction - Phase 1

Assessment of the technical feasibility of developing a horizontal shaft rotor wind turbine and verticalized power transmission

New Washer Concept Manufacturing Process

Development of a friction test bench for tests on alternative friction surface finishes

Improved Measurements of Gears Efficiency in back-to-back test rig

This research aims in a more reliable power losses measurements in a powercirculating test rig

Development of high added value manufacturing processes

©Fraunhofer IPK ©CCM-ITA

High Performance Production

Development, deployment and adaptation of production and manufacturing technologies

Residual stresses heterogeneity assessment of high performance powder metallurgy gears

Comprehension of the residual stress state of gears manufactured by powder metallurgy

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

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 Fluid Analysis to Aerospace Industry

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

Proposal for the optimization of mold and matrix machining processes

Programming procedures and definition of processes parameters

Assessment of power losses in rotary systems

©Fraunhofer IPK ©CCM-ITA

Development of analysis tools for mechanical vehicle systems

Development of tools for analysis of vehicular mechanical systems for gears and crankshafts

Improved Measurements of Gears Efficiency in back-to-back test rig

This research aims in a more reliable power losses measurements in a powercirculating test rig