eTruckPro | Flexible and Convertible Production Systems for Electric and Conventional Trucks

Mixed production systems for symbiotic production of electric and conventional trucks

In recent years, global greenhouse gas emissions have continued to rise, from 23 billion metric tons of CO2 in 1995 to 35 billion metric tons in 2020. Applicable climate targets are in danger of being missed. Therefore, the climate-friendly conversion of road-based commercial vehicles (HGVs) must contribute to reducing emissions. The most significant leverage is the electrification of 40-ton trucks, which account for 48 percent of the CO2 emissions of all commercial vehicles due to long-distance traffic and high transport masses (see Fig. 1).

Classification of commercial vehicles according to CO2 emissions
© MAN Truck & Bus
Classification of commercial vehicles according to CO2 emissions

The development of sales of electric commercial vehicles (eVs) is still subject to major uncertainties. In order to reduce economic risks, enabling assembly systems for the parallel production of two vehicle variants (conventional and electric) is considered a sensible solution in the transition phase.

Convertible mixed production with electric trucks | eTruckPro joint project

Process model for the integration of electric trucks into existing assembly lines

This is where the joint project eTruckPro comes in. The aim of the project, funded by BMWK, was to develop a versatile mixed production system for the symbiotic manufacture of conventional and electric trucks. By using existing production facilities and adapting line balancing, it was possible to avoid costs such as acquiring additional operating equipment and production areas and developing transformation paths. An employee assistance procedure was also developed to reduce the start-up time and prepare the plant workforce for their new work content.

The integration of electrification components has an overall impact on the existing line structure. The partner Hörmann Rawema therefore developed a simulation model from this level, by means of which the existing structure and the changing personnel requirements at the individual assembly stations could be determined for different production scenarios. Fraunhofer IGCV focused on the detailed planning of individual assembly line sections around the assembly of battery packs and e-drives, as this is where the highest adaptation requirements at the station level were expected. For example, the distribution of additional assembly contents to the assembly personnel while complying with scheduling restrictions (assembly sequence, assembly time and installation location) was examined and optimized using digital planning tools. In order to make such planning processes more efficient in the future, Fraunhofer IGCV has developed and published a process model with its partners MAN Truck & Bus and Hörmann Rawema.

Creation of a transparent database as a basis for planning

To succeed in rescheduling an existing production system to a mixed production with electric trucks, the availability or development of a transparent and consistent database is a prerequisite. Laser scanning was used to create a digital image of the production areas, which could be used for the real spatial layout planning of new product variants in the simulation models.

In addition to the spatial information, the collection and processing of production data is indispensable for rescheduling. In eTruckPro an individual procedure was developed, which describes how, from existing rough knowledge of the assembly planning in combination with very detailed ACTUAL data from the current production a database can be created, which can be used as a basis for the simulation of future scenarios.

Erprobung von Montageassistenzsystemen
© Fraunhofer IGCV
Demonstrator of the Fraunhofer IGCV for testing assembly assistance systems

Method for employee qualification

Cognitive assistance systems individually support assembly workers during their assembly activities depending on the personal and necessary degree of support. For this purpose, Fraunhofer IGCV developed a software system that links up to seven different cognitive assistance systems from other manufacturers and can be configured and reconfigured with little effort. A demonstrator platform was developed for the demonstration of these assembly assistance systems.

The added value of the new approach in factory planning

Thanks to the agile and simulation-based approach to redesigning the existing production system in eTruckPro, production efficiency and quality significantly increased. The flexible planning methods will enable the optimized production of electric trucks on conventional lines in the future.
The project's most important findings were summarized in a guideline, which will be published at the end of the project.
The future of e-mobility for road-based transport is adaptable and flexible!

Outlook

The electrification of commercial vehicles marks a decisive step toward a sustainable future. But this step is just the beginning of a series of disruptive changes that await the commercial vehicle industry. The next wave of groundbreaking developments is already approaching: fully autonomous driving. Eliminating the driver's cab will open up new possibilities for commercial vehicle design and efficiency, revolutionizing the entire way commercial vehicles are used.

However, there are also challenges to overcome. Legal requirements for CO2 reduction are becoming increasingly stringent, and customer awareness of sustainability continues to rise. The industry must adapt to develop greener solutions and meet rising expectations. In addition to external influences, product life cycles are shortening, requiring even faster adaptation of the production system. Planning efficiency must continue to improve to meet demands and make production agile and efficient.

The road to the future is both exciting and challenging. Based on the results from eTruckPro, we are ready to take this path and actively participate in shaping a more sustainable and innovative industry. The future of commercial vehicles is electric, autonomous and sustainable - and we are excited to be part of this pioneering development.

References

Word Resources Institute: Höhe der weltweiten Treibhausgasemissionen in den Jahren 1990 bis 2019. Internet: https://de.statista.com/statistik/daten/studie/311924/umfrage/treibhausgasemissionen-weltweit/

Global Carbon Project: Entwicklung des weltweiten CO2-Ausstoßes. Internet: https://de.statista.com/statistik/daten/studie/208750/umfrage/weltweiter-co2-ausstoss/

EDGAR/JRC: Verteilung der CO2-Emissionen weltweit nach Sektor bis 2020. Internet: https://de.statista.com/statistik/daten/studie/167957/umfrage/verteilung-der-co-emissionen-weltweit-nach-bereich/

Europäische Kommission: Europäischer Grüner Deal. Erster klimaneutraler Kontinent werden. Internet: https://ec.europa.eu/info/strategy/priorities-2019-2024/european-green-deal_de?gclid=EAIaIQobChMI6uC537fl-gIVKo9oCR3X7woBEAAYASAAEgL1sPD_BwE

MAN auf dem Weg zum CO2-freien Transport. Internet vom 03.06.2023: https://www.youtube.com/watch?v=fScQjz1Kljo

Kampker, A.; Burggräf, P.; Deutskens, C.: Produktionsstrukturen Für Komponenten Künftiger Elektrofahrzeuge. ATZproduktion 3 (2010) 2, S. 48–53

Ott et. al (2023), Simulationsgestütztes Vorgehen für eine Mischproduktion mit elektrischen Nutzfahrzeugen: Hybridisierung bestehender Montagesysteme, WT Werkstattechnik online, vol. 113 Heft 3, S. 101-106

Competences

We are shaping the way into the future of efficient engineering, networked production and intelligent multi-material solutions.

Industry solutions

The key sectors of Fraunhofer IGCV:

  • Mechanical and plant engineering
  • Aerospace
  • Automotive and commercial vehicles

Cooperation with Fraunhofer IGCV

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