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

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.

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!