InfrastructureRWTH Aachen Campus GmbH / capricorn development
Presentation of the research project start-up factory and eLab in the center for electric vehicle production
Motivation and Introduction of CEP
The Center for Electric Vehicle Production, CEP for short, explores the electro-mobile production process, from development to production. The start-up factory and the eLab represent two areas of expertise, in which development and production processes can be explored and optimized. In eLab the manufacturing processes of the battery and the electric powertrain can be analyzed in a real production environment. In addition to the automation of production and research of engineering systems and prototyping is the efficiency of the processes in the foreground. The start-up factory is focused on the entire vehicle. Annexes to the body shop, an assembly line and end- of-line tests offer the possibility to display start-up and production processes in a very accurate way.
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Objectives of CEP
- Support through expertise and construction of a comprehensive infrastructure for the development of electric vehicles to series production.
- CEP as a point of contact for companies in the development of electric vehicles and their components.
- Project-related and cross-project collaborations are possible.
- eLab: Laying the foundation for the series production of electric vehicles through a highly sophisticated development environment for battery and drive train components.
- Start-up factory: Creation of skills for ensuring the manufacturability of the components at the highest possible quality and flexibility.
Research and Development in the Following Areas
- Battery production: Shuffle, coating, formation & aging, cell contacts, pack assembly
- Rotor Assembly: Gluing and assembling with magnets, heating of the rotor core, joining the rotor shaft, balancing, cleaning, magnetizing
- Stator: The stator winding, impregnation, interconnect
- Final assembly: Heating the housing, joining of housing and stator, joining of the bearings on the shaft, joining of the rotor in the stator assembly of bearing shields and seals, end-of-line test, rework
3D- Printing Technology at the Center for Electric Vehicle Production
As part of the research project ramp-up factory II, a 3D printer (Stratsys Objet 1000) could to be purchased with a variety of plastics suitable for tool manufacturing. We have developed taxonomies for demanding equitable tool manufacturing and we tested and validated the use of the tools in thermoforming and PRIM manufacturing processes. It is possible to produce components up to a size of 1000 x 800 x 500 mm (LxWxH) and an average level of detail of 20 - 85 µm for small components(<50mm) and 300µm for larger parts.