EDAG GmbH and Co. KGaA

Fulda, Germany

EDAG GmbH and Co. KGaA

Fulda, Germany
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Grant
Agency: European Commission | Branch: FP7 | Program: CP-FP | Phase: NMP-2009-3.2-2 | Award Amount: 5.14M | Year: 2010

Wind turbines and aeronautic are sectors where Europe is leading the world class competition. To guarantee this competitiveness, their productivity has to be improved. The adoption of an automation strategy is a key factor to increase productivity. In the wind turbine manufacturing, the assembly is one of the core processes. Most of these assembly operations are manual which has the quality of being the most flexible way to do the work. The main objective for COSMOS is the design/development/implementation of a control system for factory management with a flexible, modular and evolvable automation approach which will permit to increase the assembly factory productivity by 20% without losing flexibility, focused on wind turbine assembly process although the solution will be suitable for other sectors. Cost models will be defined to assist in establishing the economically optimum factorys configuration and automation level. The achievement of the main objective will be obtained by fulfilling the following technical objectives: -Create a factory organisation conception based on intelligent factory units for facilitating the self-adaptation to production changes under a flexible and modular automation configuration basis. -Develop the distributed control system architecture according to such factory organisation. -Develop the service layer infrastructure between control system and equipment involved in production. COSMOS system features: -Autonomous behaviour of the factory units. -Multilayer decentralised control. The control will work in three interconnected levels. -Interoperable connectivity with factory units equipment/devices. -Local intelligence (self-adaptation to different parts conditions without human intervention). -Collaboration among equipment/devices to complete specific tasks. COSMOS will be implemented as a pilot installation for the assembly of wind turbines nacelles (most critical and added value part).


Ruby M.,Celanese Corporation | Reif M.,Celanese Corporation | Begert M.,EDAG GmbH and Co. KGaA | Gerster M.,EDAG GmbH and Co. KGaA | And 3 more authors.
International SAMPE Technical Conference | Year: 2014

Improved process efficiency with potential for lower costs at higher production volumes has been demonstrated for a structural-composite doorframe support for a storage door on a commercial truck cab. The study compared thermostamped 70-wt% unidirectional (UD) fiberglass-reinforced polypropylene (PP) composite vs. incumbent stamped steel. Structural simulation and performance validation loops were conducted to optimize ply layup and fiber orientations. A semi-automated four-step production process was developed to demonstrate potential of producing structural-composite parts within 60 sec. Process benefits include high levels of design flexibility regarding fiber orientation, allowing engineers to take full advantage of aligned fibers with opportunities to boost performance or reduce mass and thickness. Versus fabric-reinforced sheet composites, it eliminates fiber undulation, assuring fiber-reinforcement properties are fully utilized. Even without optimizing the design for composites, the thermoplastic-composite solution offers lower mass than the baseline design. Study details and results are reported here. Copyright 2014. Used by the Society of the Advancement of Material and Process Engineering with permission.


Clark G.,Celanese Corporation | Reif M.,Celanese Corporation | Begert M.,EDAG GmbH and Co. KGaA | Gerster M.,EDAG GmbH and Co. KGaA | And 3 more authors.
CAMX 2014 - Composites and Advanced Materials Expo: Combined Strength. Unsurpassed Innovation. | Year: 2014

A lightweighting study was conducted on a doorframe structural support for the storage bin on a commercial truck cab last year. Compression-molded composite laminates produced from unidirectional fiber-reinforced thermoplastic tapes were compared to incumbent stamped steel and shown to reduce mass 18 % while providing slightly better torsional resistance and significantly better wind-loading performance. This was accomplished despite the fact that it was not possible to modify the part design other than to allow slightly thicker wall stock and somewhat larger radii. A robust protocol was used to develop properties for material cards for use in an iterative series of analyses, which were conducted first to see what was possible with the composite laminates and then to meet thickness restrictions in carryover tooling from an earlier study. Once a final ply schedule was produced, it was passed to a second team in charge of conducting a novel process characterization study, which considered drape-ability in various orientations, quality of the laminate (via microscopic examination), and finally developed a temperature vs. time process chart from data obtained from thermocouples embedded at key locations in the laminate stack. Last, data from this study was used to optimize a 4-step semiautomated process that was capable of producing the doorframe support part in less than 90 sec (from preheating/consolidation through molding and de-molding). This supports the researchers' belief that the material/process combination could be translated to commercial vehicle production. Details of the study are provided in this report.


Eastep D.,Celanese Corporation | Reif M.,Celanese Corporation | Begert M.,EDAG GmbH and Co. KGaA | Gerster M.,EDAG GmbH and Co. KGaA | And 3 more authors.
Proceedings of the American Society for Composites - 29th Technical Conference, ASC 2014; 16th US-Japan Conference on Composite Materials; ASTM-D30 Meeting | Year: 2014

To help transportation OEMs meet pending fuel efficiency and emissions standards and become more comfortable with composites and use them in higher volume vehicles on more structure-critical applications where these materials can have the greatest impact on mass reduction and hence fuel efficiency/emissions, the automotive supply community must demonstrate the accuracy of its predictive engineering tools, the reliability of faster production processes, and the ability of molded parts to maintain long-term performance. One such study that concluded last year evaluated the use of thermostamped 70-wt% unidirectional (UD) fiberglass-reinforced polypropylene (PP) composite tape in a structural-composite doorframe support for a storage door on a commercial truck cab. The study involved structural simulation and performance validation loops to optimize ply layup and fiber orientations; a process study that evaluated different layup schedules on fiber movement in the same geometry, a microscopy study to see if and where fibers twisted or broke along the part's length, and a temperature study where thermocouples were inserted into the ply stack to identify the correct processing window for the material to avoid glass breakage due to attempts to mold a cold matrix; and lastly a process-optimization study to help reduce cycle time for preheating/consolidation and molding steps. The result was development of a semiautomated four-step production process that demonstrated the potential of producing structural-composite parts within 60 sec. Process benefits include high levels of design flexibility regarding fiber orientation, allowing engineers to take full advantage of aligned fibers with opportunities to boost performance or reduce mass and thickness. While the part design (based on the incumbent part in stamped steel) was not optimized for composites, the thermoplastic-composite solution offers comparable costs at lower mass than the baseline design.


Schneider J.,EDAG GmbH and Co. KGaA | Stamm K.,EDAG GmbH and Co. KGaA | Breitenbach F.,EDAG GmbH and Co. KGaA
AutoTechnology | Year: 2011

Edag has introduced its Light car sharing concept designed entirely as a sharing vehicle that is to be used as a communication element, for details of range and availability. Both the interior and exterior surfaces of the Light Car that include the floor covering or sill trim are durable and easy to clean. Painting and anti-corrosion treatment processes were kept to a minimum, due to the kind of materials selected using plastic to produce the door plates. Modern joining methods such as Riftac high-speed tacking technology or fusing aluminum and steel enable all kinds of material combinations to be joined together, and make it easier to use modern materials. The plans for the Light Car Sharing concept involve a total production volume of 250,000 units in seven years, and its service life has been calculated at 20 years. The regular service work carried out on the cars includes a visual inspection and documentation, light test, brake and tire inspection, charging level check and battery test.


Summary Compared with serial or parallel hybrid drive trains, the synthesis of control algorithms for power split drive trains has to be considered as an advanced challange. Right from the design or planning stage there is an enhanced modelling effort. Furthermore a lot of details in power split drive trains can verify from one variant of drive train to another. Therefore generalised models of the considered class of drive trains are desired, which can be applied to a concrete drive train just by parametrising them. In this paper such generalised models for power split drive trains are derived and discussed. In addition to this, general characteristics of the considered type of drive train are figured out. © Oldenbourg Wissenschaftsverlag.


Schafer K.,EDAG GmbH and Co. KGaA
AutoTechnology | Year: 2010

The EDAG V-model with its digital system incorporating a release mode is already showing considerable potential for optimizing the production development process. The conditions under which savings potential in production can be achieved are laid down at the very start of vehicle development. In order to achieve such benefits, changes are needed in OEMs' contract awarding philosophy. Today's performance specifications, some of which contain only rough process descriptions and quantity structures, make no claim to be complete. The benefits of this advanced plant engineering with the digital release mode are evident: the OEMs' stipulations are implemented. These include an optimized product and production concept, with reductions to both production cost and development periods, whereas otherwise, the tendency is for the plant constructor to adhere to price, deadline and product specifications.


Biahmou A.,EDAG GmbH and Co. KGaA
Advanced Concurrent Engineering | Year: 2013

While the globalization has led to an increase of the competition in the automobile market, customer requirements have increased and products have to satisfy higher standards. All this drives companies to shorten their product development cycles while boosting innovation. In order to reach this objective, reusing knowledge as well as focusing on creative tasks while automating routine tasks has proven to be a successful approach. As independent engineering partner, EDAG GmbH & Co. KGaA, develops advanced methods and tools in order to keep its processes continuously efficient. This paper presents some methodologies for accelerating mechanical design using knowledge based techniques with the CAD System NX. A knowledge based concept for efficient design is presented and validated with the process of glove box development. © Springer-Verlag London 2013.

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