Schaeffler explores the engine plant of the future

The automotive and industrial supplier Schaeffler has started the AgiloDrive2 research project, funded by the Federal Ministry for Economic Affairs and Energy (BMWi), as the consortium leader with 17 partners. The goal of the three-year project is to develop an agile and digitized production system with a modular product kit for innovative electric motors. Another focus is on how E-motors can be manufactured flexibly, sustainably, and economically based on data-driven manufacturing technologies, agile process chains, and intelligent control architectures.

"Digitalization and automation are key to the sustainable factory of the future and enable opportunities along the entire value chain for us and our customers," explains Jochen Schröder, Head of the E-Mobility Division at Schaeffler AG.

The findings from the project are to be transferred to E-motor manufacturing at the Bühl site, the headquarters of the Automotive Technologies division, shortly after completion. There, a leading plant for E-motor production is being built, which is to be a global leader. The project was preceded by a 1.5-year collaboration with the Karlsruhe Institute of Technology (KIT), which was funded by the Ministry of Economic Affairs, Labor and Tourism Baden-Württemberg.

Agile Production for Schaeffler E-Motors

Depending on the type of electrified drivetrain, E-motors are technically very different in their topology, such as winding type, installation space, torque, continuous power, and operating behavior. Schaeffler offers E-motors across all electrification levels for hybrid modules, hybrid transmissions, and purely electric axle drives, with a wide power range from 20 to over 300 kW.

"We respond to the variety of variants and the volatility of the quantities with an agile production method, which we want to work on and validate together in the AgiloDrive2 project," outlines Thomas Pfund, Head of the E-Motor Business Unit at Schaeffler.

Therefore, the goal is to develop a flexible production system in terms of product-production co-design, which promotes close collaboration between product and production system development. Instead of rigid production lines, highly flexible digitized and efficient technology modules will be used. These should be easy to scale, flexibly configurable, linkable, and software-based. Standardized machine interfaces, hardware and software interfaces, and the use of cross-manufacturer communication standards are to enable control of increasing complexity and the fast integration of systems according to the "Plug and Produce" approach.

Modular Design of Machines

A modular design of the machines allows for the reuse of production equipment in favor of economy and sustainability. Digital twins allow for efficient production planning and accelerated commissioning, AI solutions enhance product quality, and digital qualification methods facilitate and accelerate employee training.

Several Partners from Industry and Research

The research project, with a duration of three years, has a total volume of 33.7 million euros. The funding is provided under the "Digitalization of Vehicle Manufacturers and Suppliers Industry" guideline and is managed by the project sponsor VDI Technology Center GmbH. Schaeffler leads the project as the consortium leader and has overall responsibility for the research activities. Other partners include: 4D GmbH, Braun Sondermaschinen GmbH, Carl Zeiss Industrielle Messtechnik GmbH, e-mobil BW GmbH, FormiKa GmbH, Gehring Technologies GmbH + Co. KG, Karlsruhe Institute of Technology (KIT), Koob Testsystems GmbH, KUKA AG, LTB Bachofer GmbH, Magnet-Physik Dr. Steingroever GmbH, pro-beam systems GmbH, SCHUNK GmbH & Co. KG, Siemens AG, STAHL GmbH & Co. KG, TRUMPF Laser GmbH, WAFIOS AG.