Electrifying the Industrial Value ChainElectrification
Consortial Study for Selected Industrial Partners
ZEPZentrum fürElektromobilproduktion
KARTMAXe
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2 Electrification
The progress of electrification is continuously shifting the value chains in nearly all industries on the Eu-ropean continent – from transportation to consumer goods. Driven by the shortage of fossil resources, stricter emission regulations, new technologies for decentralized power generation and the development of new drivetrain technologies the entire value chains of nearly all industries related to powertrain techno-logies is disruptively transforming at high speed. Affected western companies – from material supplier to OEM – that do not want to be jeopardized by this shift need to adjust their strategies in order to benefit from the tremendous new market opportunities. The challenges of high uncertainty about future powert-rain technologies, changing requirements regarding skills and competences and the access to raw materi-als (e.g. lithium, neodymium and copper) need to be addressed already today in order to stay competitive.
Prof. Dr.-Ing. Günther Schuh, Professor for Production Engineering at the Laboratory for Machine Tools and Production Engineering (WZL), Director of the Department for Technology Management at the Fraunhofer Institute for Production Technology (IPT)
The disruptive change towards electrification calls for new production concepts. Two new core compe-tencies appear on a lot of agendas: electrical engines and batteries. A lot of different players in a several branches are continuously trying to handle these promising technologies, components and solutions wi-thout even knowing their roadmaps. The worldwide market for electric vehicles and other “electrified” areas is drastically growing. The ongoing trend for mega cities, the shortage of fossil fuel sources and an increasing environmental awareness enforce a sustainable behavior. Supported by governmental subsi-dies and laws, production systems and applications will develop into a new era of electrification. Skillfully capturing growth opportunities, cutting through complexity, building competences (e.g. chemistry and electronics), ensuring access to raw materials, forming strategic partnerships and making investments in line with a stringent portfolio strategy are key for the European industry to get on the fast lane of elec-trification.
Prof. Dr.-Ing. Achim Kampker, Professor for Production Management at the Laboratory for Machi-ne Tools and Production Engineering (WZL), CEO of StreetScooter GmbH
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Electrifying the Industrial Value Chain 3
ZEP – Aachen Center for Electromobile Production Focus of the Consortial-Study
Did you know that...
� the global market for automotive powertrains will more than double to EUR 460 billion by 2030
� there will be a demand for 420.000 additional jobs mainly with electrical and chemical engineering skills in the global powertrain industry in the next 20 years
� in 10 years the installed global capacity of battery systems for photovoltaics will be almost 6 GWh – 200% above today’s level
� the global market for lithium ion battery systems for mobile machines, pedelecs and stationary energy storage will exceed EUR 4 billion in 2020
Technological alternatives of product and process
Materials
Value chain designs
Quality and reliability
Benchmarks and tandardizations
Business odels (incl. ecycling)m r
Cost structures
Specific topics can be adjusted by partners
+ +Energy storage Powertrain
Manufacturingequipment
Electrification 2030
Electrifying the Industrial Value Chain
Consortial Study for Selected Industrial Partners(Limited to 40 Participants along the Value Chain)
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4 Electrification
RWTH Aachen is the European Center for Production Technology
RWTH Aachen
� Founded in 1870 � 118 programs of study � 260 research institutes � 480 professorships � 4.500 scientists � 35.800 students � 13 special research fields � 2 clusters of excellence:
� »Integrative Production Technology for High-Wage Countries«
� »Tailor-Made Fuels from Biomass«
Fraunhofer-Gesellschaft
� Founded in 1949 � Europe’s largest application-
oriented research organiza-tion
� More than 80 institutes and facilities in Germany
� Non-profit organization � 22.000 employees � EUR 1,9 billion research
funds per year � EUR 1,6 billion through con-
tract research � 3 institutes in Aachen
New RWTH Campus
� 2 areas with 800.000 m²: Campus Melaten and Cam-pus West
� EUR 2 billion investment volume
� 19 planned research clusters � Creation of approx. 10.000
jobs � Emphasis on production
technology: � 62 professorships � 10.100 students, 2.600
employees
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Electrifying the Industrial Value Chain 5
Electrification has a great Impact on the Value Chains in many Industries
� Green thinking and green politics
� Value shift to electrics/electronics
� High uncertainties and missing standards
� Limited traceability of quality deviations
� Limited scalability of product and process
� Low degree of automation
� Limited reproducibility
� Inefficient cost structure
Initial conditions & State of the Art
� European core competencies in energy storage andpowertrain
� Reliable, scalable and highly automatedmanufacturing processes
� High standardization in product and process
� Fitted process and quality parameters andtraceability
� High degree of reproducibility
� Cost efficiency
Goals & Challenges
Electrification will have a tremendous impact on the industry of high-wage
countries with regard to the entire value chain
ELECTRIFICATION
mechanics SUPPORT electrics
MECHATRONICS
electrics SUPPORT motion
MECHANICS
mechanics SUPPORT motion
Revolution Revolution
1900 1980 2030
Be part of revolution, not just a witness
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6 Electrification
The ZEP is designed as the Integrative Solution Provider for the established network at RWTH Aachen University
Materialsupplier
Manufacturingequipmentsupplier
Componentsupplier
Tier 1/2
IndustrialPartners
Cooperation
OEM
ZEPZentrum fürElektromobilproduktion
Fitting of thecar body atdemoFactory
Joining of magnetsin e-motors at eLab
Assembling ofbattery modulesand packs at eLab
Welding robot inbody constructionat ramp-up factory
demoFactoryat Campus Melaten
Overview of theramp-up factory
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Electrifying the Industrial Value Chain 7
ZEP – Infrastructure worth EUR 20 million ready to be used by our Partners
Street Scooter
� Access to technology platform ofStreetScooter
� StreetScooter prototype availableas application example
� Focus: Car body production
� Real series production
� Education and training forindustrial partners and students
demoFactoryZEP
Cente for Electromobile Productionr
EUR 20 million investment volume
available for setting up the infrastructure
Ramp-up Factory
� Focus: Vehicle
� Body shop, assembly and end-of-line-tests for prototype production
� Optimization of producibility ofproducts during ramp-up
KEX Knowledge Exchange AGLaboratory for Machine Toolsand Production EngineeringFraunhofer Institute forProduction TechnologyWelding and Joining Instituteof the RWTH AachenInstitute for Power Electronicsand Electrical DriveInstitute of Electrical Machines
production of aDevelopment andShort Distance Vehicle (SDV)
KEXWZL
IPT
ISF
ISEA
IEMStreetScooter
eLab
� Focus: Electric Powertrain
� R&D in product design andproduction processes ofbatteries and e-motors
� Cooperation of institutes ofRWTH Aachen University
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8 Electrification
Consortial Study for Selected Industrial Partners
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Electrifying the Industrial Value Chain 9
Phase 1: Consortial Study – 12 months
Results
� Market potentials (Identification of new applications and „hidden business potentials“)
� Selection of applications
� Technological challenges: echnologies, roduction systemst p
� Selection for benchmarking of production technologies
� Proposal for phase 2
e.g.:
� PowertrainTechnologies
Automotive Mobility BuildingRenewable
Energy
e.g.:
� Marine
� Rail
e.g.:
� Smart HomeApplications
e.g.:
� StationaryEnergy Storage
Consumer &
Leisure
e.g.:
� Power Tools
� Pedelecs
Business odels (incl. ecycling)m r
Benchmarks and tandardizations
Opportunities &Solutions
Technological alternatives of product and process
Materials
Quality and reliability
MarketAnalysis
Value chain designs
Cost structures
Value ChainScenarios
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10 Electrification
Exclusive Benefits for Consortial Study Participants
� Material Supplier
� Manufacturing Equipment Supplier
� Component Supplier
� Tier 1/2
� OEMs
Consortial Study participants*
*limited to 40 participants
Materialsupplier
Manufacturingequipmentsupplier
Componentsupplier
Tier 1/2
OEM
Become part of the ZEP
production technology network
ZEP as potential showcase for your business
� (Potential) electric powertrain applications
� Production systems and technologies
� Value chain scenarios
� Business models
� Material and systems suppliers
Systematic Structured Market Overview
� Selected pplicationsa
� Production volumes
� Costs
� Existing and potential suppliers along thevalue chain
Identified Applications with Highest Potentials
and Financial Return
� Definition of project scope
� Definition of cost performance targets
� Proposal of project partnership
Selection of Key Research Topics by Partners
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Electrifying the Industrial Value Chain 11
ZEP – Worldwide Market Study for Electric Powertrain Applications. New Markets, Products and Production Technologies
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12 Electrification
Contact
Dipl.-Ing. Christoph Deutskens, M.Eng. Chief Engineer at the Laboratory for Machine Tools and Production Engineering (WZL) Head of ZEP
Steinbachstraße 19, D-52074 AachenTel.: +49 241 80-27380Fax: +49 241 80-22293 [email protected]
Dipl. Ing. Toni DrescherHead of Department Technology Management at Fraunhofer Institute for Production Technology (IPT) CEO of KEX Knowledge Exchange AG
Steinbachstraße 17, D-52074 AachenTel.: +49 241 8904-250Fax: +49 241 [email protected]
Bildnachweise:Seite 1: ©thomaslerchphoto/Fotolia.com; ©MaxeKart/Nils Poschwatta; ©Petair/Fotolia.com; Seiten 1, 7: ©Capricorn development/Henn Architekten; Seiten 1, 7, 9: ©StreetScooter GmbH; Seiten 1, 9,: ©il-fede/Fotolia.com; ©X-travagant/Fotolia.com; ©F.Schmidt/Fotolia.com; ©Petair/Fotolia.com; Seite 3: ©Ingo Bartussek/Fotolia.com, ©Kadmy/Fotolia.com; Seite 4: ©Peter Winandy; ©Fraunhofer-Gesellschaft, ©RWTH Aachen/BLB; Seite 7:©Ante 4C GmbH/Meyer Van Schooten
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