04New Solutions for Composites

08Film Activates PP Components in Tools

11Concentrated expertise focused precisely

30. – 31.5.2017

03“Connectivity and Automated Driving will bring new challenges for body construction.”Prof. Christoph Wagener, Kirchhoff Automotive Deutschland GmbH, und Dr. Thomas Rudlaff, Daimler AG

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2 | AEE – see what’s on | 2017

Dear Sir or Madam,

Almost 100 exhibitors present their innovations

One thing is certain: our industry is on the move. Whilst new demands and specifica-tions continue to drive global automotive body production, innovative ideas, technolo-gies and concepts continue to carry mobility forwards, one step at a time. This includes, for instance, connectivity and automation, in other words autonomous driving and the networking of vehicles with each other. Both will bring new challenges for body construc-tion. For example, automated driving means that ultimately no more car to car accidents will occur, which in turn will reduce the re-quirements placed on car body constructi-on. Or, as experience shows, will probably lead to completely new challenges.

It is estimated that by 2050 around 70 % of people will be living in cities according to researchers. What does this mean for mobi-lity? How can we bring exhaust emissions

and noise pollution under control? We will have to deal with new forms of propulsi-on – irrespective of whether it is based on electric batteries or fuel cells. Large cities will want to deny passenger vehicles access to their centres to restrict traffic volumes. Subjects such as the expansion of public transport, car-sharing etc. are not just of interest to major manufacturers, they have also been of interest to policy makers for a long time. New mobility concepts are therefore urgently required in order to mas-ter these challenges.

But this is not just limited to the future: the current challenges facing car body production are formidable. The number of vehicle models and derivates is increasing significantly, creating new problems for OEM as it does so, especially if multiple propulsion options are concerned. How do

we proceed in the area of fuel cells? The di-gitalisation of the process chain, or human- machine communication, is another exci-ting subject, as well as novel material con-cepts. That’s why this year’s AEE key focus on the “correct materials and suitable pro-cesses in the digital automotive body pro-cess chain” is very much appropriate.

We are currently witnessing a paradigm shift in automotive body construction, from detailed optimisation right up to holistic approaches. Where once the focus was on individual areas such as lightweight cons-truction, now manufacturers and suppliers are currently interested in system-wide pro-duct improvements, especially in connec-tion with the production chain. For this reason, the holistic approach of AEE regar-ding all aspects of the production chain is indispensable for us. The challenges facing engineers at OEM and suppliers is increa-sing steadily due to the use of composite materials and new vehicle con-cepts. How can you keep yourself informed about the new developments in these areas better and more efficiently than here at AEE? These are all subjects that

Greetings from the Trade Fair Board!

AEE offers a unique forum

Dr. Thomas Rudlaff Senior Manager Pre-Development,

Body-In-White Structures and Hang-On Parts, Daimler AG

For two days, exhibitors and trade visitors exchange information on all aspects of car body construction, body painting and final assembly.

The AUTOMOTIVE ENGINEERING EXPO is the only trade fair worldwide, which hosts all areas along the automotive body

process chain under one roof. For two days, exhibitors and visiting specialists can discuss all aspects of automotive body construc-tion, painting and final assembly in the Nuremberg Convention Centre.

After the success of the two previous events in 2013 and 2015, there are also great expectations for the AUTOMOTIVE ENGINEE-RING EXPO 2017: already, three months before the start of the

trade fair, almost 100 exhibitors have registered to present their new products and services at the end of May – this represents a 30% increase in the number of exhibitors. A significant increase in the number of visitors is also expected.

The trade fair is powered by Automotive Circle, the leading com-munication platform for the international automotive and supplier industry. Automotive Circle guarantees the best contacts and in-dustry-relevant specialist information thanks to its many years of collaboration with over 20 leading international OEM brands.

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AEE 2017: Specialist dialogue at the highest level

move our industry today and in the future and which you can expect to hear more of in Nuremberg at the end of May, when AEE opens its doors. Don’t miss this opportuni-ty! The two previous events offered a huge spectrum of content, which will be expan-ded further this year with additional exhi-bitors. We are delighted to be able to give you an initial preview of the trade fair and a taste of what to expect at the third AEE. In this edition you’ll find numerous new products, innovative solutions and trends to get acquainted with, as well as new ser-vices, technologies and much, much more – in other words, everything that represents the future of our industry. See you in Nu-remberg!

Prof. Christoph Wagener Director Research & Product Development, Kirchhoff Automotive Deutschland GmbH

Correct materials and suitable processes in the digital automotive body process chain

Electrification, lightweight materials, sustainability – the focus is squarely on the automotive body process chain at the AUTOMOTIVE ENGINEERING EXPO (AEE) on 30th and 31st May 2017. For the first time, the AEE Innovation Award will also be presented at the trade fair.

At the end of May, specialists from automotive manufacturers and suppliers involved in the design, development and production of modern automotive bodies, painting processes and assembly lines, will meet at the Nuremberg Convention Centre. “This allows us to safeguard our decisive research advan-tage and competitiveness within a field which is constantly changing,” explains Maice Middelkampf, Head of Event Services at Vincentz Network. “AEE offers a place for intensive exchanges, together with the ultimate in networking, between specialists in order to advance integrated product and process development.”

The spectrum of the trade fair covers automotive components and parts, pro-duction systems and systems engineering as well as hardware and software for construction, development and process digitalisation. In addition, exhibitors in Nuremberg will also showcase materials and semi-finished products, as well as moulding and deformation techniques. The spotlight will also fall on bonding technology, surface technology, quality assurance systems/testing and measu-rement systems as well as engineering services.

Focus topic of the trade fair

Specialist engineers from automotive manufacturers and suppliers have, in close cooperation with the organisers of the trade fair, hammered out the fo-cus topic of this year’s fair. The central theme of “correct materials and suitable processes in the digital automotive body process chain” runs through the entire concept of the trade fair and the accompanying events. Lightweight design and digitalisation are the buzzwords dominating the discussion.

The AEE Innovation Award will be presented for the first time in 2017 to reward the innovation of those exhibitors pursuing a multidisciplinary approach in the automotive body process chain.

Up-to-date and market-oriented guaranteed

Along with the exhibitions, the AUTOMOTIVE ENGINEERING CONGRESS provi-des detailed information about the state of the art in design, construction and painting production line automotive bodies. Keynote speakers from OEM will illuminate specific aspects of development (p. 10).

The concept for this trade fair was drawn up together with automotive manu-facturers and suppliers. This guarantees that the AUTOMOTIVE ENGINEERING EXPO remains up-to-date and market-oriented and enables direct dialogue between numerous creative individuals and potential suppliers.

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The supplier of simulation software for casting process optimisation, Magma, will be presenting the possibilities and potential of autonomous engineering with “Magmasoft” in Nuremberg. Using software demonstrations and presen-tations, Magma will demonstrate how they can accelerate part development through autonomous engineering with “Magmasoft”, as well as ensure robust functionality before initial prototyping and construct quality economically. The re-liable prediction of local properties and potential production risks forms the basis of a modern CAE development process. Quantitative information about the principal effects and in-fluencing factors based on virtual experiments offer casting customers and part developers more transparency and permit significant maturity improvements, risk minimisation and the potential for constructive dialogue with suppliers.Booth 12-413 | www.magmasoft.de

4 | AEE – see what’s on | 2017

At AEE 2017 Dow Automotive Systems, a business unit of The Dow Chemical Company, is presenting its portfolio for body design and assembly solutions covering key aspects such as lightweight and process benefits.

New solutions for composites

Fronius, manufacturer of welding systems, photovoltaics and bat-tery charger technology, presents the “TPS/i” CMT welding system at AEE, which combines the intelligent functions of the current device platform with an extremely stable welding process.

According to the manufacturer, the cold metal transfer process pro-duces excellent results with different materials and demonstrates the extensive settings and applications of the innovative “TPS/i” MIG/MAG current source. The new system allows users to benefit from significant increases in both efficiency and quality.

The corner stone of the “TPS/i” CMT is the new, PullMig burner. This is lighter, stronger, and cooler than its predecessor and demonstrates a more stable arc. In addition, Fronius has also optimised the liner with a dynamic and precise servomotor.

Fronius is also showcasing their impact welding unit PMC (Pulse Multi Control) in Nuremberg, which was developed from “TPS/i”. It offers welders access to a wide array of synergistic characteristics. Also on view are Robacta Drive “TPS/i”, a very small push-pull robot welding burner, as well as four new arc types for the “TPS/i” MIG/MAG welder platform.Booth 12-323 | www.fronius.com

Highlights at the Dow booth will be “Voraforce” and “Vorafuse”-composite solutions for RTM and pre-preg application and “Be-

tamate” and “Betaforce” adhesives supporting lightweight design by enabling a material mix. “Voraforce” areultra-fast curing resins for composite applications with high potential of parts integration. Dow states it’s the first carbon fiber based commercial composite solution for mass production providing mass reduction and is pre-sented alongside with Voith Composites, a technology expert for direct fiber placement and advanced RTM processing.

“Betaforce” composite adhesives enable weight reduction, im-proved acoustic performance and better corrosion protection.

Rounding-off the portfolio, also solutions from Dow Corning are showcased at AEE, including a broad port-folio of high-performance silicones and other inno-vative technologies. An extensive range of electronics design materials, adhesives, sealants, silicone elastomers, specialty lubricants, enhanced thermoplastics and ad-

vanced lighting technologies can help meet design challenges for improved acoustics, safety, durability, fuel efficiency or expanded styling options.Booth 12-317 | www.dowautomotive.com

BETAMATE: Application areas for structural adhesives.

Computer model of a structural part (image collage of caste part and simulation)

The “TPS/i” CMT welding system combines the intelligent functions of the current device

platform with an extremely stable welding process.

“TPS/i” current source expan-ded with CMT welding process

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Optimising casting processes

In many industries, automated production processes demand safe handling of loads of several tonnes. The track motion robot from Güdel effortlessly moves industrial robots, which are used in numerous applications.

In particular, the automotive industry requires a great many ap-plications for large scale production of car body parts. Track motion floors (TMF) from Güdel are perfectly suited for use in handling and welding applications as well as paint processes on bodywork as-sembly lines. As a seventh axis, the TMF models extend the working range of articulated robots and are compatible with all standard types. Track motion floors from Güdel up to design size six have been constructed for loads of up to 20 tonnes. Design sizes 3 and 4 are perfectly suited for handling and process applications in bo-

dywork assembly lines such as gripping, stamp, conveying, bolting and welding. As the axes are completely protected against dust, dirt, varnish and paint splashes by coverings and bronze wipers, the motor and guidance elements possess a long service life and are low maintenance. The axes are walkable.Booth 12-508 | www.gudel.com

Products | 5

EAG-PS demonstrates how hybridised lightweight and flexibility can be com-bined with its ‘NextGenSpaceframe.

Aleris is presenting its new concept of technical detail planning, “Simultaneous Engineering“,

in Nuremberg.

EDAG Production Solutions GmbH & Co. KG (EDAG-PS), en-gineering partner for project management and networked produc-tion engineering working towards the factories of the future pre-sents, for the first time ever, a media-independent grabbing system for automotive body parts at AEE 2017: The additive – a 3D printed grabber – is opened and closed exclusively by robot.

“This makes other media and their components such as directi-onal valves, proximity switches, cables etc. and their control units superfluous,” explains Rainer Wittich, CEO of EDAG-PS. “Assembly of the grabber is as easy as changing components after a crash. Special parts can simply be reprinted as and when needed. At the same time, storage is minimised through the use of standardised modules.”

Aside from the new grabber system the company also demons-trates how hybridised lightweight and flexibility can be combined with its “NextGenSpaceframe”. The successful implementation of their own vehicle concept allows growing vehicle variance to be brought under control through numerous types of motor and load

classifications. The associated production concept, was which is based on cooperating robots, developed in parallel using Industry 4.0 approaches.Booth 12-420 | www.edag-ps.de

Thinking consistently ahead

Aleris, a world-wide manufacturer of aluminum rolled products, is presenting its new concept of technical detail planning, “Simultaneous Engineering”, at the AEE. This allows the various stages of product design, production process and material selection to be carried out simultaneously and not one after the other.

This method is a great success due to the decrease of production development time, the improved productivity and re-duced cost. This way, OEM benefit from

significant support related to developing current and future aluminum design cri-teria, simulation activities (e.g. forming or die development) and sharing

of material data cards to conduct their own simulation.

Aleris serves the automotive and ae-rospace industries, as well as railway and other industrial applications. Its global footprint includes plants in the US, Europe and China. By increasing production for au-tomotive body sheet, Aleris is aligned with automotive industry efforts to bring lighter and more fuel efficient vehicles to the mar-ket. For over 30 years, Aleris is partnering with its customers to find the best solu-tions for their aluminum automotive body sheets. Booth 12-312 | www.aleris.com

Making Robots Flexible

Simultaneous Engineering

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European research project “epsilon” develops electronic subcompact for tomorrow’s urban mobility

Safety-optimised subcompact concept

The global spread of urbanisation is leading to high congestion and, of course, correspondingly high rates of exhaust and noise

pollution. To meet these challenges head on, new vehicle and mo-bility concepts such as “epsilon” are required.

As part of the European research project “epsilon”, leading Eu-ropean companies and institutes within automotive research and development have developed an innovative vehicle concept for the period between 2020 to 2025. Sustainability, safety, efficiency and a lightweight design form the most important factors. “One of the go-als during the development of “epsilon” was to bridge the gaps bet-ween motorcycles, small powered vehicles and quads in class L7e and conventional private cars in class M1”, explains Kristian Seidel, Senior Manager Body at Forschungsgesellschaft Kraftfahrwesen mbH Aachen (fka) and Project Coordinator.

Based on a holistic lightweight approach, a CFK-Al space frame body was constructed and investigated at all points of the vehic-le according to the safety requirements of Euro NCAP. Using finite element (FE) simulation, the passive safety requirements of sub-compact vehicles were identified. The developers were primarily concerned with achieving a weight of less than 600 kg as well as

high energy efficiency (< 80 Wh/km). The two-seater can accelerate from 0 to 100 km/h in less than 10 sec. and has an electric range of over 150 km.Booth 12-121 | www.ika.rwth-aachen.de

6 | AEE – see what’s on | 2017

For the Fraunhofer Institute for Ma-nufacturing Technology and Advanced Materials the name of the game at this year’s trade fair is “Secure Adhesion”. Ac-cordingly, the Bremen-based researchers have placed particular emphasis on the quality requirements of adhesion processes as defined by DIN 2304. The institute offers various services for implementing the stan-dard.

According to DIN EN ISO 9001 adhesion is a “special process”, the results of which can-not be tested without damaging the sample. In order to ensure a reproducible adhesion process, it is crucial to develop a strategy of stringent error prevention. This requires that adhesion must be effectively anchored wit-hin the quality management system with the appropriate use of technology.

By employing its own expertise together with DIN 2304 “Adhesive technology – qua-lity requirements for adhesion processes”, Fraunhofer IFAM offers standardised testing of industrial adhesion processes. Imple-mentation is overseen by DVS-/EWF-speci-alist adhesive engineers, who possess wide

ranging expertise and ability in industrial certification for adhesive bonding. Process controls are tailor made according to pro-duct requirements and customer desires. The goal of testing is to identify potential improvements and to carry out process op-timisation and performance evaluation ac-cording to DIN 2304.

In addition, Fraunhofer IFAM presents technical possibilities to safeguard proces-ses as well as process-integrated quality assurance of surfaces and monitoring, for example, of pre-treatment baths. Another important subject is the application of in-dustry 4.0 within quality assurance. The institute is also presenting some topics un-der the heading of “Quality assurance goes digital”.Booth 12-429 | www.sicher-kleben.de

Adhesive – that sticks!

At this year’s 2017 trade fair, the Fraunhofer Institute for Material and Beam Technology (IWS) is placing its focus squarely on digitalised laser bon-ding for the material mix automotive body assembly. The main exhibit of the researchers is the modular welding head “Remoweld Flex” for laser welding with high frequency beam oscillations up to four kilohertz.

The high frequency beam oscilla-tions enable active manipulation of the weld pool geometry, extension of the weld pool duration and an increase of the degree of mixing in the weld pool. The three modules of “Remoweld Flex” – scanner, weldseam sensor and tra-cking sensor as well as its high-speed camera (HSC) – can be put together to suit the customer’s specific needs.

Within the automotive industry this welding head can be used, for example, for pressurised laser welding of alumi-nium pressure die casting or for laser welding of dissimilar materials for com-ponents in electric mobility. Thanks to its extensive expertise in metal physics

Digitalised laser bonding

Detection of a fingerprint with the aerosol wetting test.

Based on a holistic lightweight approach, a CFK-Al space frame body was constructed and investigated at all points of the vehicle according to the safety

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Politecnico di Torino shows innovative bumper subsystem and leaf spring suspension system

The Department of Mechanics and Ae-rospace Engineering of the Turin Uni-

versity of Technology (Politecnico di Torino, Italy) is waiting for two new developments on the AEE: a bumper subsystem made of composite material and a sheet spring suspension system made of carbon fiber reinforced plastic (CFRP).

For what concerns the bumper subsys-tem, the crash boxes are integrated with the bumper beam. This single component is made in semi impregnated micro sandwich materials (SIMS) by die forming process. This leds to relatively thick structure with different extent of dry fibre content within the core thickness.

The stiffness of the component is in-creased up to 30%. Moreover, the energy absorption capability is about 20% higher than a fully impregnated structure. The sys-

tem has been developped in 2 steps: the bumper beam and the crash boxes were optimized separately, then the beam crash box integrated system.

The second main exhibit, the CFRP leaf spring, is made of carbon fiber and ther-mosetting resin. It represents a solution

where: the leaf spring has been designed to work as spring, anti-roll bar, lower and longitudinal arms. At the same time, the application is for a multilink suspension, with function integration (spring, anti-roll bar, lower and longitudinal arms). Booth 12-205 | www.dimeas.polito.it

New composite materials for the automotive industry

Efficient composite construction

and systems engineering, Fraunhofer IWS offers, amongst other things, la-ser welding technology development, special systems engineering, prototype welding, processes and systems optimi-sation as well as project engineering for welding instructions..Booth 12-330 | www.iws.fraunhofer.de

Specialists from research and industry have joined forces to work on the “Efficient composite construction for lightweight bodies” research project, also known as LEIKA. Their goal is to develop a novel con-struction for electric mobility vehicles.

The research project has looked at mass production techniques and bonding con-cepts for high load-bearing body shells featuring a composite design with high metal content. For this purpose a highly in-tegrated underfloor structure consisting of a novel metal-FRP sandwich material was developed.

The combination of steel and/or magne-sium with fibre reinforced plastics demons-trates significant potential for lightweight designs. To fully exploit the lightweight po-tential of both material classes synergisti-cally, an intelligent bonding concept is re-quired.

The Institute of Machine Tools and Production Technology has covered the following areas:• Analysis of floor structures and used

bonding techniques• Identification of applicable bonding

techniques and adhesive systems• Pre-investigation with novel sandwich

materials• Experimental characterisation of

load-bearing capacity• Creation of analogous models for crash

simulation• Analytical and conceptual design (e.g.

Δα-estimates)• Topology optimisation of individual

components• Study of corrosion characteristics

A demonstration of the developed floor structure will be presented at the trade fair stand. This research and development pro-ject is funded by the Federal Ministry of Education and Research (BMBF) as part of “Research for Tomorrow‘s Production“ (“For-schung für die Produktion von morgen”, grant number 02PJ2760 – 02PJ2763) and su-pervised by Projektträger Karlsruhe (PTKA).Booth 12-127 | www.lwf.upb.de.

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and carbon fabric resin content.

For this purpose a highly integrated underfloor structure consisting of a novel metal-FRP sandwich material was developed.

The modular welding head “Remoweld Flex” was developped for laser welding

with high frequency beam oscillations up to four kilohertz.

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DEPRAG has developed an adaptive assembly system for flow form screwdriving

The mix of materials in automotive light-weight construction means that fas-

tening systems such as flow form screwdri-ving (FFS) are becoming prevalent and undergoing continued further develop-ment. DEPRAG will present an adaptive as-sembly unit in Nuremberg, which is suitab-le for both feeding and screwing processes thanks to its controlled electric motor.

The “Adaptive DFS – DEPRAG Fastening Systems” control unit continually determi-nes the relevant current values and adapts the process values of pressing force and screwing speed to the pre-defined target values. This means that the ideal process parameters are achieved, reliably, during every screwing process. Errors that lead to expensive repairs can therefore be avoided.

In addition, the system ensures that bolts and components are subjected to the least possible stress – irrespective of the material and material combinations of components.

Other advantages of “Adaptive DFS” include reduced cycle times and optimal exploitation of material-related parameter tolerances with regard to screwing speed and torque. Separate electronic control of feed and screwing motors offers extensive parameter options.

This ensures high flexibility when wor-king different materials and material com-binations. Controlled feed motion allows precise feed processes and switching points to be defined for future materials. The screwing system features an ergonomic and intuitive user interface. Preventative main-

tenance ensures maximum system availabi-lity through an array of integrated diagnosis functions.Booth 12-308 | www.deprag.com

Polypropylene (PP) is a versatile and cost-effective material, its one disadvantage is that, due to its non-polar surface, PP must be activated before being coated. This requires an additional process step, additional systems engineering, extra handling and higher costs. At the trade show, Swiss start-up Nolax AG demonstrates “Inmolt”, a new film with which PP components can be activated directly in the tool. The multi-layer film consists of a layer of po-lypropylene, a bonding agent and a polar TPU layer. The PP layer is injected into a tool with the PP matrix and then forms a positive bond with it. The surface of the part is in turn covered with the TPU film. Transfer of the film to a mould can be performed via injection moulding at temperatures of 200-250 °C and a pressure of up to 800 bar.

“Inmolt” also acts as a buffer layer, as even the most minimal film thickness is sufficient to cover joint seams, glass fibre stria-tions and depressions. Thanks to its high breaking stress the film also provides added shatter resistance to the part. It is availab-le on rolls with varying thicknesses up to 90 µm and in varying widths up to 1500 mm.Booth 12-401 | www.nolax.com

New film activates PP components in tool

New data loggerPhoenixTM develops and produces systems for recording

temperature profiles in industrial ovens, which are passed through the oven with the product. During operation they record temperature profiles at up to 20 different positions. After being retrieved from the oven, the data are evaluated using Thermal-View software. This allows process problems to be identified be-fore they manifest themselves in the product.

To meet the growing demands of customers head on, PhoenixTM has developed a new data logger generation with its data loggers “PTM1-206“ (6 channel), “PTM1-210“ (10 channel) and “PTM1-220“ (20 channel). In particular, areas that have been optimised are measuring frequency, storage capacity, computer connections and calibration data.

The new two-way telemetry from PhoenixTM permits re-starts and downloads whilst the data logger is still in the oven. The data connection re-starts automatically if the connection is dropped. This means that data packets recorded during an interruption are not lost. A fast measuring period of 0.2 seconds means that pro-cesses with large gradients can be followed and analysed at even greater detail. To allow long-duration processes to be recorded at high measurement rates, the storage capacity has been expanded to 3.8 million measurements.Booth 12-423 | www.phoenixtm.de

PhoenixTM is presenting in Nuremberg its optimized

temperature recording in heat treatment.

“Inmolt“ has already been tested for mass

production applications, the process is patent

pending.

Thescrewing system features

an ergonomic andintuitive user interface.

Adaptive flow form screwdriving

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Automotive construction increasingly relies on composite materials comprising aluminium and high-strength steel in order to reduce weight and achieve the required level of stability for those vehicle compo-nents, which are of relevance in crashes. However these composite materials can-not be automated using normal welding techniques. Through “Flowform”, “Flow-push” and “Flexweld”, Arnold Umform-technik has developed alternative bonding solutions that can be automated.

In “Flowform”, a special screw creates a hole in the material by means of a flow form process that employs a combination of axial force and relatively high screwing speed, which heats up the material accor-

dingly. The screw then creates a threaded nut before being screwed in place (can be removed during repairs). This produces high-strength bonding for parts that are of

relevance during crashes. “Flowpush”, the insert bolt forms a hole using a pointed tip at the end of a screw shaft before being driven in to the material. A special shaft profile ensures a secure hold. Once the bolt reaches its end position, it is locked in place with a rotary motion.

With “Flexweld”, metallic resistance weld elements are introduced in the alumi-nium sheet. This allows the sheet metal to be joined with sheet steel using classic spot weld techniques within existing production systems. All three processes can be proper-ly automated.Booth 12-320 | www.arnold-fastening.com

Lightweight construction presents a challenge for automation

Process-optimised robot tooling systems

Testing automotive body parts with acoustic resonance testing

The Crack Master from manufacturer SaabMedav Technologies allows automotive body parts to be tested for relevant defects

automatically during the production cycle.The Crack Master uses ART or acoustic resonance testing to

detect cracks, cutting defects, significant contractions or undula-tions. ART exploits the fact that it is mostly defect-free parts that are produced and so it filters out conspicuous parts, whose acoustic properties deviate significantly. The resonance frequencies of auto-motive body parts are excited using an electromechanical impact hammer, also known as an impact device. A sprung probe tip is used as a sound sensor. Both are integrated in a model-specific part support. The part support facilitates vibration decoupling of the test object from its environment. The evaluation characteristics are physically connected with the geometry, mass, density, Young’s modulus and stiffness and therefore the stability of the part. As a comparative process, ART enables cross-checking of adaption parts at the start of a new production batch, in order to exclude the ad-aption of series defects.

“The main use lies in the prevention of rejection costs in the subsequent production steps,” explains Dr. Michael Weidner of Technical Sales at the Bavarian manufacturer. Booth 12-123 | www.saab.com, www.medav.de

Automatic in-line quality control

The model specific part support ensures reproducible positioning of the test object with respect to the impact device and sensor.

Stäubli Connectors, a manufacturer of automated tooling sys-tem for robots with high functional and process reliability, demons-trates two new tooling systems, the “MPS 130” and the “MPS 260”.

These model ranges are not only intended for applications wit-hin automotive body construction, but also for all other areas wit-hin automotive production, in which potential exists for increased efficiency. The robot side of the “MPS 130” only weighs 1.8 kg and the tool component just 1.1 kg. For the larger “MPS 260”, these fi-gures are 3.8 kg and 2.2 kg respectively. The “MPS 260” offers a

maximum load-bearing capacity of 350 kg and a bending moment of 2,000 Nm. The smaller “MPS 130” has a load-bearing capacity of 100 kg and a bending moment of 900 Nm.Booth 12-207 | www.staubli.com

The systems can be customized with different modules for media, data, and electrical energy transfers.

The diagram shows the structure of the connection element “Flowform“.

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Some of the automotive bodies that premiered at the EuroCar-Body Conference in October 2016 will be highlighted again at

AEE. Here, suppliers are given the opportunity to demonstrate their products in action and visitors can experience the future of the automobile up close.

Until now it was only possible to view the year’s most innovative and inspiring automotive bodies at Automotive Circle’s annual Eu-roCarBody Conference. However, these fantastic automotive body concepts will now be given a wider trade audience at the AUTOMO-TIVE ENGINEERING EXPO. “Visitors and exhibitors now have the unique opportunity to witness the best engineering from around the world and learn about its most important data regarding au-tomotive body”, explains Franziska Moennig, Director of the Stee-ring Committee of Automotive Circle. “Here, the trade public can experience, up close and personal, just what the future holds for automobile construction.”

Bodies from BMW, Škoda, Aston Martin, Bentley, Peugeot and Jaguar Land Rover will be on display. Posters accompanying the

exhibitions will relate the most important aspects about the res-pective automotive bodies. AEE’s Showcase affords suppliers and exhibitors the opportunity to demonstrate their products or ser-vices, personally, in front of their exhibits. Here, the industry can inspect the best examples of engineering under one roof and talk directly with developers – that’s a unique opportunity!

In 2017, AEE’s Showcase will be expanded to include the year’s most innovative add-on parts highlighted at the internationally conference Doors and Closures in Car Body Engineering in automo-tive body construction.

The Showcase is a real highlight of the international congress, which met with huge interest during the last AEE in 2015. That’s why the bodies are presented briefly and concepts are explained at the end of the guided tour through Innovation Alley.

It goes without saying that the Showcase wouldn’t be complete without the winner of last year’s EuroCarBody Awards in Bad Nauheim: first place went to the new Alfa Romeo Giulia. Fiat Chrysler Automobile went back to the drawing board with the sports saloon which has been com-pletely reconstructed. It is competing with Alfa Romeo after complete brand re-launch and impressed the public with an extremely aerodynamic, very stiff and therefore responsive, but light automotive body. The Giulia is based on a material mix, which most significantly contains modern high-strength steel alloys (AHSS) in its structure, including very malleable bainitic TRIP steels and novel layered dampening steel components (a laye-red sheet steel structure with a visco-

elastic plastic interim layer, which are moulded together) combined with a lightweight aluminium add-on parts.

Luigi Sciarretta, Aldo Ettore Ajmar and Stefano Tateo, who presented the Alfa Romeo Giulia in Bad Nauheim, also wowed the audience with numerous innovations

within the production and develop-ment process. This led to them being assessed as the best with a total point count of 39.46 out of 50, securing them first place.

Live at the venue: the “Giulia” from Alfa Romeo

The winner team of the “Alfa Romeo Guilia“

10 | AEE – see what’s on | 2017

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AEE presents the best automotive body concepts

publisher and organizer:

Vincentz Network GmbH & Co. KGAutomotive CirclePlathnerstr. 4c, DE-30175 HannoverT+ 49 511 9910 000, F +49 511 9910 099www.automotive-circle.com

editor-in-chief: Franziska Moennig

editorial staff: Sabine Scharf, Regine Krüger

layout/production: Nicole Unger

printing: Strube Druck & Medien OHG, 34587 Felsberg

publisher: Esther Friedebold

legal venue Hannover

© Vincentz Network GmbH & Co. KG

The specialist congress for the entire automotive body process chain

64 presentations, 4 plenary meetings, 2 exciting days – the AUTOMOTIVE

ENGINEERING CONGRESS (AEC) presents the groundbreaking trends of tomorrow to visitors from all over the world. The event focuses on current advances and practical solutions for construction, part production, assembly, painting and finishing.

In particular, the congress will focus on the question of “correct materials and sui-table processes in the digital automotive body process chain”. For Dr. Dirk Meine, Congress Editor responsible for the pro-gramme, the highlights include the mee-tings of the plenary, which frame the pro-gramme of presentations: “Both days of the congress begin and end with a motivational presentation on a key contemporary theme within the industry. This is followed by pa-nel discussion with OEM representatives.”

For instance, the first day begins with a motivational presentation by Dr. Bernd Brinkmeier of Siemens Industry Software on the subject of “Routes to a continuous simulation chain in vehicle development”. The subsequent panel discussion with re-presentatives of Adam Opel AG, Audi AG and Jaguar Land Rover Ltd. will handle this subject in more detail.

The programme continues with ano-ther motivational presentation by Dr. Frank Breitenbach of EDAG Production Solutions. His contribution focuses on “Big data management”, whilst the sub-sequent OEM panel discussion will handle the question of how much and what type of data are really relevant for automotive body construction. In between the presen-tations and panel discussions, suppliers will hold presentations of their products, services and news. In this way, the spe-cialist congress is able to offer suppliers and engineering service providers, as well as start-ups, the opportunity to showcase their abilities and ideas along.

The structure of the AEC makes it parti-cularly relevant within the industry, accor-ding to Meine: “This covers everything that exists along the process chain within auto-motive body construction – from producti-on, part production in the pressing plant, bodyshell work and surface processing, right up to the final finishing stage. These four trades are represented at the congress as four pillars, which run in parallel over both congress days from 10.15 a.m. to 5.00 p.m. This gives every participant the chance to put together his perfect programme.”

Wednesday starts with a motivatio-nal presentation on the EPSILON research project by Kristian Seidel of Institut für Kraftfahrzeuge at RWTH Aachen, who will present the concept of a compact electric

Concentrated expertise focused precisely

To combine theory with practice, the promoters are offering two expert guided tours in both lunch breaks, each one hour long that will feature the highlights of the Automotive Enginee-ring Expo. Tour 1 focuses on the subject of materials and surfaces, whilst Tour 2 concerns bonding systems. The finale of each tour is the Showcase where the participants can experience various car bodies and hang-on parts.

Expert tours

vehicle featuring a maximum-safety con-cept. This will be followed by a panel dis-cussion with OEM representatives who will discuss the idea of the automotive body in the age of the electric vehicle and autono-mous cars.

The congress finishes at 5.00 p.m. with a presentation on “How aluminium can en-able the shift to low-emission mobility” by Patrik Ragnarsson from European Alumini-um. The subsequent OEM panel discussion concerns the future material mix of auto-motive bodies.

Dates: 30th-31st May 2017

Location: Nuremberg Conference Centre, NCC-West

Conference language: German and English

Focus: Automotive body – from concept to final production stages

Special content:

64 technical presentations covering the entire process chain of “painted automotive bodies“

4 plenary meetings with OEM panel di-scussions on key contemporary themes

Thematic guided tour for congress participants through the exhibition

The congress at a glance:

Automation Engineering Congress | 11m

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Venue: Exhibition Centre Nuremberg

Opening times:30th May 2017: 09:00 - 18:0031st May 2017: 09:00 - 17:00

Ticket prices include the statutory VAT1-day ticket: EUR 18Permanent ticket: EUR 35

Get into the exhibition faster with an e-ticketYou prefer the fast and easy way? Get your personal e-ticket for AUTOMOTIVE ENGINEERING EXPO 2017 until 31 May 2017 and save the bother of registration and buying entrance tickets on arrival. https://www.automotive-engineering-expo.com/en/visitors/tickets/ticketshop

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