Projekt OsTOS - ITA Augsburg

Press Release

Pioneering project for circular lightweight solutionsthroughartificial intelligence.

Targeting the CO₂ footprint of products, using secondary raw materials and developing recyclable lightweight solutions are requirements for the products of tomorrow. As part of the OsTOS research project, this is to be developed on the hybrid molding process. One important approach is the use of artificial intelligence.

A consortium along the entire value chain has joined forces under the acronym OsTOS. The cooperation agreement was recently signed. Matthias Froning from ITA Augsburg explains exactly what the "Oven System for Tailored Organo Sheets" (OsTOS) is all about:

"Together with our partners, we are specifically developing the existing hybrid molding process further in order to be able to manufacture recyclable lightweight products with a tailored CO₂ footprint. AI-based tools are used to support the user. This combination makes the OsTOS project a particularly exciting project in our institute's research focus on digitalization."

The targeted combination of different materials opens up new possibilities in product design.

"Our customers are placing ever higher demands on new products. We want to meet these with innovations and provide new solutions. In the OsTOS project, we as consortium leader want to translate these customer requirements and bring them into machine development. The aim is to be able to offer new product generations of integral lightweight solutions on the market," says Julian Löseke, Automotive Project Manager at Centrotherm.

According to KraussMaffei, the FiberForm technology it has developed has proven itself on the market in recent years and demonstrated its potential to offer cost-effective lightweight solutions in large series as a highly automated production cell. "Applied research is deeply rooted in Germany as a business location. As a system integrator, we want to use this innovative strength of our partner network and merge individual solutions into a unique overall package," said Felix Weitmeier, Teamlead Process Engineering at KraussMaffei Technologies.

The automation is also offered in-house. Falko Jahn, Head of Development at KraussMaffei Automation, has more to say about this: "Maximum flexibility and a high level of operating convenience characterize our LRX linear robots, which we also want to use in this project. When it comes to gripper technology, we want to set new standards in process monitoring and process reliability."

One of the most important sensor systems in the process is non-contact temperature measurement. The corresponding components are manufactured by the specialist Optris.

"Our innovative products allow us to capture valuable process data. For an accurate temperature determination in the industrial environment, our pyrometers of the CT series could excel. Together with our partners, we are building a sensor landscape that allows us to identify possible trends at an early stage," explains Uwe Klonowski Head of Engineering, of Optris.

Based on this, suitable measures for fine-tuning the plant are derived. The necessary AI solution is provided by the software provider DatenBerg.

"At DatenBerg, we enable our industrial customers to successfully use production data. Our software analyzes production, environmental and quality data automatically and provides employees with recommendations for action. Our focus in the project is on the automated fine-tuning of process parameters using artificial intelligence. In this way, we automate the path between the interpretation of the quality result of the heat distribution on the organic sheet and the fine adjustment of the system," explains Maximilian Backenstos Managing Director of DatenBerg.

In order to precisely implement the recommendations for action obtained, specialized radiation technology is required during the heating process. This is where Infratec contributes its many years of know-how.

"We have great expertise in the areas of manufacturing and designing infrared emitters and systems of all kinds, as well as modular installation kits for retrofitting existing systems. In this project, we can specifically contribute with miniaturized emitter types that enable the targeted heating of individual areas on an organic sheet and ensure a high energy input on a small area," Olaf Pfeiffer, Managing Director of Infratec, knows to report.

The necessary link between the process control and the actuators is provided by Elektroschmiede.

"We are pleased to participate in the project and to develop an individual controller architecture. Thanks to our experience in the automotive sector, we will also contribute a cost-effective solution here," says Sebastian Vetter, Managing Director of Elektroschmiede.

The German Federal Ministry of Economics and Climate Protection (BMWK) supports the OsTOS research initiative under the funding code 03LB3027. It is being managed by Project Management Jülich (PTJ) as part of the Technology Transfer Program for Lightweight Construction (TTP LB).

Centrotherm

The applications of the hybrid molding process of Centrotherm Systemtechnik GmbH currently range from complete component structures and structural reinforcements of local areas, through the build-up of functional layers against mechanical or chemical influences, to the realization of multi-material build-ups based on diverse plastic matrices. In line with its corporate philosophy, Centrotherm not only manufactures energy-saving products, but also focuses strongly on sustainability. Right from the design and production phase, the aim is to be as environmentally friendly as possible. At present, the focus is on reducing emissions resulting from the company's processes or procedures, and from the manufacture of its products. Through activities related to CO₂ reduction, Centrotherm has achieved EN ISO 14001 certification. The company premises in Brilon meet the highest standards of CO₂-neutral construction.