electrification 2030 - consortial study

Electrifying the Industrial Value ChainElectrification

Consortial Study for Selected Industrial Partners

ZEPZentrum fürElektromobilproduktion

KARTMAXe

Broschüre_Benchmarking_11.04.2013_final m. Bildnachweisen.indd 1 16.04.2013 10:27:26

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


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)


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



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


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



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


8 Electrification

Consortial Study for Selected Industrial Partners



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


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



ZEP – Worldwide Market Study for Electric Powertrain Applications. New Markets, Products and Production Technologies


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


electrification 2030 - consortial study

Documents

production management

production systems

new production concepts

new technologies

production engineering

new era of electrification

electromobile production

global market