3D Ultrashall - 3D ultrasound for person recognition at shunting stations

INVESTIGATION OF 3D ULTRASOUND TECHNOLOGY FOR PERSON RECOGNITION DURING RAILWAY SHUNTING

From retail to industrial production – without goods traffic, many areas of everyday life would collapse. Every day, several million tonnes are conveyed by road, rail, air, and water. In rail freight transport alone, 364 million tonnes were transported in 2016, according to information provided by the German Federal Statistical Office. The freight wagons are used for shunting multiple times.  more about this project

AddPro-KMU - Additive manufacturing by means of modular machine concepts

ECONOMICAL ADDITIVE MANUFACTURING USING MODULAR MACHINE CONCEPTS FOR SMALL-SERIES PRODUCTION IN SMEs

3D printing enables real objects to be produced from digital three-dimensional models. In industry, the application of this technology is referred to as additive production, and is used in processes such as rapid prototyping.  more about this project

Averdi - Alternative compression processes

ALTERNATIVE COMPRESSION PROCESSES FOR NANOPARTICLE-CONTAINING INKS PRINTED USING DIGITAL PRINTING PROCESSES FOR PLANAR MID

New printing processes for electronic production have been investigated for years. Digital printing processes such as ink jet or aerosol jet printing offer many advantages compared with previous mask-bound processes, and have made their mark chiefly in the functionalization of planar components such as chip cards. The inks for the printing process are generally manufactured from nanoparticles, usually of silver or copper, because of their high electrical conductivity. However, the compression process (sintering) still presents a challenge.  more about this project

Accessibility and demographic change

ADAPTATION STRATEGIES IN THE URBAN DOMAIN TO ACCOMMODATE THE MOBILITY NEEDS AND MOBILITY BEHAVIOUR OF A CHANGING URBAN SOCIETY

In the decades to come, demographic changes will require our cities to face up to new challenges. According to current population forecasts, the number of older people in German society will continue to rise. Despite the discussions that have already taken place, the complexity of this development has not been sufficiently recognized.  more about this project

BiFIRE - Laser transmission welding process with two wavelengths

CHARACTERIZATION AND OPTIMIZATION OF THE LASER TRANSMISSION WELDING PROCESS WITH TWO WAVELENGTHS

Whether in the automotive industry or in medical engineering, many products could not be manufactured without the welding of plastics. Laser transmission welding is playing an increasingly important role in this. Its short process times, low stress on the components, and the possibility of applying heat to the joint zone in a tightly limited way give it crucial advantages over alternative processes such as ultrasound welding or heating element welding.  more about this project

BioFlexRobot - Articulated robot arm

DEVELOPMENT OF A BIONIC, LOW-COST, ARTICULATED ROBOT ARM AS AN ACTION UNIT FOR HUMAN-MACHINE COLLABORATION

Articulated robots are used in a wide variety of ways on modern production and assembly lines. They increasingly take on jobs that are either difficult to achieve or could present a high safety risk for humans, moving heavy loads or working in adverse conditions. If a person then enters the robot’s workplace, this can lead to serious injury.  more about this project

DATA∙e∙Pump - Data-based automation and drive technology for pump systems

DATA-BASED AUTOMATION AND DRIVE TECHNOLOGY FOR EFFICIENT PUMP SYSTEMS

Pump systems have a very broad area of application worldwide and therefore require a correspondingly high proportion of the total available power. Automation technology has the potential to save a significant amount of this power without changing the structure of the equipment. The diverse application areas of pumps also result in a very variable arrangement of pump system components.  more about this project

Owl neck joint - An owl’s neck joint for efficient machines

AN OWL’S NECK JOINT FOR EFFICIENT MACHINES

High-performance, energy-efficient, environmentally sustainable, and resource-saving: the requirements being placed on technical systems during the development of machines are increasing all the time. Developers are now reaching their limits, especially when it comes to the technical implementation of movement sequences. In articulated robots or construction machinery, such as dumpers and cranes, turning and swivelling movements are carried out by electric motors or pneumatic or hydraulic cylinders.  more about this project

FAMA - Freely programmable variable message traffic signs

DEVELOPMENT OF AN INNOVATIVE, FREELY PROGRAMMABLE LED VARIABLE MESSAGE TRAFFIC SIGN WITH A SINGLE-PART LENS SYSTEM AND CLUSTER-BASED LED AND DRIVER MONITORING, BASED ON INNOVATIVE CONTROL AND LENS SYSTEMS

In order to guarantee a safe flow of traffic, even in the event of construction work, accidents and other events, it is necessary to update the traffic rules rapidly and in accordance with the relevant rules. One possible way of doing this involves the use of LED variable message traffic signs.  more about this project

FlexFilament - 3D printing with variable filament paths

VARIABLE FILAMENT PATHS FOR EFFICIENT AND FAST 3D PRINTING WITH FDM

3D printing is playing an increasingly important role in industry. “Melt layering” is now the most usual method used for the additive construction of workpieces. In this procedure, which is also known as “Fused Deposition Modelling (FDM)” or “Fused Filament Fabrication (FFF)”, the workpiece is built up layer by layer from melt-processable plastic.  more about this project

FORMUS3IC - Systems improvement community

MULTI-CORE SAFE AND SOFTWARE-INTENSIVE SYSTEMS IMPROVEMENT COMMUNITY

Embedded systems are among the driving technologies of Germany as a business location. 90% of innovations in industry – for example, in the automotive or avionics sector – come from the field of embedded systems. In the automotive industry alone, the software development for these systems now accounts for over 50% of the total development costs. Increasing demands for ever more sophisticated functions, for example automated or autonomous driving, have led to a paradigm shift in the processors used in these systems.  more about this project

FORPRO2 - Efficient product and process development by means of knowledge-based simulation

SUB-PROJECT: GENERATION OF CORRECTED, REALISTIC GEOMETRIES FOR SIMULATION WITH 3D SURFACE CAPTURING

When developing and designing industrial products, the simulation process plays an important role. This is because simulation of product properties and manufacturing processes, when applied correctly, offers considerable potential for development efficiency due to the early knowledge it provides and the use of purely virtual prototypes.

→ Results

FVA801I- Dynamic dependency in the DC link circuit

DYNAMIC DEPENDENCY IN THE DC LINK CIRCUIT

The increasing spread of electric vehicles leads to increasingly large variations in the implementation of the electric drive train. These range from e-vehicles with one or more drives and various hybrid systems to vehicles powered by fuel cells. Depending on the driving situation and on the different frequencies of clocked consumers, load changes occur which lead to interdependencies between the connected components in the DC circuit.  more about this project

Hybridlok - Hybrid drive for shunting locomotives

MODELLING, SIMULATING, AND VALIDATING THE OPERATION OF ENERGY-EFFICIENT PROPULSION SYSTEMS FOR HYBRID-POWERED SHUNTING LOCOMOTIVES

Demand for energy-efficient and low-emission propulsion long ago formed the driving force behind a rethink with regard to the development of railway rolling stock. The introduction of more stringent environmental standards is putting pressure on the operators of diesel locomotives to reduce emissions such as harmful substances and noise. New fuel-saving strategies are needed, especially in order to reduce CO2 emissions.  more about this project

iKON - Intelligent operational management

INTELLIGENT OPERATIONAL MANAGEMENT BY COMMUNICATION BETWEEN PRODUCTION AND FACILITY TECHNOLOGY USING AN ARTIFICIAL NEURAL NETWORK

Almost half of German energy is consumed by the industry, trade, retail, and service sectors, and in small and medium-sized enterprises in particular, the potential for energy savings and energy efficiency is scarcely exploited. Above all, the coordination of production processes and facility technology in production operations opens up great potential, which has thus far received hardly any attention at all.  more about this project

iKSM – integrated stator cage machine

INTEGRATED STATOR CAGE MACHINE (iKSM)

Energy-efficient electrical motors and propulsion systems form an important component of the energy transition. Electrical motors of that type include individual coils with multiple windings as conductors. These are configured as a string and are distributed across the dimensions of the motor.  more about this project

IMPROVES M - Influence of the manufacturing process on magnetically soft materials

INFLUENCE OF THE MANUFACTURING PROCESS ON DIFFERENT MAGNETICALLY SOFT MATERIALS

Electric mobility is often regarded as the key to the energy transition in the area of transport. This is because electric motors have far higher degrees of efficiency than conventional petrol or diesel engines and are therefore viewed as particularly energy-efficient. In order to increase the efficiency of rotating electrical machines such as electric motors even further, it is necessary to observe, determine, and minimize the types of loss. During minimization, for example, it is particularly important to separate the overall machine losses into their individual component parts.

→ Results

IvExAP - Nozzle concept for additive production

INNOVATIVE EXTRUDER CONCEPT FOR FAST AND EFFICIENT ADDITIVE PRODUCTION

The significance of additive manufacture for industrial production is steadily rising. Usually, the workpieces are manufactured using the “melt layering” process for 3D printing. In this procedure, which is also known as “Fused Deposition Modelling (FDM)” or “Fused Filament Fabrication (FFF)”, the workpiece is constructed layer by layer from melt-processable plastic.  more about this project

KAVA UNDROMEDA - Underground robotic system

UNDERGROUND ROBOTIC SYSTEM FOR MONITORING, EVALUATION, AND DETECTION APPLICATIONS

The number of underground mines is increasing worldwide. The hazardous environments in mines result in a high risk of injuries and fatalities. The approximately 657 underground mines in the USA alone have an average of 20 fatalities and 1,972 serious injuries per year, which are mostly caused by ceilings or walls collapsing. Therefore, the demand for exploration of unknown areas for operational and safety purposes in underground mines, but also in sewage tunnels and other underground areas, is very high today and will increase in the future.  more about this project

KOBOLD - lightweight piston pin - design

LIGHTWEIGHT PISTON PIN - DESIGN

The translation of academic research results into industrial products and processes continues to be a major challenge. In Germany, this problem mainly affects the metal sector. A key factor here is lightweight construction. The automotive, mechanical engineering, and aviation industries are a major pillar of the German economy and would benefit greatly from a better transfer of the extensive research knowledge into industrial development processes for components.  more about this project

LEV@KEP - Cargo bike for sustainable urban logistics

RESEARCH ACCOMPANYING THE DEVELOPMENT OF A REGISTRATION-EXEMPT LEV (LIGHT ELECTRIC VEHICLE) FOR SUSTAINABLE URBAN LOGISTICS, ESPECIALLY FOR THE MICRO-DEPOT CONCEPT IN THE CEP SECTOR

In the “Pilot project for sustainable urban logistics by means of CEP services using the micro-depot concept within the Nuremberg Metropolitan Region”, the use of Pedelec delivery bicycles is intended to enable the CEP companies DPD and GLS to deliver packages efficiently, sustainably, and emission-free.  more about this project

Low RPM Observer - Observation process to determine the rotor position

LOW RPM OBSERVER MIT SINGLE-SHUNT STROM-MESSUNG

In the case of cost-driven propulsion applications in particular, such as ventilators in the automotive industry, efforts are being made to reduce component costs and to replace their function with smart software algorithms. An established process in the case of permanent magnet synchronous motors (PMSMs) is to forgo the use of a rotor position encoder and to use an algorithm to determine the rotor position from the three phase currents measured.  more about this project

MaInno - New approaches in the production of measuring tapes

INNOVATIVE MEASURING TAPE – ELONGATION, DURABILITY, AND ECONOMY WITH NEW APPROACHES IN MANUFACTURING AND MATERIALS ENGINEERING

Measurement is an elementary part of any development. Whilst complex measurement methods are necessary in the case of very large or very small quantities, measuring tapes are generally used to measure quantities in the range that is detectable by the human eye.  more about this project

Microalgae - Sustainable aquaculture

MICROALGAE FOR SUSTAINABLE AQUACULTURE

Within the bio-economy, biological resources are used in the production of chemicals, resources, foodstuffs, animal feed, and energy. Those production processes make use of sustainable raw materials, without creating unusable by-products. For example, microalgae are capable of producing a wide variety of products: active agents for pharmaceuticals, cosmetic products, fine chemicals, colorants, food supplements such as polyunsaturated fatty acids, food products for humans and animals and aquaculture, and even mass chemicals and bioenergy.  more about this project

Micro-depot concept - Sustainable urban logistics

PILOT PROJECT FOR SUSTAINABLE URBAN LOGISTICS BY MEANS OF CEP SERVICES USING THE MICRO-DEPOT CONCEPT WITHIN THE NUREMBERG METROPOLITAN REGION

High traffic volume is a main cause of pollution in cities. Above all, nitric oxides and particulate matter negatively affect health. Many German cities have therefore introduced environment zones, which are controversial due to insufficient control. The micro-depot concept will test a new possibility for reducing air pollution in the city of Nuremberg.  more about this project

Micro-depot concept - Transfer of the Nuremberg micro-depot concept to other cities

NUREMBERG MICRO-DEPOT CONCEPT IN THE CEP INDUSTRY: TRANSFERABILITY TO OTHER CITIES AND INTEGRATION OF INNOVATIVE SAME-DAY DELIVERY CONCEPTS

The courier, express, and package (CEP) industry is growing in Germany considerably faster than the logistics market as a whole. A large proportion of the collection and delivery takes place in urban conurbations. The goods traffic incurred by this not only contributes to the high traffic volume in cities but also pollutes the environment.  more about this project

MecDruForm - Combination of printing technologies and high-pressure moulds

MANUFACTURE OF MECHATRONIC MODULES ON THE BASIS OF PLASTIC FOILS USING A COMBINATION OF PRINTING TECHNOLOGIES AND HIGH-PRESSURE MOULDS
(SUB-PROJECT 1: PRINTING TECHNOLOGIES)

Function integration in mechatronic modules, i.e. assemblies with combined electronic and mechanical functionality, is particularly interesting for a large number of sectors. This fact is underscored, for example, by the increasing use of mechatronic integrated devices (MID).  more about this project

MoCAp4Robots

INTUITIVE OFFLINE PROGRAMMING OF INDUSTRIAL ROBOTS IN SMES WITH MOTION TRACKING

There are various ways to program industrial robots in manufacturing plants. Generally, programming can be accomplished through teach-in programming and “real” programming, e.g. through use of a programming language.  more about this project

→ Results

MRK&MoCap4Robots - New paths in robot programming

NEW PATHS IN ROBOT PROGRAMMING WITH HUMAN-ROBOT COLLABORATION (HRC) AND MOTION CAPTURE (MOCAP)

Modern industrial robots are now able to perform their working steps in direct cooperation with humans. This means that robots can be used very flexibly in production – even in mixed plants with humans and machines. However, very considerable expense is incurred for programming, which requires time and expert knowledge.  more about this project

OHM RUNNER

A SMART ROUTE FOR SELF-DRIVING MODEL VEHICLES

The amount of research currently being carried out into the Car-2-X applications and self-driving vehicles illustrates the immense efforts to ensure that self-driving vehicles are integrated into the existing road transport situation in the near future. Nonetheless, smart driver assist and self-driving systems consist of complex hardware and software systems that must meet stringent requirements.  more about this project

→ Results

Surface engineering - Improving the contact tubes used in copper wire production

DEVELOPMENT OF AN INNOVATIVE MATERIAL COMBINATION FOR PIPES AND BELTS FOR THE PROCESSING OF COPPER

In our everyday lives, we could no longer do without technical devices. The increasing demand for electronics is giving rise to an increase in the quantity of cables and leads that are incorporated in our devices. Thanks to its good conductivity, they are mostly produced using copper wire. High raw material prices and the costly production process make this an expensive undertaking, however.  more about this project

Pegnitz - Laser-generated, multi-phase materials

NEW LASER-GENERATED, MULTI-PHASE MATERIALS FOR CUSTOMIZED PUMP COMPONENTS

Pumps and fittings are often subject to high demands. For example, they have to resist high tensile and pressure loads and should be resistant to corrosion and wear. For this reason, high-alloyed multi-phase materials such as duplex materials are normally used. Currently, duplex steels are manufactured using conventional casting and forging processes.  more about this project

POF-Control - Measurement, control, and switching

POLYMER FIBRE-BASED MEASUREMENT, CONTROL, AND SWITCHING

Since its foundation in 2001, the Polymer Optical Fiber Application Center (POF-AC) at Nuremberg Tech has pursued the objective of conducting applied research into polymer optical fibres (POF) in the fields of data transmission, sensor technology, and lighting technology.  more about this project

→ Results

POF-MEM - POF fouling sensor for membrane processes

POF FOULING SENSOR FOR MEMBRANE PROCESSES

Drinking water in Germany is largely derived from ground water. However, surface waters such as well water also contribute to the supply. Often this must be treated before it is drinkable or suitable for industrial production. For water softening and desalination, reverse osmosis (RO) is currently the most important process.  more about this project

Retrox - New methods for the configuration and production of retroreflectors

AN INNOVATIVE CONFIGURATION AND PRODUCTION PROCESS FOR RETROREFLECTORS IN VEHICLE LIGHTING SYSTEMS

No car is allowed to drive on Germany’s public roads without being fitted with a retroreflector. Each of these retroreflectors therefore consists of a number of prismatic reflectors, arranged so that they utilize the total reflectivity of the mirrors in such a way that any light landing on the reflector is thrown back in the direction from which it came. Due to the stringent requirements with regard to the surface and the angular tolerance, retroreflectors can only be produced using retroreflector tool inserts with sharpened pin packages.  more about this project

SLM UNIKAL - Description of unique material and component properties with the help of additive laser generation

ENERGY-EFFICIENT AND RESOURCE-EFFICIENT DESCRIPTION OF UNIQUE MATERIAL AND COMPONENT PROPERTIES WITH THE HELP OF ADDITIVE LASER GENERATION

Selective laser melting (SLM) is an efficient method of creating complex components from metal powders, using a laser. Typical applications of this process include the manufacturing of prototypes, the production of tools, and the direct manufacturing of final products. The quick cooling of the fused areas means a unique microstructure forms in the material generated that differs considerably from that of materials of the same composition that are cast or wrought.  more about this project

Recording road conditions - recording using vibration monitoring

Recording the condition of the road surfacing by means of vibration monitoring

In order to guarantee the value-creation chain in our globalized world, individual, goods and public transport need to be able to rely on an infrastructure that works. When it comes to operating land-based means of transport, roads form an important component of that system, so maintaining them and recording their condition are of fundamental importance. In Germany, the condition of roads is recorded using measurement systems and visual methods.  more about this project

TAILWELD - Welding of plastics with IR beams

WELDING PLASTICS USING CUSTOMIZED IR RADIATION

Laser transmission welding of plastics has been gaining in importance for many years. This method enables aesthetic, hermetic connections to be generated between plastic components. Compared to other plastic joining processes, it stands out for its low thermal and mechanical strain on the component parts and short process times.  more about this project

UWR-PSU - Modular, future-oriented ultra wide-range power supply for safety and security related applications

MODULAR, FUTURE-ORIENTED ULTRA WIDE-RANGE POWER SUPPLY FOR SAFETY AND SECURITY-RELATED APPLICATIONS

In the past few years, the demand for electronic modules for industrial applications has continued to grow, without any foreseeable end. These modules are used for increasingly complex control, regulation, information or security-related tasks, in order to make the target environment more efficient or user-friendly. Irrespective of their function, all modules must fulfil the same requirement – to operate reliably as part of the electrical system, operating system or supply voltage.  more about this project

Value@Service - Sustainable logistical value-added services by means of cooperative use of resources

SUSTAINABLE LOGISTICAL VALUE ADDED SERVICES FOR STATIONARY RETAIL AND PHARMACIES BY MEANS OF COOPERATIVE RESOURCE UTILIZATION IN LOGISTICS NETWORKS

In the “Pilot project for sustainable urban logistics by means of CEP services using the micro-depot concept within the Nuremberg Metropolitan Region”, the use of delivery bicycles enabled packages to be delivered and collected efficiently, sustainably, and emission-free. The success of the concept convinced the participating businesses that the micro-depot concept has completely established itself and will be continued following completion of the pilot phase.  more about this project

ViReFuRa - Using VR to promote pedestrian and bicycle traffic

USING VR TO PROMOTE PEDESTRIAN AND BICYCLE TRAFFIC

Due to ongoing climate change, cities are increasingly focusing on low-energy mobility forms. Non-motorised types of locomotion are being promoted and be a focus of urban and traffic planning efforts, because, besides bicycling, walking is the most energy-efficient form of mobility and is extremely healthy.  more about this project

Fluidized bed sintering furnace

DEVELOPMENT OF A GAS-FIRED FLUIDIZED BED SINTERING FURNACE FOR SMALL-DIMENSION CERAMIC ELECTRONIC COMPONENTS

Electro-ceramic components are used diversely as temperature-resistant components in electrical engineering or in thermal processes due to their very good dielectric and mechanical characteristics. Typical ceramic products are socket bodies for power electronics, base plates, governor housing, bobbins, or condensers for circuit boards.

→ Results