Initial Situation

The automotive supplier sector is obliged to automate its processes as much as possible and minimise operations that do not bring added value. Processes as diverse as IML (In Mould Labelling) and IMM (Multi-Material Injection) have to be integrated within one single process, downstream operations, such as cutting and assembly have to be reduced. To achieve this, it is vital to develop new processes, integrating several work steps and therefore minimising the total number of operations whilst meeting cost and productivity targets. The need to integrate functions and systems in the same part and to increase their added value in .one step. processes is the biggest single challenge facing the automotive industry at present.

Until now, door panels have been parts with mainly aesthetic and little structural function. Secondary functions such as door opening or several embeddings have already been integrated into the same part. Now it is essential to achieve a higher level of integration with adjacent functional parts or components and of .just in time. modules.

Objectives





This Case Study focuses on the development of a complex multimaterial/multifunctional injection moulded automobile door panel. A new concept of mould architecture permits automated integration of advanced features such as touch sensors and light signalling devices in the door panel. The mould acts as a machine, producing parts with many functions and components in just one moulding operation. As innovative technologies (sensorics, ultra-high precision machining and Knowledge Based Engineering) are implemented, this manufacturing operation combines the option of processing diverse components and materials with multifunctional manufacturing.

This will lead to single step assembly, increasing speed and reducing costs. This type of tool, with highly increased value, functionality and service capability, will make the mould-maker a key strategic partner in the value chain.

Solutions

Development of the new tool concept for the 'mould as a machine', integrating many func- tions and components

Complete basic engineering of the new tool concept

Application of KBE technologies

Development and implementation of new ma- nufacturing technologies, process control and management methods

Complete Virtual Mock-Up (VMU) of the system including the mould architecture, system kinematics, mould state and process parameter sensoring, tool .black-box. and mould thermal management system. The VMU will include the tool, the in-tool operations and the new part characteristics

System prototype of the new car door panel in 3/6 tools including all the new developments in mould architecture, system architecture, textile and other material integration, electric and electronics integration as well as tool state and process parameter sensoring