Intelligent Load Carrier Management

Thread forming requires precise lubricant application because high contact pressures and process temperatures strongly influence tool loading, friction, and process stability. Although minimum quantity lubrication (MQL) systems are widely used, current spray-based approaches can still suffer from spray losses, insufficient wetting of the thread grooves, and unstable droplet transport. This article presents a concept for adaptive precision lubrication in thread forming based on computational fluid dynamics (CFD)-supported flow analysis, experimental validation, and artificial intelligence (AI)-assisted optimization. The focus is on droplet size, spray jet geometry, nozzle position, ambient flow conditions, and their influence on wetting intensity. Preliminary simulation-based investigations indicate that data-driven optimization can help identify wetting deficiencies and support the development of future control strategies for resource-efficient lubricant application.

In the manufacturing industry, the integration of digital human models into the product development and manufacturing process is becoming increasingly important. Particularly in assembly, which is characterized by a high proportion of manual tasks, motion simulations enable a realistic representation of human work and thus make a significant contribution to the evaluation of motion economy, process validation, and efficiency improvement. However, widespread application in production planning faces various challenges, such as the high initial effort required to create human simulations as well as volatile planning conditions. This article presents a practice-oriented solution from the automotive assembly sector that enables the creation of simulations with reduced effort as well as their early and consistent use in the planning process.

Swivel bending is an established forming process that minimizes material loss and enables efficient use of resources. However, the process requires complex optimizations that have traditionally relied heavily on the expertise of machine operators. This results in significant time and material costs, as optimization steps are performed iteratively. Given the shortage of skilled workers, a technological upgrade of the machines in line with Industry 4.0 is necessary. As part of a research project, intelligent sensor technology was used to record critical influencing factors that reveal correlations between product defects and machine deformations. Based on this, a methodology was developed that forms the foundation for inline compensation, enabling the equipment to autonomously adjust process parameters to correct product defects and, in the long term, enable defect-free production from the very first component.

With the increasing complexity of production and logistics systems, traditional factory planning approaches are reaching their limits. In this context, digital factory planning offers a promising solution for enabling well-informed decisions, particularly during the early planning phases. For startups, the optimal planning of a production facility is challenging, as they often operate with limited financial and infrastructural resources. This paper presents a methodological approach to digital factory planning that utilizes VR simulation for the layout planning of a factory hall for a young company in the solar industry. The proposed approach demonstrates how simulations can support the design of flexible production structures, particularly in startup environments.

Due to its dynamic environment, space planning in intralogistics is not a one-time task but a recurring decision-making process subject to numerous constraints imposed by existing infrastructure. Decisions are often based on incomplete data, resulting in a high risk of poor planning decisions and inefficient use of space. This paper presents a practice-oriented process model for space evaluation in brownfield projects. The proposed approach improves the standardization and consistency of space evaluation and promotes best practices among all stakeholders. By supporting systematic decision-making, the process model contributes to optimized planning and resource allocation, thereby reducing risks and avoiding costly implementation errors.The process model is demonstrated through a case study conducted at a commercial vehicle manufacturer.