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B2GreenHub supports

Digital Lifecycle of Hybrid Electric Propulsion Units

Project:

Partners involved:

Pilot Environment:

CHESCO GmbH

CHESCO GmbH was founded to strengthen the transfer of university knowledge and technology into the industry. It participates as a partner in research initiatives. It also has a dedicated test area for electro-mechanical drive systems and components, as well as specialized environments. 

Size:

​​Small company (< 50 employees and/or turnover or balance sheet total ≤ EUR 10 million)​ 

Sector:

Other

Country:

Germany

Region:

Bradenburg

Solution Provider:

DIREKT @ BTU Cottbus-Senftenberg

DIREKT is a project aimed at improving how propulsion systems are assembled. Its main objective is to develop an approach that keeps product data and instructions consistent, while capturing evidence to validate key steps. Its main outcome is the Assembly Twin, used for worker guidance and training.

Key Focus Area:

Data Analysis and Artificial Intelligence

Country:

Germany

Region:

Brandenburg

Challenge

• Necessary optimization of technical systems through simulation processes

• Insufficient development approaches across the entire lifecycle

• Unlocking potential through integration of key information in networked production systems within value chains

• Required data and information availability from development to operation of complex products  

Solution & Result

The content is the creation of an information concept that maps the lifecycle of (hybrid-)electric propulsion systems for aviation – from design, through production planning and manufacturing, to operation. The information concept is characterized as a digital twin of both the product and its associated processes in the respective lifecycle phases. This complex approach forms the foundation for efficiency across all lifecycle phases of future sustainable aviation.

As a result of the successful implementation of a prototype at the CHESCO demonstrator labs, it was possible to validate the project’s main output in a realistic operating environment, marking an important step in the development of this technological solution. 

Learning tips & recommendations

Start small: Pick a handful of assembly steps that truly drive quality or rework, and focus your digital capture and guidance there before expanding.

Treat the first iterations as calibration rounds: Align the virtual instructions with the real workstation, then refine based on what people actually do and what the data consistently shows.

Keep the technology “in service of the team”: Make it quick to use, easy to override or comment on, and ensure feedback from the shopfloor is acted on visibly.