The application of hybrid material composites offers the opportunity to optimally utilise the potential of the different materials. In particular, the combination of aluminium die casting and thermoplastic injection moulding is predestined for the large-scale production of complex lightweight structures with high specific mechanical properties. Against the background of the desired climate targets, such components must be able to be produced in a resource-saving manner on the one hand and be separable and recyclable on the other in the sense of a targeted circular economy.

This is where the national joint project "METEOR" comes in. Using the example of a hybrid transmission component, different manufacturing processes such as die-casting and injection moulding are investigated with regard to the efficient use of thermal energy. In addition, it is advantageous to include renewable energy sources like solar thermal fields in the process network of the different processes in order to reduce CO2 emissions. To this end, a complex system diagram for an energy-coordinated process network for hybrid metal-thermoplastic composite components was developed

Both the energy input and the process energy required are subject to environmental and process-related fluctuations. The utilisation of heat and cold storage is therefore of central importance for energy management. In addition, injection moulding and die casting have different requirements for the temperature control of the tools, which is why these processes can be managed in cascade via the energy process network. A mobile demonstrator was designed and constructed in order to gain crucial insights into the design and operation of such a complex system before it is commissioned.

By operating the mobile demonstrator, locations can be assessed in terms of their energy generation capacities and the orientation of the collector. In addition, conclusions can be drawn regarding the achievement and duration of peak temperatures. This makes it possible to dimension the heat pump and the adsorption chiller. Together with the previously installed conventional energy management system, these investigations form the basis for successful integration of the full-scale solar thermal system and corresponding production studies.