AiHyRess
HyRess studies a resource saving process route for highly integrated hydraulic systems, using an electrified mobile working machine as the example. We bring the data of the manufacturing steps together in a digital shadow.
What it is about
In HyRess, highly integrated hydraulic systems are made along a new process route that includes additive manufacturing. Every manufacturing step supplies data and documents, often on machines from different manufacturers. Only when this information comes together do the relations within the process route become visible, and its potential to save carbon can be quantified.
Our contribution
Our sub-project is called “Digitalisation of the HyRess process route by means of a virtual middleware to form a digital shadow”. A digital shadow is the continuously updated data image of a process. We acquire the data through edge devices and provide it in an Industry 4.0 middleware. We bring manufacturing data and documents together in asset administration shells on an AAS server that we operate ourselves; the project partners store their documents there and access them. The focus lies on the requirements of an adaptable production, as additive manufacturing brings them, and on new interfaces.
What comes out of it
The aim is to connect machines from different manufacturers to the IoT platform and to make several manufacturing steps traceable as a digital process route. The information of the manufacturing process can thus be assigned to a digital twin. The collected data also serves to quantify the carbon saving potential of the new process route.

Runtimeuntil the end of 2026
MinistryFederal Ministry for Economic Affairs and Climate Action
ProgrammeTechnology Transfer Programme Lightweight Construction
Project management agencyProjektträger Jülich
Funding reference-
Consortium
Nine partners from research and industry work together in the consortium.
- Research: RWTH Aachen University with the Institute for Fluid Power Drives and Systems and the Chair Digital Additive Production
- Industry: H&H Engineering und Prototypenbau, OWL AM Additive Manufacturing, Extrude Hone, Element Materials Technology, HYDAC INTERNATIONAL, KION GROUP
- Digitalisation: IQstruct Engineering

