#Research & Development

2022-08-18

Sensor-based structural monitoring of automotive hydrogen

Due to its storage capacity and versatile applicability, hydrogen plays a central role in satisfying future mobility demands and minimizing the associated risks of climate change. H2 fuel cells are an effective technology for electrified vehicles, but their widespread market introduction has so far been associated with many technical and systemic risks as well as high economic challenges.

As highly stressed safety components, pressure vessels for the storage of gaseous fuel represent a core element of H2 drive systems for motor vehicles. In terms of lightweight construction, they are usually manufactured from fibre-plastic composites using the industrially established wet winding process. The stresses caused by operating pressures of up to 700 bar are essentially absorbed by endless carbon fibres in this design.

For safety reasons, recurring inspections of the gas system are prescribed every two years during the service life of the vehicles as part of the general inspection. Up to now, damage has been detected by means of a visual inspection for external damage to the tanks, caused for example by impact or shock loads.

The ambitious innovation project HyMon takes up the challenge of sensor-based on-board structure monitoring for 700 bar H2 pressure tanks. Specifically, the project is investigating acoustic emission and strain sensors with a focus on acoustic and strain-based measurement principles and the new sensor principle of a low-cost, printed resistance sensor with a diode matrix. A strategy for the integration of fibre-optic sensors in the manufacture of composite pressure vessels using the wet winding process and the derivation of the requirements for the manufacturing process are being developed. The overall sensor system is finally integrated into a test vehicle with an adapted tank control unit and validated by a combination of virtual crash and real test set-up.

"This continuous on-board structural monitoring of the pressure vessels ensures a high safety level of H2BZ vehicles, as possible damage can be detected even in the case of minor impacts, such as hitting a bollard," explains Christian Kaufhold, technical project manager at Hexagon.

Dr. Volker Strubel, joint coordinator of the project, adds that "this will enable an automated, electronic evaluation of the installed containers within a few minutes with the information stored in the vehicle in the future". This sensor-based evaluation on the basis of structural monitoring data reduces the repair costs in the case of over-conservative replacement of fully intact containers. Furthermore, the sensor technology can also be used for cost-effective and efficient monitoring of production quality.

The recently launched three-year research project HyMon is funded by the German Federal Ministry of Digital Affairs and Transport within the framework of the National Innovation Programme Hydrogen and Fuel Cell Technology Phase 2 (NIP II) with about 1.4 million €. The funding guideline is coordinated by NOW GmbH and implemented by the Project Management Jülich (PtJ). In the joint project, Hexagon, as a supplier of hydrogen pressure vessels, is working together with the material and simulation specialist MeFeX, FEV as an automotive engineering service provider, the Fraunhofer Institute for Structural Durability and System Reliability LBF, Cologne University of Applied Sciences and the ITA Institut für Textiltechnik of RWTH Aachen University.

2026 general meeting of the Friends and Supporters of RWTH Aachen at ITA

The Friends and Supporters of RWTH Aachen e. V. (proRWTH) looked back on a successful year of support at their 2026 general meeting. The meeting took place at Institut für Textiltechnik (ITA) of RWTH Aachen and was combined with a joint session of the Executive Board and the Administrative Board. Before the general meeting began, participants were given a guided tour of ITA, providing them with fascinating insights into current research and development topics in textile engineering.

TERNAfil wins first place at PitchMiUp Night 2026 in Minden

The RWTH spin-off TERNAfil has developed MAXCarbon, a new high-performance hybrid fibre that combines the mechanical performance of carbon with the temperature and corrosion resistance of ceramic materials. For this development, TERNAfil was awarded first prize at the PitchMiUp Night in Minden on 21 May 2026.

Carbon-ceramic hybrid fibre proves its worth – NRW Minister for Science Mona Neubaur congratulates ITA start-up TERNAfil

MAXCarbon technology, a novel carbon-ceramic hybrid fibre developed by ITA spin-off TERNAfil, secured third place at the HIGH-TECH.NRW Demo Day on the TÜV NORD campus in Essen. The technology combines the strength of carbon fibres with the temperature and corrosion resistance of ceramic materials. Mona Neubaur, Minister for Science in North Rhine-Westphalia, congratulated the team on their success and on winning prize money of 4,000 euros.

TCLF: Resilient value chains in times of crises

The textiles, clothing, leather and footwear (TCLF) industry was at the centre of the webinar “Resilient value chains in times of crises”, which took place on 28 April 2026. Global supply chains continue to face increasing pressure, raw material dependencies are growing and economic uncertainties are affecting the entire sector.

Meadow Grove Research joins ITMF as Corporate Member

Meadow Grove Research is a commodity research firm specializing in supply, demand, and trade analysis in cotton and other soft commodities. Providing clarity to the complex nature of the global fiber supply chain is one of its most formidable services. The firm thrives on customer engagement and providing the best framework for critical decisions.

ALADIN paves the way for circular and demand-driven textile production in Europe

Textile production can be organized sustainably by utilizing short supply chains and preventing overproduction. This can already be achieved today by intelligently connecting and efficiently utilizing existing infrastructure. At the same time, production becomes circular when innovative technologies and materials are used that enable high-quality recycling. The ALADIN research project, launched in May 2026 and co-funded with five million euros under the EU Horizon Europe program, is creating the conditions for this.

TERIS reaches milestone: Fraunhofer consortium develops new standards for tire analysis

In the “TERIS” project, the Fraunhofer institutes ICT, IGD, and IWM—led by the Fraunhofer Institute for Structural Durability and System Reliability LBF—have reached a decisive milestone. For the first time, the teams aim to generate, analyse, and predict tire wear in the laboratory in a standardized and practical manner. As part of this milestone, results are now available on reference abrasion, particle analysis, tribological models, AI-based surface analysis, a test bench concept, and methods for accelerated aging and VOC detection. The tire industry, testing services, and environmental agencies will in future benefit from reliable, rapid laboratory procedures for emissions assessment.

Geotextiles made from recycled materials: GREEN leads the way into the industry

For the industry, recycled materials are creating new opportunities in geotextile production. In the GREEN project, the Fraunhofer Cluster of Excellence Circular Plastics Economy CCPE demonstrates that recycled polypro-pylene (PP), polyethylene terephthalate (PET), and high-density polyeth-ylene (HDPE) can be processed into nonwovens, fibers, and membranes that meet industrial requirements. This creates opportunities for use in existing production lines and new value chains in the geotextile market.

Rieter sees Barmag integration on track as orders and sales rise

The first half of 2026 was shaped by the successful completion of the largest acquisition in Rieter’s history. The Man-Made Fiber Division enables entry into the growth segment of man-made fibers and sustainably strengthens Rieter’s market position in the Asia region. The expanded Group is now the world’s leading system supplier for the processing of natural and man-made fibers. In the first half of the year, initial cost savings in material costs and operating expenses have already been realized. The targeted synergies are expected to amount to at least CHF 20 million by the end of the 2028 financial year. Due to the completion of the acquisition on February 2, 2026, the first half of the year for the Man-Made Fiber Division only amounts to five months.