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A case study on the use of open source hardware in mechanical engineering

Procedia CIRP 2024年 128卷 680-685页

作者： Cäcilia Veliu Valentin Petzold Dirk Reichelt Maximilian Stange Steffen Ihlenfeldt Dresden University of Applied Sciences Friedrich-List-Platz 1 01069 Dresden Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Strasse 88 09126 Chemnitz Germany Institute of Mechatronic Engineering Technical University Dresden Helmholtzstr. 7a 01069 Dresden Germany

Open Source Hardware (OSH) enables innovative developments and business models. The OSH approach creates new forms of cross-company product development and community-based innovation processes. Open source has been state of the art in software industry for years. When it comes to OSH projects, however, the focus is primarily on the consumer sector. The use of OSH for industrial products, especially in mechanical engineering, is still in its early stages. The paper presents a case study on the development of an application module based on OSH components in a R&D testbed. The developed module is intended to enable electronic functional testing. For this purpose, the development process involved, among other things, creating solutions for a tool changing system. Using the case study, we analyse the advantages and disadvantages of the open source licenses used and derive implications for the R&D process. Building on this, various concepts for the use, adaptation and expansion of OSH components and the resulting implications for development processes and business models are presented. The case study is used to analyse which established open source software concepts can be transferred to material assets, but also which additional requirements arise from OSH components, e.g. in the area of safety.

关键词： Open Source Hardware Open Innovation Design: challenges & innovation

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Data Acquisition Framework for spatio-temporal analysis of path-based welding applications 57

Data Acquisition Framework for spatio-temporal analysis of p...

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18th IFAC Workshop on Time Delay Systems, TDS 2024

作者： Safronov, Georgij Theisinger, Heiko Sahlbach, Vasco Braun, Christoph Molzer, Andreas Thies, Anabelle Schuba, Christian Shirazi, Majid Reindl, Thomas Hänel, Albrecht Engelhardt, Philipp Ihlenfeldt, Steffen Mayr, Peter BMW AG Petuelring 130 München80788 Germany Technical University of Munich Materials Engineering of Additive Manufacturing Freisinger Landstraße 52 Garching bei München85748 Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Nöthnitzer Straße 44 Dresden01187 Germany Nebumind GmbH Willy-Messerschmitt-Straße 1 Taufkirchen82024 Germany

The use of digital technologies in industrial manufacturing reduces operational costs and improves production quality. The "Framework for Spatiotemporal Production Data Acquisition" (PathSense) aims to improve access and usability of production data by applying a common data ecosystem. Through integrating operational technology (OT) and information technology (IT), PathSense supports decision-making and process optimization. The framework uses the concept of digital shadows to collect critical information from sensors within the continuous manufacturing processes, e.g., welding or gluing lines. Spatial and temporal digital shadows are developed in accordance with human spatial cognition to support sophisticated-yet intuitive-human-computer interactions without the need for advanced data science skills. The backbone of the framework consists of robust data pipelines with a setup incorporating modern IT protocols, such as OPC UA and MQTT, to support the efficient acquisition and management of data. The paper addresses the challenges associated with the combination of IT and OT in cyber-physical systems, stressing modern complex data-intensive manufacturing as one exemplary domain to be tackled by scalable and secure data architectures. The paper identifies two major future directions: refining data integration processes and embedding advanced machine learning algorithms to enable automated data analysis and improve process quality monitoring. In summary, PathSense proposes a data-driven approach for quality inspection in manufacturing, which may eventually enhance industry practices and move towards data-driven decisions and increased operational flexibility. © 2024 The Authors.

关键词： Spatio-temporal data

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Classification and Evaluation of the Integration of Process Mining and Digital Twins: A Roadmap

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Procedia CIRP 2025年 134卷 467-472页

作者： Maxi Grobis Sven Solterbeck Oliver Kempf Steffen Ihlenfeldt Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 09126 Chemnitz“ Germany DB Systel GmbH Jürgen-Ponto-Platz 1 60329 Frankfurt a. Main Germany Institute of Mechatronic Engineering Technische Universität Dresden Helmholtzstraße 7a 01069 Dresden Germany

Process mining has established itself as an essential technique for discovering and analyzing business processes by bringing transparency to complex process landscapes. The application of process mining provides a solid foundation for the further development of digital twins - virtual replicas of real systems that are updated in real-time to generate simulations and improve predictions. The combination of process mining with digital twins necessitates an in-depth exploration of the fundamental aspects of this synergy, particularly to delineate the criteria that constitute a digital process twin or an organizational twin. Currently, there are initial research activities and definitions in this area, characterized by significantly divergent approaches. To address this, the authors developed a concept in the form of a roadmap laying the foundations for a future maturity model and utilized the Reference Architecture Model Industry 4.0 (RAMI 4.0) to systematically evaluate the integration and progress of process mining in connection with digital twins and their characteristics.

关键词： Process Mining Digital Twin Maturity Model RAMI 4.0

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Mycelium-based-composites – Vision for substitution of fossil-based materials

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Procedia CIRP 2024年 125卷 78-83页

作者： Steffen Ihlenfeldt Stefan Schillberg Christoph Herrmann Simon Vogel Robar Arafat Simon Harst Chair of Machine Tools Development and Adaptive Controls Insitute of Mechatronic Engineering TU Dresden Helmholtzstraße 7a 01069 Dresden Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Pforzheimer Str. 7a 01189 Dresden Germany Chair of Molecular Biotechnology Worringerweg 1 RWTH Aachen University 52074 Aachen Germany Fraunhofer Institute for Molecular Biology and Applied Ecology IME Forckenbeckstr. 6 52074 Aachen Germany Chair of Sustainable Manufacturing & Life Cycle Engineering Institute of Machine Tools and Production Technology IWF Technische Universität Braunschweig Langer Kamp 19b 38106 Braunschweig Germany Fraunhofer Institute for Surface Engineering and Thin Films IST Riedenkamp 2 38108 Braunschweig Germany

For decades, fossil-based materials have formed the basis of an almost endless range of technical products. Through variable chemical composition and several additives, especially plastics can have a wide range of properties, which form the basis for the diversity of plastic-based products. While this variability enables many sustainability strategies, such as lightweighting, it is also impeding a fully circular economy. Therefore, in recent years, a number of new raw materials have been developed, but they can only cover a very limited part of the wide range of properties of fossil-based plastics. Another promising class of materials are composites based on fungal mycelium. However, these are mainly limited to the consumer sector, e.g. vegan leather, where there is smaller demand for durability, functionality etc. The step from consumer to engineering materials require the production (or growth) process to be reproducible within the necessary quality requirements. Cyber-physical production systems have the potential to realise necessary technical qualities despite e.g. quality fluctuations of the raw material and production processes that are susceptible to interference. For this reason, this paper analyses the state of the art in production of mycelium based composites, shows the existing gaps and draws a vision to close these gaps.

关键词： cyber-physical production biological transformation mycelium-based composites

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Hybrid approach to evaluate surface integrity based on grinding power and Barkhausen noise 6th

Hybrid approach to evaluate surface integrity based on grind...

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6th CIRP Conference on Surface Integrity, CSI 2022

作者： Heinzel, Jonas Jedamski, Rahel Rößler, Maximilian Karpuschewski, Bernhard Epp, Jérémy Dix, Martin Mapex Center For Materials And Processes University Of Bremen Bibliothekstr. 1 Bremen28359 Germany Leibniz Institute For Materials Engineering Iwt Badgasteiner Str. 3 Bremen28359 Germany Fraunhofer Institute For Machine Tools And Forming Technology Reichenhainer Straße 88 Chemnitz09126 Germany

In this paper the potential of a reliable characterization of surface and subsurface properties is presented by measurement of process forces for determining the specific grinding power Pc and the micromagnetic Barkhausen noise in cylindrical grinding trials. Therefore different dressing conditions by grinding with conventional wheel with varying process parameters are investigated. It is shown that an identified lower thermal limit in a Pc-t-diagram (contact time t) to prevent tempering zones in the ground surface and subsurface area of case hardened steel is applicable even if the condition of the grinding wheel is intentionally influenced by dressing. Finally a soft sensor concept for the use of the specific grinding power and in perspective also the use of the Barkhausen noise for process control is derived. © 2022 The Authors.

关键词： Grinding (machining)

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Comparative analysis of topology optimization versus material substitution: Is there a best method for vehicle weight reduction?

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Procedia CIRP 2024年 128卷 132-137页

作者： Gibson P. Chirinda Stephen Matope Philani Zincume Whisper Maisiri Andreas Sterzing University of Stellenbosch Private Bag X1 Matieland Stellenbosch 7602 South Africa North West University Private Bag X6001 Potchefstroom 2531 11 Hoffman Street South Africa Fraunhofer Institute of Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Chemnitz Germany

The United Nations (UN) Sustainable Development Goal 13 focuses on taking urgent action to combat climate change and its impacts. Resource efficient production and strict emission regulations have made vehicle weight reduction a subject of great interest. Common lightweighting techniques include topology optimization and material substitution. The benefits include reduced raw material usage, low fuel consumption, and low carbon emissions. There is a gap in the complex balance of decision-making. If an engineer is faced with the option of topologically optimizing or materially substituting, is one method better than the other? This paper comparatively analyses these lightweight design strategies.

关键词： topology optimization material substitution lightweighting automotive industry

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Extending a factory-based discrete event simulator for parallel optimization of production and supply chain level

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Procedia CIRP 2025年 134卷 885-890页

作者： Omid Safari Marc Münnich Florian Zumpe Yen Mai Thi Pierre Grzona Mario Henrique Callefi Steffen Ihlenfeldt Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Strasse 88 09126 Chemnitz Germany University of Applied Sciences Zwickau Faculty of Economics Kornmarkt 1 08056 Zwickau Germany Chemnitz University of Technology Professorship of Factory Planning and Intralogistics Str. der Nationen 62 09111 Chemnitz Germany Dresden University of Technology Institute of Mechatronic Engineering Helmholtzstraße 7a 01069 Dresden Germany

Factory-based discrete event simulation (FB-DES) tools are primarily used to model production systems at the factory level. However, integrating factory activities with supply network optimization has been challenging due to data barriers, leaving the application of FB-DES tools in supply chain (SC) contexts underexplored. This study addresses this limitation by enhancing the capabilities of FB-DES tools to integrate network and factory simulations within a single framework. By incorporating genetic algorithms (GAs) into the simulation model we present an approach to optimize production and supply networks based on key performance metrics such as production cost, time, and resource efficiency. The model features an automated scenario generation system using SimTalk methods and Python scripts to simulate and test potential production scenarios continuously. Additionally, Google Cloud Services (Google Maps API) are utilized for more accurate transportation time calculations, further improving network planning capabilities. This comprehensive simulation framework bridges the gap between factory and SC simulation methods, enhancing performance at both levels. This paper highlights the transformative potential of DES tools augmented with GAs and real-time data, paving the way for more resilient supply and production networks.

关键词： Discrete event simulation Optimization Genetic algorithm Supply chain Siemens Tecnomatix Plant Simulation Automated simulation process

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Robust entropy search for safe efficient Bayesian optimization 24

Robust entropy search for safe efficient Bayesian optimizati...

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Proceedings of the Fortieth Conference on Uncertainty in Artificial Intelligence

作者： Dorina Weichert Alexander Kister Sebastian Houben Patrick Link Gunar Ernis Fraunhofer Institute for Intelligent Analysis and Information Systems IAIS Sankt Augustin Germany VP.1 eScience Federal Institute for Materials Research and Testing BAM Berlin Germany University of Applied Sciences Bonn-Rhein-Sieg Sankt Augustin Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany and Institute of Mechatronic Engineering TUD Dresden University of Technology Dresden Germany

The practical use of Bayesian Optimization (BO) in engineering applications imposes special requirements: high sampling efficiency on the one hand and finding a robust solution on the other hand. We address the case of adversarial robustness, where all parameters are controllable during the optimization process, but a subset of them is uncontrollable or even adversely perturbed at the time of application. To this end, we develop an efficient information-based acquisition function that we call Robust Entropy Search (RES). We empirically demonstrate its benefits in experiments on synthetic and real-life data. The results show that RES reliably finds robust optima, outperforming state-of-the-art algorithms.

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Robust Entropy Search for Safe Efficient Bayesian Optimization

arXiv

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arXiv 2024年

作者： Weichert, Dorina Kister, Alexander Houben, Sebastian Link, Patrick Ernis, Gunar Fraunhofer Institute for Intelligent Analysis and Information Systems IAIS Sankt Augustin Germany VP.1 eScience Federal Institute for Materials Research and Testing BAM Berlin Germany University of Applied Sciences Bonn-Rhein-Sieg Sankt Augustin Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Institute of Mechatronic Engineering TUD Dresden University of Technology Dresden Germany

关键词： Entropy

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Objective validation for short-term material flow simulation

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Procedia CIRP 2025年 134卷 526-531页

作者： Heiner Reinhardt Boran Bogdanow Roman Arnold Bastian Prell Philipp Klimant Frank Seifert Mahtab Mahdaviasl Steffen Ihlenfeldt Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Chemnitz Germany Volkswagen Sachsen GmbH Kauffahrtei 47 09120 Chemnitz Germany Technical University of Applied Sciences Wildau Hochschulring 1 15745 Wildau Germany Professorship Virtual Technologies Hochschule Mittweida - University of Applied Sciences Technikumplatz 17 09648 Mittweida Germany Chemnitz University of Technology Straße der Nationen 62 09111 Chemnitz Germany Institute of Machine Tools and Control Engineering Technische Universität Dresden Helmholtzstraße 7a 01062 Dresden Germany

Material flow simulation, by means of discrete event simulation (DES), is utilized in various industries to support production planning and control. This is due to the fact that changes to manufacturing systems and production strategies can be virtually examined before actual implementation. Since the manual development and repeated adjustment of simulation models is time-consuming and error-prone, numerous studies suggest computerized model generation and synchronization. However, validation of such generated or synchronized models is rarely considered. Here, we present an extendible objective validation technique for the repeated short-term simulation of a generated model. To illustrate this, the technique is applied to a high-volume automotive production line and a series of simulation cycles.

关键词： Digital Twin Simulation Quality Optimization Manufacturing system Control Analysis

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