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20th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2020

作者： Uhlmann, E. Polte, M. Polte, J. Kuche, Y. Wendorf, S. Siebel, D. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools Factory Management IWF Technische Universität Berlin Germany Baublies AG Renningen Germany

ISBN: (纸本)9780995775176

High demands on product quality force companies to reduce production costs. Due to the growing international competition, optical surfaces for tool and mould making need to be produced economically. These surfaces are commonly produced using ultra-precision cutting. However, the efficiency is limited due to low feed velocities vf, small depth of cut ap and associated long process times tPr. An innovative manufacturing process represents diamond burnishing, which can be carried out directly after the high-precision milling process. For this purpose, super-hard materials made of single crystalline diamond (SCD) are currently used as tool materials. Since the material costs are high and the availability is limited, SCD needs to be substituted. An innovative substitution material is polycrystalline diamond (PCD). Within this paper, a machining strategy for the high-precision production of PCD spheres for diamond slide burnishing tools is presented. The processes grinding, polishing and electrical discharge machining (EDM) were applied. Therefore, the manufacturing costs, the surface roughness, the shape accuracy as well as the concentricity accuracy were analysed. Based on these investigations, an efficient and economical machining strategy for the production of high-precision spherical geometries made of PCD can be provided. First results showed that the prefered machining strategy uses a cross-process chain consisting of grinding and polishing. Thereby, the advantages of both processes with the fast manufacturing of the macro-geometry by the grinding process as well as the high surface qualities, which can be achieved by the polishing process, are combined. Copyright © Proceedings of the 20th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2020. All rights reserved.

关键词： Surface roughness

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PowerGrasp - design and evaluation of a modular soft-robotic arm exosuit for industrial applications 52

PowerGrasp - Design and evaluation of a modular soft-robotic...

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52nd International Symposium on Robotics, ISR 2020

作者： Goppold, Jean-Paul Kuschan, Jan Thiele, Gregor Schmidt, Henning Krüger, Jörg Hackbart, Roman Kostelnik, Jan Liebach, Jana Wolschke, Mirko Fraunhofer Institute for Production Systems and Design Technology IPK Berlin Germany Würth Electronics Künzelsau Germany Reha-Zentrum Lübben Lübben Germany

ISBN: (纸本)9783800754298

Absence from work caused by overloading the musculoskeletal system lowers the life quality of the worker and gains unnecessary costs for both the employer and the health system. Classical (rigid link) body-worn exoskeletons can help to reduce critical loading but show many disadvantages, preventing exoskeletons from extensive use in industrial environment. The presented PowerGrasp system is a very robust modular softrobotic arm exosuit sting of robust fabric with embedded rubber tubes as pressure chambers and soft-electronics and who's design is capable to overcome the critical limiting factors of classical exoskeletons. By inflating the tubes via pressure-control valves, it is possible to vary the stiffness of the chambers, which can be effectively used to generate assisting forces and moments at human joints. By using a joint based pressure control, it is possible to decrease the physical demand of overhead working for the wearer. Although the system is designed for industrial overhead assembly, it can also be used in rehabilitation, craftsmanship and construction due to its portable and stand-alone concept. For assessing the impact of the PowerGrasp system, the raise of about 50 percent was shown. Finally, an evaluation study of the overall system has been conducted, showing very high user acceptance and usability. © 2020 VDE Verlag GMBH.

关键词： Musculoskeletal system

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Novel Advances in Machine Tools, Tool Electrodes and Processes for High-Performance and High-Precision EDM

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Procedia CIRP 2022年 113卷 611-635页

作者： Eckart Uhlmann Mitchel Polte Sami Yabroudi Technische Universität Berlin Institute for Machine Tools and Factory Management Pascalstrasse 8-9 Berlin 10587 Germany Fraunhofer Institute for Production Systems and Design Technology Pascalstrasse 8-9 Berlin 10587 Germany

High-performance electrical discharge machining (EDM) is a key technology for manufacturing high-precision components in a broad range of industrially relevant applications. Formation of debris in the working gap leads to arcing and short-circuits on the surface as well as related inaccuracies and process instabilities. Despite decades of research in the field of EDM excessive tool wear and limited process performance are still challenging. In order to overcome highly complex state-of-the-art challenges, dedicated processes, machine tools, peripheral systems, software, tool electrodes and technologies for the application of alternative dielectric fluids have been developed. Within this work novel advances in the development of a sophisticated dry EDM machine tool, including generator and process control technology based on open architecture, open source software, and commonly available machine tool components, are presented. Solutions for challenges regarding remaining debris and gas bubbles as well as related arc discharge and short-circuit pulses in sinking EDM are presented by new flushing methods, technologies and devices. A new system for inverted pressure flushing of a dielectric fluid in ED-drilling enables a highly efficient removal of debris and gas bubbles through the interior channels of the tool electrode. A new multi-fluidic spindle system for EDM provides the ability to use performance- and material-related application of gaseous, near-dry and liquid dielectric fluids sequentially within a single machining process. Recent advances in tool electrode design, tool electrode material application, modification and production have led to essential process improvements. A helical tool electrode design significantly improved flushing conditions and related material removal rate in ED-drilling. Modification of ED-drilling tool electrode surfaces by thermal oxidation of copper reveals a promising approach to minimize ineffective discharges. Application of a spec

关键词： Electrical discharge machining (EDM) precision manufacturing material removal tool geometry micro machining simulation spindle machine tool machining heat treatment process control algorithm surface modification fluid inishing optimization productivity additive manufacturing

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Process strategies for optimizing the cooling behaviour of laser-welded Tailor Welded Blanks made of advanced high strength steels (AHSS)

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Procedia CIRP 2024年 124卷 570-573页

作者： Josefine Lemke Matthias Höfemann Max Biegler Michael Rethmeier Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstrasse 8-9 10587 Berlin Germany Salzgitter Mannesmann Forschung GmbH Eisenhüttenstraße 99 38239 Salzgitter Germany Institut für Werkzeugmaschinen und Fabrikbetrieb IWF Technische Universität Berlin Strasse des 17. Juni 135 10623 Berlin Germany Bundesanstalt für Materialforschung und -prüfung (BAM) Unter den Eichen 87 12205 Berlin Germany

AHSS with 1000 MPa tensile strength show promising properties for the use in Tailor Welded Blanks (TWBs) to locally strengthen car body parts. Challenges in laser beam welding of the sheets are hardness-drops and -peaks in the heat-affected zone (HAZ) and weld, which cause risks during cold-forming. This happens due to rapid cooling caused by laser welding. A numerical approach aiming for slower cooling rates in the weld region is presented in this article. Laser welded sheets served as reference for setting up a process simulation. Models for pre-heating and a coaxial setup with power split were set up. A correlation between cooling-rate and hardness in the joining zone was established and applied to the modelled strategy. Splitting the power led to a slightly narrower weld seam and experimental pre-heating of the sheets to 600 °C could lower total seam hardening. It achieved a homogenization of the fusion zone.

关键词： AHSS laser welding FEM Tailor Welded Blanks hardness HAZ

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Digitalisation toolkit for SMEs

Digitalisation toolkit for SMEs

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2020 Interoperability for Enterprise systems and Applications Workshops, I-ESA Workshops 2020

作者： Gering, Patrick Fraunhofer Institute for Production Systems and Design Technology Pascalstraße 8-9 Berlin10587 Germany

The digitalisation toolkit combines technological and methodological competencies tailored for small and medium-sized enterprises. In a series of workshops, participants learn the fundamentals of process optimisation and digitalisation through a learning game and prototypical digitalisation of own use cases. Proving the potential for improvement of optimisation measures with concrete measured values is particularly difficult in flexible production environments without it support. This paper presents a technical solution that provides the necessary data for a performance analysis with process mining methods without technical preconditions. © 2020 Copyright for this paper by its authors. Use permitted under Creative Commons License Attribution 4.0 International (CC BY 4.0). CEUR Workshop Proceedings (***)

关键词： Optimization

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Learning factory for digitization of enterprises

Learning factory for digitization of enterprises

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2020 Interoperability for Enterprise systems and Applications Workshops, I-ESA Workshops 2020

作者： Rieckmann, Jens Mathis Knothe, Thomas Fraunhofer Institute for Production Systems and Design Technology Pascalstraße 8-9 Berlin10587 Germany

The fourth industrial revolution stands for higher flexibility and productivity of companies. This requires intelligent and interconnected production systems with a well-trained staff. This article describes how the necessary qualification processes can be performed. A high degree of individualized products requires more digitized information (e.g. via IoT, sensors, RFIDs) and a flexible form of work. Today's changes in enterprises are focusing on upgrading the technical equipment. Dealing with changing the mental setting of the staff, enabling employees for digitalization and learning to cooperate in a smoother way (social learning) play an important role. Sensitization regarding necessary changes, decentralized decision-making and cooperating are the main goals for a training. Nevertheless, company's employees also need new technical skills to prepare the enterprise for higher levels of digitization. Learning factories include a stepwise evaluation and transformation of a model factory by the participants themselves. Performing group work sessions, participants have to agree on the future organizational structures, regardless of their function or role as worker, manager or administrative employee. In the upper level of production system design, a high level of digitization is the aim and most of the information flow should be automatically handled. In order to give participants a feeling for introducing extended IT support and using standard interfaces, they have to overcome some technological gaps. An example of a training factory is presented, which is focusing on the transformation of these production systems with different production steps. © 2020 Copyright for this paper by its authors. Use permitted under Creative Commons License Attribution 4.0 International (CC BY 4.0). CEUR Workshop Proceedings (***)

关键词： Industry 4.0

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Teleoperation of an Industrial Robot using Public Networks and 5G SA Campus Networks

Teleoperation of an Industrial Robot using Public Networks a...

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IEEE International Conference on Robotic Computing (IRC)

作者： Jannik Rohde Olga Meyer Quy Luu Duc Christoph Jürgenhake Talib Sankal Roman Dumitrescu Robert H. Schmitt Competence Center DigITools for Production Fraunhofer Institute for Manufacturing Engineering and Automation IPA Stuttgart Germany Systems Engineering Fraunhofer Institute for Mechatronic Systems Design IEM Paderborn Germany Digital Infrastructures Fraunhofer Institute for Production Technology IPT Aachen Germany Heinz Nixdorf Institute University of Paderborn Paderborn Germany Laboratory for Machine Tools and Production Engineering WZL of RWTH Aachen University Aachen Germany

ISBN: (纸本)9781665472616

The next generation of cellular mobile communication standard 5G is considered to have more stable and secure communication links, low latency and higher flexibility which can be enablers for various new scenarios and applications. Teleoperation is the field that can benefit greatly from 5G technology. Demanding and mission-critical use cases such as telesurgery have challenging requirements like low latency and high reliability of the communication channel, which can be possibly met by 5G in the future. This work presents a 5G architecture for the teleoperation of an industrial robot over long distance. For this purpose three fraunhofer institutes were connected over public internet and 5G campus networks. Furthermore, this work describes the latency performance of the investigated teleoperation use case. The measurements in the experiment are performed with two 5G standalone (SA) networks and an edge cloud.

关键词： Cloud computing 5G mobile communication Service robots Mission critical systems Computer architecture Communication channels Reliability

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Numerical study on the temperature characteristic of material absorptivity and its significance in high-power laser beam welding

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Procedia CIRP 2024年 124卷 585-589页

作者： Stephen Nugraha Putra Xiangmeng Meng Fan Yang Marcel Bachmann Michael Rethmeier Bundesanstalt für Materialforschung und -prüfung Unter den Eichen 87 Berlin 12205 Germany Technical University Berlin Institute for Machine Tools and Factory Management Pascalstraße 8-9 10587 Berlin Germany Fraunhofer Institute for Production Systems and Design Technology Pascalstraße 8-9 10587 Berlin Germany

The absorptivity of metallic materials plays an important role in high-power laser beam welding. It affects the amount of absorbed laser power leading to the heating and melting of the surfaces to be joined and is highly dependent on the temperature. Nonetheless, this key characteristic is often ignored in numerical simulations and an empirical parameter determined by trial-and-error approaches is rather implemented to calibrate the results. In the present work, the temperature dependence of laser absorption is included in a three-dimensional multiphase numerical model considering the coupled fluid flow and heat transfer. The calculated laser absorption is determined by the temperature-dependent material properties, laser characteristics, and incident angle of the laser beam. It is found that the temperature dependence of the laser absorption is crucial for accurately determining the keyhole and weld pool geometries, which is validated by experimental measurements using 304 austenitic steel.

关键词： Laser beam welding temperature dependent absorption weld pool keyhole dynamics numerical modelling

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Systematics for an Integrative Modelling of Product and production System

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Procedia CIRP 2023年 118卷 104-109页

作者： Louis Schäfer Matthias Günther Alex Martin Mariella Lüpfert Constantin Mandel Simon Rapp Gisela Lanza Harald Anacker Albert Albers Daniel Köchling wbk – Institute of Production Science Karlsruhe Institute of Technology (KIT) Kaiserstr. 12 76131 Karlsruhe Germany Fraunhofer Institute for Mechatronic Systems Design (IEM) Zukunftsmeile 1 33102 Paderborn Germany IPEK – Institute of Product Engineering Karlsruhe Institute of Technology (KIT) Kaiserstr. 10 76131 Karlsruhe Germany BENTELER Automobiltechnik GmbH An der Talle 27 – 31 33102 Paderborn Germany

Due to shorter product life-cycles, manufacturing companies nowadays must maximize efficiency in development and planning of products and production systems. To achieve this, new methods and tools are required to cope with increasing product variants and system complexity. Therefore, we propose a holistic systematics to develop a consistent, model-based architecture for products, production systems and their interdependencies. For this, we give a domain-specific ontology containing model elements, relationships and attributes. Ontology and systematics are applied to a use-case from the automotive industry. In summary, the approach deals with modern-day demands in engineering by considering interdependencies between product and production systems.

关键词： Model-Based systems Engineering Advanced systems Engineering Product-production-Codesign

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Knowledge transfer and engineering methods for smart-circular product service systems 31st

Knowledge transfer and engineering methods for smart-circula...

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31st CIRP design Conference 2021, CIRP design 2021

作者： Halstenberg, Friedrich Dönmez, Jasmin Mennenga, Mark Herrmann, Christoph Stark, Rainer Fraunhofer Institute for Production Systems and Design Technolog Pascalstr. 8-9 Berlin10587 Germany Institute of Machine Tools and Production Technology Chair of Sustainable Manufacturing and Life Cycle Engineering Technische Universität Braunschweig Langer Kamp 19 b Braunschweig38106 Germany

Smart Product Service systems (Smart PSS) have the potential to contribute to a Circular Economy (CE), but in the design of these systems engineering teams often lack information and knowledge on CE strategies and processes. Against this background, the authors propose a knowledge transfer system for the design of Smart-circular PSS. The system can be used in the concept phase of the Smart PSS development process and delivers information on CE strategies via a Smart-circular PSS Lifecycle Flowchart (SCPLF) and service archetypes. These strategies can be selected, supplemented and extended according to individual user requirements. The approach was validated using an intelligent street lighting system. This paper summarizes findings from the application and provides insights into potentials and limitations for the design of Smart-circular Smart PSS. © 2021 The Author(s).

关键词： systems engineering

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