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Production Technologies and Systems for E-Mobility (EPTS), International Conference on

作者： Sebastian Wieland Tingyan Sun Lars Kanzenbach Jörg Schneider Jan Edelmann Martin Dix Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany

ISBN: (数字)9798350386172

ISBN: (纸本)9798350386189

The transmission of high electrical power via separable contact connections is a key challenge in the context of the energy transition. A well-known example is the charging interface of electric vehicles. To counteract the presently long charging time of battery systems, an innovative fast charging system using a face contact instead of classic plug-in contacts is being developed. To enable charging power in the megawatt range, an electrical contact surface is functionalized in such a way that, on the one hand, the contact resistance is reduced and, on the other hand, the thermal as well as the mechanical properties are improved. In addition to the simulation-based design of the contact surfaces and the development of manufacturing technologies, the required measurement and testing technology is a fundamental challenge. In this article the experimental setup for the long-term test of the electrical face contacts is being introduced. Using the test bench, electrical contacts can be automatically evaluated with regard to their temperature development and contact resistance at normal forces of up to 500 N with a current load of up to 600 A DC under constant or cyclic conditions. In this context the test procedure as well as first results of the thermo-mechanical properties of a face contact setup are being discussed.

关键词： Temperature measurement Temperature Surface resistance Thermal resistance Thermomechanical processes Surface charging Contact resistance

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Synthetically Generated Images for Industrial Anomaly Detection 29

Synthetically Generated Images for Industrial Anomaly Detect...

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29th IEEE International Conference on Emerging Technologies and Factory Automation, ETFA 2024

作者： Wagenstetter, Marco Gospodnetic, Petra Bosnar, Lovro Fulir, Juraj Kreul, Donovan Rushmeier, Holly Aicher, Thomas Hellmich, Arvid Ihlenfeldt, Steffen Powertrain Production System Planning Bmw Group Germany Synthetic Data Generation Fraunhofer Itwm Germany Yale University Synthetic Data Generation United States Machine tools and forming technology Fraunhofer Iwu Germany

ISBN: (纸本)9798350361230

Automation of inspection for quality control is needed to overcome the errors and delays inherent in manual processes. machine learning methods have the potential to greatly improve automated inspection. However, machine learning techniques require training data that are precisely labeled and reflect the distribution of defects to be detected. Physically collecting suitable training data requires significant time and prolongs the overall time for system development. To address this challenge, a new study is presented that explores synthetic data generation for a state-of-the-art anomaly detection (AD) model in the electric motor housing (EMH) surface inspection. The study successfully demonstrates using synthetic data for anomaly detection and presents a comparison of detection performance by models trained solely on synthetic data and models trained on both synthetic and real data. The study shows that real data combined with synthetic data can increase overall model performance. The study also addresses current challenges in using synthetic data and proposes directions for future work. © 2024 IEEE.

关键词： Adversarial machine learning

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Overview of methodologies for the lifecycle management of smart product-service systems

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Procedia CIRP 2024年 128卷 174-179页

作者： Anton Mauersberger Heiner Reinhardt Mohaned Alaluss Mahtab Mahdaviasl Steffen Ihlenfeldt Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Chemnitz Germany

Nowadays, companies are operating in increasingly competitive and dynamic markets with rapidly changing customer demands. In order to meet these challenges, digitalization can be leveraged to achieve a transformation in product and service development. As a result, new concepts and methods are emerging, including smart product-service systems (smart PSSs). In combination with smart, connected products (SCPs), added value can be generated for several contracting parties. There are various methodologies available for the development and usage of smart services. However, these are insufficiently applied in practice. Here, an overview of methodologies supporting the various phases of the lifecycle of smart PSSs is presented. In doing so, a classification of these approaches is derived and discussed, while the need for further methodological research is outlined.

关键词： Smart PSS Smart service Smart technologies Product-service system Innovation management Sustainable development Lifecycle Decision making Methodology Digital manufacturing system

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Development of a suction gripper network based on the biological role model of an octopus

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Procedia CIRP 2024年 125卷 184-189页

作者： Rayk Fritzsche Henriette Kunze Erik Jäger Head of group Adaptable System at Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz 09126 Germany Scientific employee at Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz 09126 Germany

The handling of fragile, sensitive or flexible components in assembly technology and production requires grippers that are designed for gentle handling of the objects to be gripped. Suction grippers are still a widespread standard solution for this purpose. However, rising energy prices are making pneumatic grippers, which work with a central upstream compressed air supply, increasingly unattractive. The generation of the compressed air itself, the mostly leaky transmission and the relatively inefficient vacuum generation are cost drivers that many users would like to avoid. Consequently, vacuum-based gripper means are required for industrial production, which work without externally generated compressed air. At the fraunhofer iwu, a compressed-air-free suction pad composite has been developed that enables gripping of components with a wide variety of shapes. The underlying concept is inspired by the function of the suction arms (tentacles) of an octopus. By evacuating several small volume areas, which can be individually mechanically actuated, safe and sensitive gripping of objects is possible. For the generation of the vacuum, a piston system and a principle of an artificial muscle were developed, which is controlled based on shape memory alloys.

关键词： artificial muscle shape memory alloys (SMA) suction gripper suction gripper network

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AI-driven force torque control strategies for further automate flexible high-precision, contact-intensive assemblies 57

AI-driven force torque control strategies for further automa...

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18th IFAC Workshop on Time Delay Systems, TDS 2024

作者： Gu, Yunqi Otto, Ruth Maria Naumann, Martin Gjakova, Leutrim Löser, Rico Dix, Martin University of Applied Sciences Munich Lothstr. 34 Munich80335 Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz09126 Germany Chemnitz University of Technology Chemnitz09111 Germany

Robotic assembly processes are integral to industrial manufacturing, traditionally relying on pre-programmed sequences that exhibit limited adaptability to uncertain conditions. Recent advancements propose AI-enhanced vision systems as viable solutions to mitigate uncertainty in automated tasks. Despite the potential of vision, contact-intensive, high-precision assembly processes need customized force-torque feedback strategies to perform the task. Parametrization for setup and adaption of force-torque processes are time consuming, but decisive for quality. This work outlines an AI-driven force-torque control strategic solution for peg-in-hole assembly task, which employs object detection algorithm to grasp the workpiece and determine flexible assembly position, with force-torque-informed DNN algorithm for error correction in terms of position, and digital twin to monitor the process and collect virtual data. © 2024 The Authors.

关键词： Robotic assembly

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Software support for the development of flexible plant technology in highly automated and high-rate body-in-white production 16

Software support for the development of flexible plant techn...

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16th CIRP Conference on Intelligent Computation in Manufacturing Engineering, CIRP ICME 2022

作者： Fritzsche, Rayk Ahrens, Antje Hd. of Grp. Adaptable Assembly Syst. at Fraunhofer Inst. for Mach. Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany Scientific Employee at Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany

The remarkly high degree of automation within body-in-white production, with high quality requirements and the increasing demand for product-flexible production form a conflict of objectives. The most significant challenges in making the operating resources of body-in-white manufacturing more flexible arise with the the development of model-flexible geometry fixtures, with the geometric and qualitative requirements being most significant in the production of vehicle doors. For the efficient design of model-flexible fixtures specific methods and software tools for part alignment, clamp point grouping and fixture design have been developed. © 2023 Elsevier B.V.. All rights reserved.

关键词： Product design

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Innovative actuating process for machining CFRP with force-controlled radial feed movement 33

Innovative actuating process for machining CFRP with force-c...

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33rd CIRP Design Conference

作者： Peter, Marie Sauer, Konstantin Regel, Joachim Dix, Martin Institute for Machine Tools and Production Processes Chemnitz University of Technology Reichenhainer Str. 70 Chemnitz09126 Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 Chemnitz09126 Germany

The use of lightweight materials such as carbon fibre reinforced plastics (CFRP) is increasing due to the demand for rising resource and energy efficiency, especially in the aerospace and automotive industries. Because of the high delamination tendency of these materials and their abrasive impact on the tool, the challenges in machining CFRP lie primarily in the drilling process and thus in the design of the drilling tool. In this paper, an innovative design of a drilling tool for machining CFRP with force-controlled radial feed movement of the cutting edges is presented. The aim of this tool is to create a tool axial force free process that uses a force-controlled radial feed motion, which matches the chip cross-section to the wear condition of the cutting edge. The tool concept is explained based on the functionality of the actuating process. Tests were evaluated with regard to process forces and drilling quality to show that the tool is capable of producing delamination-free bores in a tool axial force free process. © 2023 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (https://***/licenses/by-nc-nd/4.0)

关键词： Carbon fiber reinforced plastics

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Operational modal analysis used to identify dynamic behaviour of machine tools during milling 16

Operational modal analysis used to identify dynamic behaviou...

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16th CIRP Conference on Intelligent Computation in Manufacturing Engineering, CIRP ICME 2022

作者： Berthold, Jan Regel, Joachim Dix, Martin Drossel, Welf-Guntram Institute for Machine Tools and Production Processes Chemnitz University of Technology Reichenhainer Str. 70 Chemnitz09126 Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 Chemnitz09126 Germany

The dynamic behaviour of machine tools during cutting is investigated by Operational Modal Analysis (OMA), which overcomes the disadvantages of the Experimental Modal Analysis (EMA) using excitation methods such as shakers or hammers, not considering effects occurring during operation. The assumptions of OMA such as time-invariance and white noise excitation are difficult to fulfil considering the boundary conditions of a milling process. The results show that feed motions classify the varying dynamic behaviour in the working space and excitation is controlled by modification of the milling conditions. Modal Parameters, identified by OMA, provide process-related results enabling to improve performance. © 2023 Elsevier B.V.. All rights reserved.

关键词： machine tools

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Development approach of a workflow for 3D printing of living mycelium materials and their growth manipulation

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Procedia CIRP 2024年 125卷 302-307页

作者： Sophia Elsner Rebekka Jesch Linda Weisheit Lukas Boxberger Steffen Ihlenfeldt Welf-Guntram Drossel Fraunhofer Institute for Machine Tools and Forming Technology IWU Nöthnitzer Straße 44 01187 Dresden Germany

As a viscous mycelium-substrate-composite, mycelia can be processed into more complex geometries in generative extrusion-based processes, even without molding tools. Biological transformation can also affect the properties of a printed object such that the mycelium still lives and grows after the 3D-build-process and changes the object over time. Depending on the substrate composition, type of fungus and growth conditions, different properties of the object can be manipulated. Different test geometries with corresponding preliminary characterization tests are shown. The present results demonstrate that test geometries could be successfully 3D printed with living mycelium material and manipulated during cultivation.

关键词： Free forming Material Processing 4D+ Printing Biological Transformation Biomechatronics Mycelium Materials

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Novel method for manufacturing herringbone gears by power skiving 15

Novel method for manufacturing herringbone gears by power sk...

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15th CIRP Conference on Intelligent Computation in Manufacturing Engineering, ICME 2021

作者： Bauer, Ruben Dix, Martin Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenainer Str. 88 Chemnitz09126 Germany

Due to the symmetrical flank configuration, herringbone gears have no resulting axial forces and a smaller tooth width than helical gears. Because of existing manufacturing limitations, currently only double helical gears with wide center space or assembled herringbone gears are applied. In the present work, a novel machining method for herringbone gears by power skiving is presented. For this purpose, tool and technology are designed using a mathematical process model and tested subsequently. It is shown that the process can produce the required geometry with significant improvements on productivity and accuracy. Additionally, the unused center area can be eliminated. © 2022 The Author(s).

关键词： Helical gears

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