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SSRN 2024年

作者： Sokolov, Dmitrii Dementyev, Alexander Hänel, Albrecht Ihlenfeldt, Steffen Mechtcherine, Viktor Institute of Construction Materials TU Dresden Dresden Germany Fraunhofer Institute for Machine Tools and Forming Technology Dresden Germany TU Dresden Dresden Germany

The Digital Twin (DT) is one of the most promising approaches to digitalisation of industrial processes in Industry 4.0. The interconnection of two entities – a real world and its virtual replica via two-way data communication is the key feature of the Digital Twins, which should enable the handling of high complexity systems. In the field of 3D Concrete Printing (3DCP), DTs have great potential not only to improve design, construction, and maintenance of concrete structures, but foremost to facilitate technological development in regard to robustness, reliability, scalability and market readiness. Combining a pool of well-established and yet growing technologies, DTs in 3DCP deal with highly demanding materials whilst facing their own, unique challenges. This paper explores the burgeoning landscape of DT enablers, highlights their specificities in regard to integration into a DT in 3DCP, addresses particular challenges, reveals technical boundaries, and proposes possible ways to overcome some of them. © 2024, The Authors. All rights reserved.

关键词： Cyber Physical System

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Antibacterial Surface Protection using Electrical Discharge Machining with Zinc Tool Electrode for Medical Devices

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Procedia CIRP 2024年 125卷 278-283页

作者： Viet D. Bui André Martin Thomas Berger Philipp Steinert Andreas Schubert Chemnitz University of Technology Professorship Micromanufacturing Technology Reichenhainer Str. 70 09126 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Str. 88 09126 Chemnitz Germany

Electrical discharge machining (EDM), widely used to fabricate medical devices, is applicable for antibacterial surface protection. Silver, transferred from tool electrode or powder suspended in the dielectric to the modified layer during the EDM process, significantly enhanced antibacterial properties of the modified surface. However, bacterial resistance to silver, which was widespread in clinical, still posed challenges for the modified surfaces containing silver. Zinc, owing to its strong antibacterial effects and no challenge related to Zn-resistant bacteria hitherto reported in clinical, was therefore used as tool electrode material to modify Ti6Al4V surfaces during the EDM process. Discharge energies up to 170 µJ with different polarities were applied in the EDM milling process using deionized water-based dielectric fluid. Results show that discharge energy and polarity play a vital role in chemical composition and roughness of the modified surfaces as well as material removal rate and tool wear rate. The surfaces containing zinc contents up to 28 % can be generated. The use of a low energy generates zinc-rich surfaces with less micro-cracks. The EDM process using zinc tool electrode shows a promising potential for antibacterial surface modification of medical devices.

关键词： EDM Zinc electrode Medical device Antibacterial surface

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Developments in Powder Mixed EDM and its perspective Application for targeted Surface Modification 15

Developments in Powder Mixed EDM and its perspective Applica...

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

作者： Schubert, Andreas Bui, Viet D. Schaarschmidt, Ingo Berger, Thomas Martin, André Chemnitz University of Technology Professorship of Micromanufacturing Technology Reichenhainer Strasse 70 Chemnitz09107 Germany Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Str. 88 Chemnitz09126 Germany

Although widely studied over the few decades, there are conflicting theories on the discharge mechanisms of powder mixed electrical discharge machining (PMEDM). Additionally, the dielectric flow plays a vital role in the distribution of powder particles in the machining gap, which significantly affects the powder deposition to the modified surface. In this paper, the literature on PMEDM surface modification is thoroughly reported. The conflicting mechanisms and the effects of PMEDM main machining conditions, such as powder and electrical parameters on improving mechanical and antibacterial properties as well as biocompatibility of the surface, have been discussed. To verify the separation mechanism of the discharge in PMEDM, single discharge investigations have been performed when silver nano-powder is mixed into the hydrocarbon-based dielectric fluid to modify Ti6Al4V surfaces. Surface topography, chemical composition as well as the deposited silver content and distribution over the crater surface when using positive and negative polarities are analyzed and discussed. Current waveforms of PMEDM and EDM without powder at varying discharge energies as well as with and without ultrasonic vibration assistance are recorded and analyzed. For the transfer of fundamental results to a perspective application, CFD simulation is used to calculate the flow field of the dielectric fluid and analyze the velocity and distribution of the nano-powder within the working gap of a setup with internal flushing. The results show that PMEDM is a potential technology for machining medical devices with simultaneous antibacterial surface modification. © 2022 The Authors. Published by Elsevier B.V.

关键词： Titanium alloys

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Robotic Visual Servoing for Tracking Structureless Moving Parts

Robotic Visual Servoing for Tracking Structureless Moving Pa...

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Iberian Robotics Conference (ROBOT)

作者： Christian Schroder Marco Schumann Rico Loser Philipp Klimant Martin Dix Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Professorship Virtual Technologies Hochschule Mittweida - University of Applied Sciences Mittweida Germany Institute for Machine Tools and Production Processes Chemnitz University of Technology Chemnitz Germany

ISBN: (数字)9798350376364

ISBN: (纸本)9798350376371

The European Union has committed to achieving the 1.5-degree Celsius limit set by the Paris Climate Agreement, emphasizing the necessity for substantial energy savings across various sectors, particularly in industry. This ambitious goal requires a delicate balance between reducing energy consumption and maintaining economic strength. Concurrently, there is a noticeable shift from mass production to mass customization, driven by the need for more flexible and adaptable manufacturing processes. Cognitive robotics emerges as a pivotal technology in this context, offering enhanced capabilities for flexible production lines. One significant advantage is the ability to assemble moving parts which optimizes cycle times and therefore contributes to energy savings. This paper presents a novel approach to object tracking using NC robot-based position control, demonstrating its potential to support the industry's transition towards more sustainable and efficient manufacturing practices. The image processing algorithm, which consists of a fused methodology merging an iterative 2D image registration and stereo vision-based point cloud registration, demonstrates the ability to track an object with a mean L2-error of 3.5 mm in a dynamic environment.

关键词： Industries Point cloud compression Service robots Heuristic algorithms Energy conservation Position control Production Visual servoing Object tracking Meteorology

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Data quality in environmental assessment methods - Implications for the operational management in manufacturing 31

Data quality in environmental assessment methods - Implicati...

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31st CIRP Conference on Life Cycle Engineering, LCE 2024

作者： Elsner, Juliane Brings, Hanna Sohnius, Felix Schmitt, Robert H. Laboratory for Machine Tools and Production Engineering WZL of RWTH Aachen University Aachen52074 Germany Fraunhofer Institute for Production Technology IPT Steinbachstraße 17 Aachen52074 Germany

To implement environmentally sustainable, resource-efficient manufacturing, the quantification of the environmental impacts is a central task. This task requires suitable methods. Various lifecycle phases, including remanufacturing concepts, and the associated increasing complexity demand a change from static to dynamic assessment methods. Flexible changes must be considered. Thereby, data quality has a major impact on the subsequent assessment results. Though the available data amount in a manufacturing environment is constantly increasing, the influence of data quality on the respective method - and thus, the reliability of the results - remains a key issue. To address this problem, this paper investigates the necessary developments regarding data quality for environmental assessment methods in dynamically changing manufacturing settings. First, relevant data quality dimensions are identified. Subsequently, a cross-comparison of data quality dimensions and different approaches of environmental evaluation in manufacturing is developed. The necessary changes to data quality requirements in operational environmental assessments are derived. Finally, a concept for the improvement of data quality in dynamic assessments is proposed and discussed based on the use case of battery modules' remanufacturing. This paper contributes to the development of environmental assessment methods that are evolving from static, historical data-based evaluations to dynamic assessment tools of flexible productions. © 2024 Elsevier B.V.. All rights reserved.

关键词： Sustainable development

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Robot-based, sensitive mating of electrical connectors using automatically designed gripper jaws 57

Robot-based, sensitive mating of electrical connectors using...

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18th IFAC Workshop on Time Delay Systems, TDS 2024

作者： Gebauer, Daniel Roith, Alexander Dirr, Jonas Daub, Rüdiger Institute for Machine Tools and Industrial Management Technical University of Munich Boltzmannstraße 15 Garching85748 Germany Fraunhofer Institute for Casting Composite and Processing Technology Am Technologiezentrum 10 Augsburg86159 Germany

Designing suitable gripper jaws is crucial for automating complex assembly tasks, such as mating electrical connectors. In previous work, we developed a methodology for these kinds of workpieces to generate gripper jaws automatically with parameterizable clearance, which is a proven way for robust grasping. Since there is uncertainty about the resulting in-hand pose, this paper investigates whether a sensitive joining strategy can compensate for this to ensure robust mating of electrical connectors. We conducted 600 grasp and about 450 mating tests using multiple high-voltage electrical connectors and clearances. In most experiments, sensitive joining strategies compensate for the in-hand pose uncertainty. © 2024 The Authors.

关键词： Grippers

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

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Procedia CIRP 2024年 130卷 348-354页

作者： Yunqi Gu Ruth Maria Otto Martin Naumann Leutrim Gjakova Rico Löser Martin Dix University of Applied Sciences Munich Lothstr. 34 80335 Munich Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU 09126 Chemnitz Germany Chemnitz University of Technology 09111 Chemnitz 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.

关键词： Robotic Assembly Force-torque control Deep-Neural-Network Cognitive Robotics

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Coupled CFD model of tool environment and workspace to determine the convective heat transfer in jet cooling of milling processes in machine tools

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Procedia CIRP 2025年 133卷 280-285页

作者： Steffen Brier Alexander Geist Janine Glänzel Christian Naumann Joachim Regel Martin Dix Steffen Ihlenfeldt Chemnitz University of Technology Professorship Production Systems and Processes Reichenhainer Str. 70 09126 Chemnitz Germany Fraunhofer-Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 09126 Chemnitz Germany Technical University Dresden Institute for Machine Tools Development and Adaptive Controls Helmholtzstraße 10 01069 Dresden Germany

The responsible use of resources is an essential part of the manufacturing of industrial products. This includes the economical use of cooling lubricant and requires precise knowledge of the cooling mechanisms and their effect on the accuracy of the machine tool and thus the thermal error. A temporal and spatial resolution of the dynamic coolant flow near the tool and in the entire workspace in a single model would require a large simulation time. Therefore, a composite model was developed, that consists of a near-tool model and a larger surrounding workspace model. The required static near-tool cooling lubricant distribution is obtained via data discretization methods from a separate static simulation that resolves the turbulence of the cooling lubricant created by the tool rotation. The identified coolant distribution is integrated into a CFD near-tool model (with simplified tool geometry) which is coupled with a surrounding CFD workspace model. The workspace model is thus able to identify the effects of the coolant wetting on the machine surface temperature and finally, using thermo-elastic FEM simulations, on the resulting thermal error. This approach allows the composite model to simulate the entire workspace with reduced simulation effort and map the coolant-influenced heat transfer coefficients on the machine surface.

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Challenges and Opportunities in Composite Cathode Production of Polymer-Based Solid-State Batteries 57

Challenges and Opportunities in Composite Cathode Production...

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18th IFAC Workshop on Time Delay Systems, TDS 2024

作者： Dhom, Jonas Röß-Ohlenroth, Richard Stumper, Benedikt Berger, Christoph Daub, Rüdiger Fraunhofer Institute for Casting Composite and Processing Technology IGCV Am Technologiezentrum 10 Augsburg86159 Germany Institute for Machine Tools and Industrial Management Technical University of Munich Boltzmannstr. 15 Garching85748 Germany

Higher energy densities and a high level of safety are decisive for the energy storage systems of electric vehicles to satisfy the high range requirements. The polymer-based solid-state battery is a promising technology that stands out due to its high energy density and theoretical safety advantages. Research into this innovative battery technology in Germany and Europe mainly focuses on the laboratory scale. For the production of polymer-based solid-state batteries, there is a lack of accessible information to transfer the laboratory scale to pilot production. Therefore, competence in upscaling the polymer-based composite cathode is essential. The current work investigates the cause-effect relationships of individual production processes of the polymer-based composite cathode in order to establish an in-depth understanding of how they can be scaled. In particular, mixing, coating, and calendering are compared with the corresponding processes of the conventional electrode production of lithium-ion battery cells to identify similarities and differences. The comparison demonstrates that the calendering process is particularly challenging due to the minimization of the porosity of the polymer-based composite cathode. For this reason, the challenges of calendering are discussed in detail. An existing empirical model of the calendering of lithium metal is used to enhance the comprehension of the calendering process. This results in a reduced material consumption and experimental setup time. By using a temporary foil to protect the calender rollers from the high adhesion, polymer-based composite cathodes can be calendered with a conventional roll-to-roll process. The results provide first informations of the scalability of the process of polymer-based composite cathodes from laboratory-based work to a larger scale. © 2024 The Authors.

关键词： Solid-State Batteries

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Assessing the Human Competence and Individual Support Level in Manual Assembly through Cognitive Assistance Systems

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Procedia CIRP 2024年 126卷 811-816页

作者： Klaus Fink Anna Ziegler Christian Härdtlein Christoph Berger Rüdiger Daub Fraunhofer Institute for Casting Composite and Processing Technology IGCV Technical University of Munich Institute for Machine Tools and Industrial Management (iwb)

In today’s industrial landscape, production challenges arise from increasing demand for personalized products and demographic changes. Production facilities and employees must be agile and adaptable to changing requirements, while limited automation in multi-variant production elevates the importance of human workers. Cognitive assistance systems, such as digital instructions and pick-by-light systems, can enhance efficiency and reduce errors but should be customized to worker competence levels. This article presents a method for assessing worker competence and individual support using cognitive assistance systems in manual assembly, with an example from fraunhofer IGCV’s "Learning factory for cyber-physical production systems" in Augsburg.

关键词： Manufacturing system Production Human aspect

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