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

作者： Wunderlich, Tim Hansert, Jonas Koch, Sandro Heinrich, Robert Schlegel, Thomas Ihlenfeldt, Steffen Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 Chemnitz09126 Germany Karlsruhe University of Applied Sciences Moltkestr. 30 Karlsruhe76133 Germany Karlsruhe Institute of Technology Am Fasanengarten 5 Karlsruhe76131 Germany Institute of Mechatronic Engineering Technische Universität Dresden Dresden01062 Germany

The requirements for cyber-physical production systems (CPPS) grow steadily, leading to increased complexity of such systems. To address issues due to reconfiguration or failures, we present an approach to creating a context model of the CPPS components during runtime and to detect deviations from the planned production processes. Furthermore, we present a concept for modelling production processes that allows for dynamic process adaption during runtime. We then utilize this process adaption and the context model to cope with unforeseen failures and increase the resilience of the system. Finally, we evaluate the feasibility of our approach by applying it to an Industry 4.0 production system. © 2023 Elsevier B.V.. All rights reserved.

关键词： Dynamics

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Development of general data-based process models for self-pierce riveting 24

Development of general data-based process models for self-pi...

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24th International ESAFORM Conference on Material forming, ESAFORM 2021

作者： Jäckel, Mathias Falk, Tobias Kropp, Thomas Drossel, Welf-Guntram Fraunhofer Institute for Machine Tools and Forming Technology IWU Nöthnitzer Straße 44 Dresden01187 Germany

ISBN: (纸本)9782870193020

The determination of ideal process parameters for mechanical joining processes such as self-pierce riveting currently requires a comprehensive understanding of the process, the availability of the materials to be joined and the corresponding system technology. General process models can simplify the use of these joining technologies, accelerate development cycles and thereby reduce the effort for implementation into production. In this paper, the development of general data-based process models for the mechanical joining method self-pierce riveting with semi-tubular rivet is described. Extensive experimental and numerical investigations with more than 2300 joint combinations for steel and aluminum sheets with tensile strengths between 240 - 1020 MPa were generated for the building of the models. Based on these results, different meta-models are fused into general data-based process models for the self-pierce riveting process in order to show the general relationships between material properties, process parameters and joining results. The paper discusses the acquisition of the experimental and numerical data, the statistical methods for evaluation and the application of the data-based process models. © ESAFORM 2021 - 24th Inter. Conf. on Mat. forming. All rights reserved.

关键词： Riveting

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Semi-automatic process control for efficient refurbishment of turbine blades 23

Semi-automatic process control for efficient refurbishment o...

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23rd International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2023

作者： Uhlmann, E. Polte, J. Mühlich, C. Mönchinger, S. Ebrahimi, P. Technische Universität Berlin Institute for Machine Tools and Factory Management IWF Germany Fraunhofer Institute for Production Systems and Design Technology IPK Germany Gestalt Robotics GmbH Germany Germany

ISBN: (纸本)9781998999132

The refurbishment of turbine blades requires the precise removal of damaged surface coatings. In manufacturing companies, this usually involves time-consuming activities such as detecting residual coatings and adapting process settings to varying turbine blade geometries. The use of automated systems therefore opens up opportunities to improve the efficiency of turbine blade refurbishment processes by replacing manual tasks. This paper presents an conceptual approach for a semi-automatic decoating process of turbine blades that integrates abrasive blasting technology into a closed loop process control system. The experimental setup consists of a robot for guiding the turbine blade in a blast machine and a nozzle system for local removal of residual coatings using abrasive material. Based on image processing the residual coatings of a turbine blade are labeled by a neural network and mapped to a 3D model of the turbine blade, which is used by a software control system to coordinate the decoating process. Using a prototype setup this paper investigates the applicability of the proposed approach and evaluates its feasibility. © 2023 Euspen Headquarters.

关键词： Turbomachine blades

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Micro-texture dependent temperature distribution of CVD diamond thick film cutting tools during turning of Ti-6Al-4V 6th

Micro-texture dependent temperature distribution of CVD diam...

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6th CIRP Conference on Surface Integrity, CSI 2022

作者： Uhlmann, E. Schröter, D. Gärtner, E. Pascalstr. 8-9 Berlin10587 Germany Fraunhofer Institute For Production Systems And Design Technology Ipk Pascalstr. 8-9 Berlin10587 Germany Fraunhofer Institute For Machine Tools And Forming Technology Iwu Reichenhainer Str. 88 Chemnitz09126 Germany

Machining titanium alloys such as Ti-6Al-4V results in a high thermomechanical load on cutting tools and consequently short tool lifes. With respect to a necessary reduction of the resulting cutting tool temperatures, ultrashort pulse (USP) laser fabricated micro-textured rake faces offer direct supply of cooling lubricant into the cutting zone and lead to a reduced heat induction. As a result, micro-textured CVD diamond thick film cutting tools are also capable of machining high-performance materials due to reduced contact temperatures. In the scope of the research, the resulting temperature distribution for micro-textured rake faces will be compared under both dry and wet process conditions. Measurements show a reduction of the resulting cutting tool temperatures of ΔÏ't = 27.9 % using micro-textured cutting tools compared to non-textured cutting tools. A validated simulation provides valuable information about the contact temperatures enabling a specific development of the micro-texture geometry. As a result, a reduction of the contact temperature between chip and rake face by ΔÏ'T = 24.7 % was possible. © 2022 The Authors.

关键词： Turning

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Replicative Production of Multifunctional Microfluidic Polymer Films for Biomedical Disposables

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Procedia CIRP 2024年 125卷 207-212页

作者： Eric Gärtner Frederic Schell Lukas Nitschke Richard Chukwudi Okafor Christoph Zwahr Claudia Hackl Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Strasse 88 09126 Chemnitz Germany Fraunhofer Institute for Material and Beam Science IWS Winterbergstr. 28 01277 Dresden Germany Leibniz Institute of Surface Engineering IOM Permoserstr. 15 04318 Leipzig Germany

Increasing demands on the reproducibility and accuracy of lab-on-a-chip systems in the life science sector require new tools for the molding of polymer films with spatially selectively functionalized surfaces. By applying local micro- and nanostructuring to the molding tools, the aim is to achieve multifunctionality of the polymer films, by setting certain wetting properties. This means that fluid-affecting properties (hydrophobic, hydrophilic) should be possible. To functionalize polymer films, the replication tools were specifically microstructured using laser-based surface functionalization. The periodic micro- and nanostructures were produced with the help of nanosecond pulsed and picosecond pulsed laser systems using Direct Laser Interference Patterning. For this purpose, complex functional microstructures in the range of 0.1 µm to 100 µm were developed based on a bionic approach. The functional properties were transferred in a one-step replicative process using UV-imprinting and were subsequently verified by determining the wetting behavior of the molded microfluidic films and the corresponding laser microstructured replication tools. This publication presents the successfully developed processes and the promising results of this series of experiments.

关键词： laser microstructuring surface functionalization lab-on-a-chip DLIP UV-imprinting

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Design requirements for a modular framework of industrial surface defect detection system designs in the context of machined, automotive workpieces

Design requirements for a modular framework of industrial su...

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IEEE International Conference on Industrial Informatics (INDIN)

作者： Marco Wagenstetter Thomas Aicher Arvid Hellmich Steffen Ihlenfeldt Powertrain Production System Planning BMW Group Munich Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Dresden Germany

The planning phases of industrial surface defect detection systems for machined, automotive workpieces are time-consuming and require project teams comprised of experts from different disciplines in order to achieve optimal systems regarding the prioritized objectives. To master this challenge current research is aiming for flexible inspection system concepts that are not application-specific and thus can be used for a range of industry-dependent specifications without the necessity to complete each planning phase from the beginning. This paper presents a thorough analysis of the influencing factors at the beginning of the inspection planning process of an industrial surface defect detection system for machined, automotive workpieces. Based on this analysis, design requirements for a modular framework for industrial surface defect detection system designs in this sector are derived and contextualized with available system components. Finally, an outlook for future research is presented with the goal to further increase the flexibility of industrial surface defect detection systems.

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Development and Validation of a Screw Interlock Recognition Method based on Logistic Regression 10

Development and Validation of a Screw Interlock Recognition ...

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10th CIRP Conference on Assembly technology and Systems, CATS 2024

作者： Jaya, Tanureza Bastidas-Cruz, Arturo Krüger, Jörg Fraunhofer IPK Pascalstrasse 8-9 Berlin10587 Germany Industrial Automation Technology Department Institute of Machine Tools and Factory Management Technische Universität Berlin Pascalstrasse 8-9 Berlin10587 Germany

Conventional robotic screw methods rely on position control and the use of a threshold value, normally a contact force value, to detect the contact between tool and screw, so the nut-runner can be placed correctly on the workpiece. In the case of a dynamic workspace, the variance of the workpiece position will likely cause the nut-runner to be positioned incorrectly and will significantly decrease the success rate of the screw task. This paper proposes a novel method based on a logistic regression model for flexible Human-Robot-Collaboration (HRC) screw assembly operations in highly dynamic workspaces. The proposed method is part of a screwing strategy based on impedance control and developed for HRC applications. The screwing strategy consists of a spiral movement executed by the robot while approaching the workpiece and it is used as a search procedure to find the screw. The proposed method is used to detect when the tool correctly interlocks with the screw head so the robot can proceed with the screwing process. The goal is to stop the spiral movement timely when the nut-runner has correctly interlocked with the screw head to ensure a successful screw task and avoid potential damage to the nut-runner or the workpiece. The proposed screw interlock recognition method utilizes a logistic regression model to observe the contact forces between tool and screw head. The learning model is trained using force data collected from experiments and then its feasibility is validated with further testing. © 2024 Elsevier B.V.. All rights reserved.

关键词： Screws

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Automated defect detection of CT projection image data using Monte Carlo simulation 22

Automated defect detection of CT projection image data using...

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22nd International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2022

作者： Uhlmann, E. Hein, C. Fehlhaber, F. Wang, Y. Duerre, G. Fraunhofer Institute for Productionsystems and Design Technology IPK Germany Institute for Machine Tools and Factory Management IWF Technical University Berlin Germany

ISBN: (纸本)9781998999118

During the last decade industrial computed tomography has become one of the most important metrological procedures for internal inspection, where it sees widespread application in additive manufacturing. Evaluating the CT volume data for defects is currently a lengthy process involving data acquisition, reconstruction, surface reconstruction, and nominal/actual comparison. The goal of the presented project is the development of a new pipeline for automated defect detection operating solely with projection data. Using this pipeline, the amount of necessary projections NP and therefore the measurement time of each object will be heavily reduced. Reference projection data of non-defect objects were generated using a multi-GPU Monte Carlo X-ray simulation. The innovative implementation of the Monte Carlo simulation on GPUs makes the photon number of 5x1011required for a proper simulation of an X-ray projection feasible for the first time. This generated reference data was then compared to real data and the differences evaluated. With this new processing pipeline, it is now possible to achieve a defect analysis with less than six projection images, which decreases the minimum measurement time tmby nearly two magnitudes. © European Society for Precision Engineering and Nanotechnology, Conference Proceedings - 22nd International Conference and Exhibition, EUSPEN 2022. All rights reserved.

关键词： Defects

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Additive Manufacturing of Ceramics opens the door to Components for Biomanufacturing Applications with high Functionality 6

Additive Manufacturing of Ceramics opens the door to Compone...

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6th CIRP Conference on BioManufacturing, BioM 2024

作者： Scheithauer, Uwe Holtzhausen, Stefan Wiemer, Hajo Fraunhofer Institute for Ceramic Technologies and Systems Group Additive and Hybrid Manufacturing Winterbergstr. 28 Dresden01277 Germany TUD Dresden University of Technology Institute of Machine Elements and Machine Design Virtual Product Development Group Advanced Geometric Modeling And Analysis Dresden01062 Germany TUD Dresden University of Technology Institute of Mechatronic Engineering Machine Tools Development and Adaptive Controls Department of Machine Data Processing Dresden01062 Germany

Significant advancements in production technology, materials, component design, and data science foster innovation across industries, including biomanufacturing. Ceramic materials, adapted additive manufacturing processes, and novel construction methods hold immense innovation potential due to ceramics' exceptional thermal, chemical, and mechanical properties. Additive manufacturing enables the creation of intricate ceramic components with unprecedented functionality. Hybridizing manufacturing technologies and materials facilitates direct integration of additional features like sensors and actuators. Despite their potential, ceramic materials remain underutilized. This article aims to spark a discourse on leveraging high-performance ceramic components in biomanufacturing, leveraging superior material properties, innovative design methods, additive manufacturing, process data analysis, and AI. © 2024 The Authors.

关键词： Ceramic materials

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Biologicalisation of manufacturing on a factory scale - Taking a wider approach to envision a biologically transformed pulp-factory 56

Biologicalisation of manufacturing on a factory scale - Taki...

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56th CIRP International Conference on Manufacturing Systems, CIRP CMS 2023

作者： Schömig, Oliver Arafat, Robar Abraham, Tim Herrmann, Christoph TU Braunschweig Institute of Machine Tools and Production Technology Langer Kamp 19b Braunschweig38106 Germany Fraunhofer Institute for Surface Engineering and Thin Films IST Braunschweig38108 Germany

The biologicalisation of manufacturing (BoM) is becoming a major driver for innovation, rendering conventional production processes more sustainable and efficient. So far, most biological transformation approaches focus on improving single technologies or materials in the production chain irrespective of the adjacent processes. However, the potential for BoM might even be greater if a broader approach is taken. Similar to how biological systems achieve efficiency by utilizing self-sufficient, highly interconnected processes, linking multiple individual BoM-technologies in a factory environment could lead to previously unattained improvements. This paper examines the potential of such a holistic transformation using the example of a manufacturing process from the pulp and paper industry. A production process for bleached pulp based on the chemical kraft process was chosen and screened for its inherent environmental challenges. Existing bio-based optimization approaches were then collected and assigned to the production steps followed by an evaluation of possible synergies and interactions concerning their simultaneous implementation on a factory scale. The survey revealed similarities and interlocking functions for a wide variety of BoM-technologies that might help to overcome some of the current hurdles faced in their individual implementation. Based on the findings a vision is presented about i) how a factory scale BoM holds the potential to improve sustainability of kraft pulp production in the short term and ii) how it could play a role in enabling more flexible and circular processes in the long term. The presented ideas should thereby serve as an impulse for a general investigation of wider biologicalisation approaches and provide a starting point for the creation of systematic methodical procedures to investigate and evaluate biological transformation processes on a factory scale. © 2023 The Authors. Published by Elsevier B.V. This is an open access article un

关键词： Biologicalisation of manufacturing Pulp and Paper Sustainability

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