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Surface Roughness Prediction in Hard Turning (Finishing) of 16MnCr5 Using a Model Ensemble Approach

Procedia CIRP 2024年 126卷 504-507页

作者： Jannis Jacob Markus Meurer Thomas Bergs Laboratory for Machine Tools and Production Engineering (WZL) of RWTH Aachen University Campus-Boulevard 30 Aachen 52074 Germany Fraunhofer Institute for Production Technology IPT Steinbachstr. 17 52074 Aachen Germany

This paper investigates the predictive quality in finishing turning processes of 16MnCr5, specifically focusing on the use of model ensemble methods to predict surface roughness. Surface roughness plays a critical role in determining the quality and functionality of machined components. The objective of this study is to develop an accurate and robust predictive model for surface roughness after finishing turning operations. The proposed approach employs a model ensemble method, which combines multiple predictive models to enhance the accuracy and reliability of the predictions. The experimental setup includes collecting data using various types of in-situ sensors along with corresponding surface roughness measurements. The collected dataset is used to train and test the ensemble model, which integrates different machine learning algorithms and statistical techniques. The results demonstrate that the model ensemble method yields superior predictive performance compared to individual models, effectively capturing the complex relationships between process signals and surface roughness.

关键词： Turning Finishing machine Learning Predictive Quality Model Ensemble

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Enhancing cooling tower performance with condition monitoring and machine learning based drift detection

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Procedia CIRP 2022年 112卷 146-150页

作者： Sina Nahvi Stefan Polster Sebastian Melzer Anke Stoll Marc Münnich Stefan Mannstadt Philipp Klimant Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Chemnitz Germany Multi Kühlsysteme GmbH Zschorlauer Straße 56 08280 Aue Germany

Process cooling is crucial to many manufacturing processes. To monitor the performance of a cooling tower, it was equipped with extensive sensors for internal and environmental data acquisition. The aim is to improve reactive and predictive maintenance by estimating the actual condition as well as predicting defective behavior of the cooling tower. We designed a method, which derives the degree of defect from data of the non-defective cooling tower. A concept drift detection approach was implemented, which monitors the model estimation error of a multilayer perceptron model. Increasing model estimation error indicates changing system behavior and increasing risk of failure.

关键词： Condition monitoring Fault detection Neural Network Concept drift Cooling Tower

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Ultrasonic Vibration assisted Silver Integration by Powder Mixed EDM for Antibacterial Surfaces

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Procedia CIRP 2024年 123卷 410-415页

作者： Viet D. Bui André Martin Thomas Berger Karsten Harnisch Joachim Döring Jessica Bertrand Andreas Schubert Chemnitz University of Technology Professorship Micromanufacturing Technology Reichenhainer Str. 70 09126 Chemnitz Germany Otto-von-Guericke University Magdeburg Institute of Materials and Joining Technology Universitätsplatz 2 39106 Magdeburg Germany Otto-von-Guericke University Magdeburg Department of Orthopaedic Surgery Leipziger Str. 44 39120 Magdeburg Germany Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Str. 88 09126 Chemnitz Germany

Powder mixed electrical discharge machining (PMEDM) with silver nano-powder has demonstrated its potential capability in antibacterial surface modification. Analyses in the cross-sectional layer showed that silver was mainly integrated near the topmost surface layer, and its content is reduced within the layer towards the substrate. However, to achieve a long-term antibacterial efficacy, silver needs to be deeply integrated in the modified layer. Previous studies indicated that ultrasonic vibration (UV) assisted PMEDM can homogenize the silver content in the deposited layer. In this study, the effect of UV on the silver distribution within the modified layer is investigated. Ti6Al4V workpieces were stimulated by UV with a frequency of 22.3 kHz and an amplitude of 2.5 µm. Hydrocarbon-based dielectric fluid, mixed with silver nano-powder with concentrations up to 15 g/L, were internally flushed through a hollow tool with a pressure of 4 bar. PMEDM without UV was investigated for comparison. The layer thickness, micro-cracks and the cross-sectional distribution of deposited silver were analysed by confocal microscopy, scanning electron microscopy, and energy-dispersive X-ray spectroscopy. Results indicate that applying UV leads to the highest silver content in the middle region of the layer, a significant decrease of micro-cracks and a slight reduction of the layer thickness.

关键词： powder mixed EDM ultrasonic vibration silver distribution modified layer antibacterial effect

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Application of Topic Modeling for the Identification of Innovation Potentials in the Product Environment

Application of Topic Modeling for the Identification of Inno...

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IEEE International Conference on Industrial Engineering and Engineering Management

作者： M. Riesener M. Kuhn H. Lauf G. Schuh Laboratory for Machine Tools and Production Engineering (WZL) RWTH Aachen University Aachen Germany Fraunhofer Institute for Production Technology IPT Aachen Germany

One way to counter the increased competitive pressure in globalised markets is to increase a company's own innovation capacity. In most cases, innovations are a particular result of the environmental influences on the product. Text mining aids the systematic analysis of the various external influence dimensions with their large amount of data. The developed method developed in the context of this research identifies innovation potentials in the product environment and showcases their influence on the existing product. First, text data is retrieved from external influence dimensions. Through specific preprocessing, this data is transformed into a document term matrix, which is the basis for subsequent topic modelling. Finally, a semantic network shows the interconnection of both, the existing product and the analysis results.

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Evaluation of augmented reality supported approaches for product design and production processes

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Procedia CIRP 2021年 97卷 160-165页

作者： Marco Schumann Christian Fuchs Christian Kollatsch Philipp Klimant Institute for Machine Tools and Production Processes Chemnitz University of Technology Reichenhainer Straße 70 09126 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Straße 88 09126 Chemnitz Germany

Augmented Reality (AR) has been a focus of research in the field of production for many years with the goal to improve e.g. monitoring and maintenance processes. Although the benefits have been well researched, the AR technology has not been widespread yet in the industry. This article discusses reasons why existing approaches have not become established outside the research context. Following this, solutions are examined for three identified problematic areas. First, this article presents a theoretical method to create use cases for AR applications in the product design process based on the Double Diamond design process model. The second main part discusses which device properties are relevant for a production environment. A catalogue of criteria is presented, weighting properties according to their importance. Third, a discussion is described regarding data integration concepts, problems and solutions for AR design and production use cases.

关键词： Augmented reality Production Design Double Diamond design process model

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Concept for the Evaluation and Prioritization of machine Learning Use Cases in Industrial Production

Concept for the Evaluation and Prioritization of Machine Lea...

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IEEE International Conference on Industrial Engineering and Engineering Management

作者： G. Schuh L. Cassel Marc Uedelhoven Laboratory for Machine Tools and Production Engineering (WZL) RWTH Aachen University Aachen Germany Fraunhofer Institute for Production Technology IPT Aachen Germany

In the course of the advancing digitalization of industrial production, many enterprises have already laid the foundations for a more comprehensive end-to-end recording and accessibility of production related data. machine learning (ML), implemented in specific industrial use cases, offers the possibility of automated analysis of these large volumes of data with considerably reduced manual effort. In industrial practice, however, the selection of use cases with an economic and long-lasting strategic impact poses challenges, since much of the decision-relevant information of individual use cases is mostly discovered during the actual implementation phase. Additionally, as the datasets required for a successful application are often not sufficiently known prior to this phase, a previous assessment regarding the data basis for individual use cases is also needed. To address these challenges, this paper presents a concept constructed in the research process for applied sciences according to Ulrich for a-priori evaluation and prioritization of use cases for machine learning in industrial production. In particular, the potential benefits, implementation efforts, and the technical feasibility are considered as evaluation dimensions.

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Holistic animation and functional solution for digital manikins in context of virtual assembly simulations

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Procedia CIRP 2021年 97卷 15-20页

作者： Christian Fuchs Christoph Allmacher Philipp Klimant Matthias Putz Institute for Machine Tools and Production Processes Chemnitz University of Technology Reichenhainer Straße 70 09126 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Straße 88 09126 Chemnitz Germany

Assembly simulations in virtual reality were used increasingly in recent years. Even though a multitude of solutions exists in the commercial market, research is focusing on improving soft factors like usability and financial accessibility. Therefore, this paper proposes a holistic solution for animation and integration of functionality of a digital manikin in Unity. The solution is using Unity's integrated inverse kinematics system and physics engine. The result is a fully animated human manikin based on the tracking data of a head-mounted display and its two controllers, which is extrapolating motion data for untracked body parts. Furthermore, the solution enables the user to manipulate objects and explore the virtual environment. The solution is validated in comparison to established motion capture methods using joint error analysis.

关键词： Virtual reality Digital manikins Motion capture Inverse kinematics Animation Assembly simulation

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Framework for the Implementation of Continuous Innovation for Technical Products

Framework for the Implementation of Continuous Innovation fo...

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Portland International Conference on Management of Engineering and technology (PICMET)

作者： Michael Riesener Maximilian Kuhn Stefan Perau Thilo Walter Alexander Keuper Guenther Schuh Laboratory for Machine Tools and Production Engineering (WZL) RWTH Aachen University Aachen Germany Fraunhofer Institute for Production Technology IPT Aachen Germany

In order to face current challenges of dynamic market environments, customer-specific requirements and shorter development cycles, manufacturing companies need to focus on new innovation approaches like continuous innovation (CI). Thereby, the approach CI focuses on the ability of a company to continuously improve or renew products or features during the product usage phase. Although, manufacturing companies are aware of the opportunities to ensure their own competitiveness through CI, the implementation is not successful. In particular, there is a lack of a process model that illustrates the relevant aspects in the dimensions business models, processes and products, which are required for the realization of continuous innovations. This paper attempts to close this gap by introducing a framework for the implementation of CI for technical products in the usage phase. The framework consists of 12 process steps and respective implementation activities in order to realize CI. Furthermore, influencing factors on the implementation process are identified and enable the transformation of the generic framework into a company specific implementation guide. Thus, the framework supports manufacturing companies in the operative realization and implementation of continuous innovation.

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Time-Sensitivity of Intermediate Product Properties in Lithium-Ion Battery Cell Production

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Procedia CIRP 2024年 130卷 470-478页

作者： Anna Kollenda Maximilian Lechner Alessandro Sommer Rüdiger Daub Technical University of Munich TUM School of Engineering and Design Institute for Machine Tools and Industrial Management (iwb) Boltzmannstraße 15 85748 Garching Germany Fraunhofer Institute for Casting Composite and Processing Technology (IGCV) Am Technologiezentrum 10 86159 Ausgsburg Germany

Lithium-ion batteries play an increasingly crucial role in electric vehicles, grid energy storage, and portable devices. In lithium-ion battery manufacturing systems, quality assurance measures are essential throughout the production chain to identify intermediate products that do not meet specifications, ensuring that the finalized cells meet the high-quality standards expected by the customer. This also supports the reduction of the scrap rate and thereby raises the sustainability of production. Parts of the intermediate product properties, particularly evident in electrode production, change over time. Therefore, measurements and tests must be planned accordingly to ensure that decisions regarding the product quality and further processability are accurate. This paper presents a procedure to investigate the time-sensitivity of intermediate product properties and to determine the validity durations for measurement results accordingly. The procedure is experimentally applied to examine the viscosity, density, and solid content of slurries, as well as the coating masses and the spring-back effect of electrodes in an NMC/graphite system.

关键词： Quality management quality assurance lithium-ion battery cells measurement systems battery production springback effect

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Towards the Integration of Direct Contact Prelithiation into the Manufacturing Process for Large-Format Lithium-Ion Batteries

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Procedia CIRP 2024年 130卷 1659-1666页

作者： Felix Diller Moritz Günthner Benedikt Stumper Rüdiger Daub Technical University of Munich TUM School of Engineering and Design Institute for Machine Tools and Industrial Management (iwb) Boltzmannstr. 15 85748 Garching Germany Fraunhofer Institute for Casting Composite and Processing Technology (IGCV) Am Technologiezentrum 10 86159 Augsburg Germany

The increasing requirements for high-performance lithium-ion batteries from applications such as electric aviation and electric mobility require further improvement of this energy storage technology. Prelithiation is a method to improve the energy density and lifespan by integrating additional lithium during battery cell production to compensate for occurring irreversible losses of active lithium, which lead to a reduced energy density and capacity fade. Direct contact prelithation incorporates lithium metal in contact to the anode active material to generate a lithium reservoir, which can be consumed by parasitic reactions inside the cell. One factor limiting direct contact prelithiation to laboratory scale is the missing knowledge how to integrate direct contact prelithiation into the manufacturing system of battery cells and how subsequent process steps after lithium insertion are affected. The presented work investigates the effect of direct contact prelithiation on the cell assembly and cell finalization processes of the lithium-ion battery production chain. The occurring challenges to integrate the formed anode-lithium-composite in the cell assembly processes are likely to be similar to those for pure lithium electrodes. The electrolyte filling and formation processes show a high need for adaptation regarding direct contact prelithiation, since the first lithiation of the anode and the formation of the solid electrolyte interphase is already initiated with electrolyte filling. Successful industrialization of direct contact prelithiation requires attention to safety concerns due to exothermic chemical reactions, accurate determination of the solid electrolyte interphase to ensure high cell quality, and streamlining of the currently time-consuming formation process.

关键词： Lithium-ion battery battery manufacturing prelithiation direct contact prelithiation

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