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Virtual Prototyping Technologies Enabling Resource-Efficient and Human-Centered Product Development

Procedia Manufacturing 2018年 21卷 749-756页

作者： C. Allmacher M. Dudczig P. Klimant M. Putz Chemnitz University of Technology Reichenhainer Str. 70 09126 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 09126 Chemnitz Germany

In modern production environments employees work progressively closer together with autonomous robots and vehicles. Besides the technical specifications, the development of these products focuses on the human-machine interaction. Within the federally funded Project FOLLOWme an automated guided vehicle (AGV) for intralogistics that follows and interacts with the user is developed using virtual reality based prototypes. The benefits in comparison to using only physical prototypes are on the one hand specific user feedback regarding ergonomics and trust. On the other hand the validation of navigation and collision avoidance algorithms and optimization of technical parameters is achieved considering complex environmental conditions. This paper focuses on the latter in detail and deals with the optimization of a fuzzy logic controller using the game engine Unity3D to create the required virtual setup. This approach saves valuable time at early project stages and allows the optimization of a larger number of parameters compared to just physical tests. Furthermore it reduces resources like occupied physical infrastructure and improves the comprehension by using virtual reality.

关键词： Resource Efficiency Human Factors Virtual Prototype Automated Guided Vehicle Obstacle Avoidance Fuzzy Logic Controller Unity3D

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Active flow control in wind turbines - Integration technologies and assessment of economic effects 12

Active flow control in wind turbines - Integration technolog...

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Smart Systems Integration 2018 - 12th International Conference and Exhibition on Integration Issues of Miniaturized Systems

作者： Schüller, Martin Lipowski, Mathias Weigel, Perez Symmank, Christina Meynerts, Lilly Walther, Marco Dziuba, Franz Otto, Thomas Götze, Uwe Kroll, Lothar Department Multi Device Integration Fraunhofer Institute for Electronic Nano Systems Chemnitz Germany Management Accounting and Control Chemnitz University of Technology Chemnitz Germany Department of Lightweight Structures and Polymer Technology Chemnitz University of Technology Chemnitz Germany Forschungszentrum Systeme und Technologien für textile Strukturen STEX Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz Germany Center for Micro Technologies Chemnitz University of Technology Chemnitz Germany

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Equivalence assessment method for the resource efficiency of equipment, technologies and production systems

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Procedia Manufacturing 2018年 21卷 525-532页

作者： A.P. Kuznetsov H.-J. Koriath A.V. Kalyashina T. Langer Moscow State University of Technology “STANKIN” 127055 Moscow Russia Fraunhofer Institute for Machine Tools and Forming Technology IWU 09126 Chemnitz Germany Kazan National Research Technical University Kazan Russia

The paper analyses different assessment methods for the overall equipment effectiveness (OEE), energy efficiency and productivity of equipment and production systems. The proposed model and systematic assessment approach define the total and relative resource efficiency of equipment, technologies and production systems in the form of material, energy and information efficiency. This common resource efficiency assessment method is based on the physical and mathematical equivalence of efficiency indicators including probable events for resource usability. Three typical relations, determining any kind of efficiency, are obtained from those equivalents. Examples for resource efficiency assessment types are energy efficiency, productivity and accuracy. Integrated evaluation indicators for a comparative benchmarking of equipment, technologies and production systems are provided based on the equivalence assessment method and the proposed three typical relations. This method is also applicable to process chains.

关键词： equipment resource efficiency technology production system

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Computational Manufacturing for Multi-Material Lightweight Parts

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Procedia CIRP 2019年 85卷 102-107页

作者： André Hürkamp Ralf Lorenz Bernd-Arno Behrens Klaus Dröder Technische Universität Braunschweig Institute of Machine Tools and Production Technology Langer Kamp 19b 38106 Braunschweig Germany Open Hybrid LabFactory Hermann-Münch-Straβe 2 38440 Wolfsburg Germany Leibniz Universität Hannover Institute of Forming Technology and Machines An der Universität 2 30823 Garbsen Germany

In this contribution, a computational approach for the manufacturing of multi-material lightweight parts is presented. For an efficient online optimization procedure, a proper orthogonal decomposition on offline obtained numerical results is carried out to construct a surrogate model. The functionality of the proposed framework is demonstrated on a use case study of a multi-material component consisting of a sheet metal basic structure and a plastic reinforcement structure. The manufacturing process chain consists of a deep drawing process followed by an injection molding process of short fiber reinforced plastics. The proposed methodology provides a fast and accurate computational model for structural properties with respect to the process settings.

关键词： Composites Simulation Production planning Finite element method (FEM)

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Conserving Resources in Production - Breaking New Ground

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Procedia Manufacturing 2017年 8卷 619-626页

作者： Landgrebe, D. Kräusel, V. Bergmann, M. Werner, M. Rautenstrauch, A. Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Straße 88 Chemnitz 09126 Germany Machine Tools and Forming Technology Technische Universität Chemnitz Reichenhainer Straße 70 Chemnitz 09126 Germany

Many approaches focus on more efficient production processes, on avoiding waste and scrap and on more efficient use/operation of products within one life cycle, i.e. from raw materials to the end of use. All these approaches share the goal of an increase in resource efficiency. In contrast, the reProd® approach is characterized by a comprehensive view of cycles. By shortening the cycle process, a huge potential can be opened up for metal products regarding a reduction of energy requirements and CO₂ emissions. Approx. 70% to 90% of the energy requirements and also of the greenhouse gas emissions are necessary for melting the metals and for the first processing stage. If secondary semi-finished products are obtained from used goods, energy-intensive processes are eliminated. Thus a decisive contribution for the energy turnaround and for protecting climate and environment lies in “non-destructive recycling” and “re-use without melting” © 2017

关键词： material cycle recycling economie

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Improving the cutting performance of coated tools via appropriate pre- and post-treatments 5

Improving the cutting performance of coated tools via approp...

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5th International Conference of Engineering Against Failure, ICEAF-V 2018

作者： Bouzakis, Konstantinos Skordaris, Georgios Bouzakis, Emmanuil Kotsanis, Tilemachos Laboratory for Machine Tools and Manufacturing Engineering Mechanical Engineering Department Aristotle University of Thessaloniki Greece Fraunhofer Project Centre Coatings in Manufacturing LMTME Fraunhofer Institute for Production Technology Aachen Germany German University of Technology in Oman Department of Engineering Oman

The cutting performance of PVD coated tools can be significantly improved by appropriate pre- and post- treatments of the substrates and coated surfaces respectively. Substrate pre-treatments aim, among others, at improving the coating adhesion. In this way, lower coating loads develop during cutting leading to a decelerated wear evolution. Furthermore, the potential to increase the wear resistance of coated tools via micro-blasting is presented. Micro-blasting parameters such as of grain material, pressure, dry or wet etc., affect significantly the superficial coatings' hardness and brittleness and in this way their wear behaviour. To check the effectiveness of all these methods, innovative coating's characterization procedures providing information concerning the film and substrate properties as well as adhesion are applied, thus reducing the required experimentation time. © The Authors, published by EDP Sciences, 2018.

关键词： Wear resistance

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A Virtual Hip Replacement Surgery Simulator with Realistic Haptic Feedback

A Virtual Hip Replacement Surgery Simulator with Realistic H...

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IEEE Annual International Symposium Virtual Reality

作者： Maximilian Kaluschke René Weller Gabriel Zachmann Luigi Pelliccia Mario Lorenz Philipp Klimant Sebastian Knopp Johannes P. G. Atze Falk Möckel University of Bremen Computer Graphics and Virtual Reality IWP Chemnitz University of Technology Fraunhofer Institute for Machine Tools and Forming Technology IWU FAKT Software

We present the first VR training simulator for hip replacement surgeries. We solved the main challenges of this task - high and stable forces during the milling process while simultaneously a very sensitive feedback is required - by using an industrial robot for the force output and the development of a novel massively parallel haptic rendering algorithm with support for material removal.

关键词： Haptic interfaces Surgery Hip Rendering (computer graphics) Training Milling Robots

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Towards energy flexible and energy self-sufficient manufacturing systems

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Procedia CIRP 2019年 81卷 683-688页

作者： Christine Schulze Stefan Blume Lukas Siemon Christoph Herrmann Sebastian Thiede Chair of Sustainable Manufacturing and Life Cycle Engineering Institute of Machine Tools and Production Technology (IWF) Technische Universität Braunschweig Langer Kamp 19b 38106 Braunschweig Germany Fraunhofer Institute for Surface Engineering and Thin Films IST Bienroder Weg 54 E 38108 Braunschweig

In order to respond to environmental requirements, a growing number of manufacturing companies operate on-site renewable energy generation as part of their own energy supply. As a vision, plants could be fully energy self-sufficient and independent from electricity suppliers. From perspective of manufacturing systems, this requires the ability to flexibly adapt the energy demand of production machines and processes to current electricity generation and availability from grid. Such energy flexible manufacturing systems can achieve different development levels of energy flexibility: energy demand flexibility, balanced energy self-sufficiency and real energy self-sufficiency. Within this work, scenario-based simulations are used to assess strategies towards energy self-sufficiency for the case of a manufacturing system in a learning factory environment. Several aspects regarding dimensioning of on-site renewable energy generation and resulting oversupply, productivity and demand side management are addressed to show occurring tradeoffs related with energy self-sufficiency. The study shows, that a coupling of demand side management and storage technologies is the most promising combination to achieve a high degree of energy self-sufficiency (88%) for the regarded manufacturing system.

关键词： Energy flexibility Energy self-sufficient manufacturing system Scenario-based simulation

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Piezoceramics in sheet-metal compounds for icing detection 8

Piezoceramics in sheet-metal compounds for icing detection

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8th ECCOMAS Thematic Conference on Smart Structures and Materials, SMART 2017 and 6th International Conference on Smart Materials and Nanotechnology in Engineering, SMN 2017

作者： Drossel, W.-G. Nestler, M. Mäder, T. Schönherr, J. Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Str. 88 Chemnitz09126 Germany

ISBN: (纸本)9788494690938

Icing detection and de-icing techniques play an important role to assure a safe operation of airplanes and wind turbines [1, 2]. Integration of piezoceramics in structural parts allow for additional functionalities like health monitoring, impact detection and even to solve icing problems. The paper deals with innovative sheet-metal compounds, consisting of a piezomodule in a layer of adhesive embedded between two aluminum sheets. An airfoil demonstrator structure with integrated piezomodules is used for icing detection. A special production and forming technology was presented in earlier studies, where forming takes place in a viscous condition of adhesive. This concept allows for a forming of brittle piezoceramic fibers inside the compound. This demonstrator structure was built with this production technology. The integrated sensor is used for a detection of additional local masses. Aim is the implementation for aerodynamic icing detection and a vibration assisted de-icing. Within the paper preliminary tests for an icing detection are described. Therefore impedance and loss angle of an integrated piezomodule are measured for a broad frequency range under variation of additional masses and temperature. Icing was performed inside a cold chamber at -40 °C. It is shown that the impedance is significantly influenced by additional masses at room temperature, by a reduction of temperature without additional masses and by additional masses (ice) at reduced temperatures. The results imply that the assumptions are correct and the continuative investigations are worthwhile to potentially develop an icing detection technology. © 2017 International Center for Numerical Methods in Engineering. All rights reserved.

关键词： Adhesives

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Evaluation of manufacturing processes for the production of graded ultrafine grained materials

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Procedia Manufacturing 2018年 21卷 45-52页

作者： D. Landgrebe U. Götze M. Bergmann A. Schmidt R. Selbmann Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Straße 88 09126 Chemnitz Germany Technische Universität Chemnitz Professorship of Management Accounting and Control 09107 Chemnitz Germany

Scientific research results show that graded ultrafine grained aluminum-based materials offer technical advantages by possible material property improvements (e.g. yield strength, corrosion resistance) especially when applied to heavily stressed components like screws. The commercial screw production is currently conducted without gradation of the semi-finished workpiece. Until now there is no evaluation on whether and under which conditions graded materials (screws) can technically and economically compete with conventional materials. In this paper, an innovative process chain for the production of graded ultrafine grained components is presented and analyzed based on a methodology for an integrated technical-economic evaluation. The evaluation especially of the yield strength of graded materials, energy consumption of the forming steps, energy costs, and revenue effects of improved material properties will outline the technical and economic potential of the technology. Despite higher energy consumptions positive profit effects can be expected due to improved material properties.

关键词： Severe Plastic Deformation aluminium screw technical-economic evaluation process chain evaluation

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