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29th CIRP Conference on Life Cycle Engineering, LCE 2022

作者： Münnich, Marc Rein, David Reinhardt, Heiner Ihlenfeldt, Steffen Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Institute of Mechatronic Engineering Technische Universität Dresden Dresden Germany

Recent efforts in climate politics increase the ecological pressure of manufacturing companies in terms of intelligent and efficient usage of resources during operations. Rising energy prices lead to further economic pressure. Especially companies with a high share of energy cost on total costs are forced to continuously improve processes regarding the energy usage. Existing guidelines and methodologies are usually concerned with either of the two dimensions energy efficiency (EnEff), or energy flexibility (EnFlex). While EnEff addresses the reduction of the energy consumption for a defined manufacturing output, EnFlex addresses the advantageous shift, increase, and decrease of energy demand. Although both dimensions address the total reduction of cost, they are usually considered separately in literature. Here, we examine both dimensions while focusing on the provision and usage of electric energy due to its manifold conversion and usability opportunities in factory processes. Therefore, we developed an overview of measures of both dimensions as well as their application characteristics within the factory. To identify EnEff and EnFlex measures, a practicable methodology is introduced. This aims to enable especially companies with few experiences in EnEff and EnFlex measure application to improve energy aware operations. We illustrate our examination by means of an industrial application example. © 2022 Elsevier B.V.. All rights reserved.

关键词： Energy efficiency

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Micro structure rolling process with laser structured roller tools 21

Micro structure rolling process with laser structured roller...

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21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021

作者： Schmidt, Torsten Gärtner, Eric Schneider, Jörg Edelmann, Jan Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany

ISBN: (纸本)9780995775190

In recent years, there has been an enormous increase in the need to specifically functionalize surfaces through microstructures and coatings. This is an attempt to meet increased performance requirements and the use of new materials in mechanical and automotive engineering. In most scientific publications on this subject, microstructures are created by laser ablation. However, this process is often not economical in the context of large-scale production. The structure rolling process for microstructuring of rotationally symmetric workpieces can close this gap. Short process times, comparatively simple handling and resource-efficient structuring characterize the structure rolling process. In the publication the workflow for structuring typical components is described. In addition, different processing strategies for the production of structured rolls using laser material processing are presented and compared. Based on the optimal manufacturing strategy derived from this, several structured rollers with different microstructure variants were manufactured. The successful application of the workflow and the tooling concept used for the structure rolling process is validated by experimental replication tests with different microstructures. The main focus is on the evaluation of the methodology for predicting and setting the necessary embossing force on the structure rolling tool to achieve the required structure depth. © 2021 Proceedings of the 21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021. All rights reserved.

关键词： Tribology

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Dismantling and remanufacturing strategies in the automotive sector 31

Dismantling and remanufacturing strategies in the automotive...

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31st CIRP Conference on Life Cycle Engineering, LCE 2024

作者： Haase, Rico Farioli, Daniele Selbmann, Rene Werner, Markus Kräusel, Verena Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz09126 Germany Politecnico di Milano Department of Mechanical Engineering Milan20156 Italy

The contemporary recycling of automobiles takes place on a very baseline material level. In order to fundamentally improve the ecologic footprint of the vehicle, a wider application of remanufacturing strategies is intended. Following different recycling approaches ranging from direct reuse or refurbishment through remanufacturing until repurpose, a well-aimed dismantling followed by manufacturing processes adapted to the post-consumer components is mandatorily required. For use on an industrial scale, environmental efficiency and economic viability must be balanced well. Within the paper, possible remanufacturing technologies and necessary prerequisites such as input data are discussed. For the design of remanufacturing operations, material properties and geometric information are a crucial starting point. Seamless integration of the specific properties is intended to encourage wider utilization of pre-used components and materials. With reference to the well-established process design for metal forming operations, adapted material cards and curvature equivalence values are proposed. The approach is illustrated by a reforming operation, where a brake disc cover is remanufactured from a used car body roof. © 2024 Elsevier B.V.. All rights reserved.

关键词： Recycling

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Joining of Laminated Core and Shaft of an Electric machine Rotor by Electromagnetic forming

Joining of Laminated Core and Shaft of an Electric Machine R...

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International Electric Drives Production Conference (EDPC)

作者： Verena Psyk Linda Fleischer Maik Linnemann Mirko Bach Martin Dix Department Forming Technology Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz Germany

ISBN: (数字)9798350356885

ISBN: (纸本)9798350356892

In the mobility industry and especially in case of electrically powered vehicles the implementation of lightweight powertrain components with high efficiency and minimum in-stallation space is of utmost importance. One approach to realize a particularly compact and light design is using a central motor, which is aligned with a planetary gearbox via coaxial (partly) hollow rotor shafts positioned one within the other to operate the left and right-hand wheels of the car. To enable further weight reduction, aluminium alloys might be considered for the hollow shafts instead of the conventionally used steel. When the electrical machine is assembled, the shafts must be firmly connected to the rotor core, which is typically made of laminated electrical steel core. Electromagnetic forming is a promising technology for joining tubular aluminium components with similar or dissimilar materials. In this paper, the suitability for the described joining task is investigated. For this purpose, an inductor specifically suitable for expanding a round tube into a non-rotationally symmetric cross section shape is suggested and the corresponding joining process is developed using coupled electromagnetic and structural mechanical simulation. Experimental validation is carried out using a technology demonstrator.

关键词： Shafts Space vehicles Shape Rotors Wheels Mechanical power transmission Topology Steel Electromagnetics Joining processes

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An assessment method of machine components for usage-based value creation in complex manufacturing systems 56

An assessment method of machine components for usage-based v...

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

作者： Alaluss, Mohaned Kurth, Robin Mauersberger, Anton Drechsler, Chris Ihlenfeldt, Steffen Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany Institute of Mechatronic Engineering Dresden University of Technology Helmholtzstr. 7a Dresden01069 Germany

Rising demands on manufacturing technologies lead to an increase in the complexity of corresponding machines and systems. This complexity acts as an obstacle to the development and realization of digital, usage-based business models for complex manufacturing systems. Particularly in the case of pay-per-use business models, it is necessary to monitor the actual machine load in operation to minimize the business risk on the operator and supplier side. This complicates the transition towards data-oriented value creation in manufacturing system environment. To overcome this challenge, a novel method to assess machine components regarding their potential to monitor the actual load and usage behavior of the whole manufacturing system is proposed. On this basis, the transparency and therefore confidence in digital, usage-based value creation like pay-per-use business models can be increased. The resulting approach is demonstrated by taking the example of a sheet metal forming press. © 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) Peer-review under responsibility of the scientific committee of the 56th CIRP International Conference on Manufacturing Systems 2023.

关键词： Decision making Forning Manufacturing Methodology Service

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Potential of Radar Based Measuring Systems in Hot Forging 18th

Potential of Radar Based Measuring Systems in Hot Forging

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18th Global Conference on Sustainable Manufacturing, GCSM 2022

作者： Bergmann, M. Dix, M. Wallbaum, T. Selbmannn, R. Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Straße 88 Chemnitz09126 Germany Institute for Machine Tools and Production Processes Chemnitz University of Technology Chemnitz09126 Germany

ISBN: (纸本)9783031288388

Hot forging processes and process chains provide components, which meet highest demands due to mechanical properties. A wide range of applications in different industries like oil and gas, automotive and aviation are based on such processes. As those processes are very productive unfavorable process conditions and unnecessary reject or rework are a strong issues and still not solved for industrial scale production. One key challenge is to generate geometrical information of the workpiece. The geometrical characterization of hot forged parts is usually carried out in cold condition resulting in an extensive time delay to processing. Information about the part geometry during processing and right after processing – in hot condition -- is not accessible. An approach to address this are radar based measuring systems. Those systems have specific characteristics like sufficient accuracy and robustness which qualifies them for measuring tasks under rough conditions typically occurring during forging processes. In the paper, different use cases for the application of radar-based measuring systems are identified and analyses based on laboratory scale experiments. © 2023, The Author(s).

关键词： Radar measurement

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Definition and Description of Matrix Production Systems 57

Definition and Description of Matrix Production Systems

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18th IFAC Workshop on Time Delay Systems, TDS 2024

作者： Ranke, Daniel Trierweiler, Michael Berkhan, Patricia Münnich, Marc Bauernhansl, Thomas Fraunhofer Institute for Manufacturing Engineering and Automation IPA Nobelstr. 12 Stuttgart70569 Germany Institute of Industrial Manufacturing and Management IFF Nobelstr. 12 Stuttgart70569 Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany

The industry's use of adaptable production systems, such as matrix production, is increasing. However, these systems vary in their specific details. The lack of a unified definition, delimitation, and description hinders comparability and the transfer of lessons learned between different systems. This paper aims to propose a comprehensive definition of matrix production and differentiation between different implementation forms. To achieve this, the paper first examines existing approaches to define and describe production systems and their manifestations. Various frameworks and models have been proposed in the literature, but they often focus on specific aspects of production systems, neglecting the complexity of matrix production. The paper identifies common elements and challenges in defining and describing production systems by analyzing these approaches. A second investigation analyzes various existing descriptions of matrix production from the scientific literature. While some definitions focus on the organizational structure, others emphasize operational aspects. By synthesizing these definitions, the paper proposes a comprehensive definition of matrix production encompassing both dimensions. Furthermore, the paper includes cases of industrial implementations as a third investigation. These cases provide insights into the practical application of matrix production systems across different industries. The paper identifies common characteristics, challenges, and benefits associated with matrix production by analyzing these implementation examples. Finally, all three investigations are combined to create a unified definition and a complementary descriptive model. The proposed framework provides a systematic approach to define and describe matrix production systems. It allows for a better understanding and comparison of different implementations, facilitates the transfer of lessons learned, and promotes the exchange of best practices. This framework will enable r

关键词： Production efficiency

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Investigation of alternative attention modules in transformer models for remaining useful life predictions: addressing challenges in high-frequency time-series data

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Procedia CIRP 2024年 122卷 85-90页

作者： Eugen Boos Jan Zimmermann Hajo Wiemer Steffen Ihlenfeldt Technische Universität Dresden Fraunhofer Institute for Machine Tools and Forming Technology

Predicting the Remaining Useful Life of a machine components or systems is a pivotal technology in condition-based maintenance and essential for ensuring the reliability and safety in various production-engineering applications. The influx of extensive industrial data has notably enhanced the efficacy of data-driven Remaining Useful Life prediction models, especially deep learning models. One of the promising deep learning model architectures is the Transformer-based model with the Self-Attention mechanism at its core. However, inherent limitation arise when applying Self-Attention to high- frequency time-series data with large window sizes. Due to its high computational complexity, hardware limitations hinder the practical implementation of Transformer with Self-Attention in production-engineering applications. This study looks into the utilization of alternative Attention modules with reduced complexity, making it more applicable to high-frequency time-series data. In order to allow comparability, this study uses the well-known C-MPASS dataset for benchmarking Remaining Useful Life approaches. Although this dataset does not consist of high-frequency data, it demonstrates the usefulness of alternative Attention modules without noteworthy losses in model accuracy.

关键词： Remaining useful life Attention Complexity Transformer Deep learning

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Automated shop floor reconfiguration and process integration: towards product driven manufacturing systems

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Procedia CIRP 2025年 134卷 49-54页

作者： Marcel Albus Florian Duewel Katharina Barbu Jan Eric Huebner Christian Keilig Christian Gollee Fraunhofer Institute for Manufacturing Engineering and Automation IPA Nobelstraße 12 70569 Stuttgart Germany Fraunhofer Institute of Optronics System Technologies and Image Exploitation IOSB Fraunhoferstraße 1 76131 Karlsruhe Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Pforzheimer Straße 7a 01189 Dresden Germany

Flexible manufacturing systems are crucial in today’s rapidly evolving manufacturing landscape, characterized by supply chain disruptions, shorter product lifecycles, and diverse customer demands. Introducing new products necessitates extensive planning efforts, including price estimates, production cost evaluation and ensuring resilience. This paper presents a comprehensive approach through an integrated digital toolchain for reconfiguration planning in manufacturing companies, from production feasibility to shop floor execution. The solution leverages data space connectors to facilitate information exchange between customers and Modular Production (MP) environments. Key features include the STEP decomposition, resource capability matching, automated assembly line reconfiguration and balancing, as well as the automated integration and execution of manufacturing processes on the shop floor. This toolchain aims to enable automated data exchange, coordinated order planning, and efficient shop floor operations, allowing manufacturers to adapt to market changes while maintaining cost-effectiveness and resilience.

关键词： Shop Floor Reconfiguration Automated Process Execution Assembly Line Balancing

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

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Procedia CIRP 2023年 118卷 918-923页

作者： Rayk Fritzsche Antje Ahrens Head of group Adaptable assembly systems 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 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.

关键词： Body in white Automated fixture design Methodical synthesis Analysis software Optimization Product flexibility

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