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14th International Electric Drives Production Conference, EDPC 2024

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

ISBN: (纸本)9798350356885

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. © 2024 IEEE.

关键词： Epicyclic gears

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Joint Design for Strut Connections in Airplane Structures Produced by Electromagnetic forming 14th

Joint Design for Strut Connections in Airplane Structures Pr...

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14th International Conference on technology of Plasticity, ICTP 2023

作者： Psyk, Verena Linnemann, Maik Henkel, Marcel Kräusel, Verena Dix, Martin Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz Germany

ISBN: (纸本)9783031413407

Electromagnetic forming offers high potential for producing high-quality joints of similar and dissimilar materials. This can be exploited e. g. in aircraft design for assembly of struts. In order to give insight in the interactions between different influencing parameters and their effect on the loadability of the resulting joint in electromagnetic form-fit joining, design of experiments was used in a comprehensive study. Groove parameters (shape, depth, width and edge radius) and the capacitor charging energy were varied in joining experiments considering tubes made of EN AW-2024 (T351) with an outer diameter of 70 mm and, a wall thickness of 1.6 mm together with end parts made of the same material with a diameter of 66.8 mm. The loadability of the resulting compound was evaluated considering axial compression force. One important finding was that triangular grooves can provide highest loadability if relatively deep grooves, well-adjusted groove width and suitable capacitor charging energy are applied. An optimized groove edge radius can contribute to further improvement of the loadability. Numerical simulations on different groove shapes were performed in order to study the development of the forming stages during the process and to explain the trends observed in the experimental study. © 2024, The Author(s), under exclusive license to Springer Nature Switzerland AG.

关键词： Aluminum

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A novel model-based approach for the design of scalable crimp connectors for SMA wire-based actuators

A novel model-based approach for the design of scalable crim...

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2024 International Conference on Shape Memory and Superelastic Technologies, SMST 2024

作者： John, Benjamin Kübler-Tesch, Johannes Pagel, Kenny Drossel, Welf-Guntram Fraunhofer Institute for Machine Tools and Forming Technology Saxony Dresden Germany

ISBN: (纸本)9781627084840

While SMA wire-based actuators hold great potential across a range of industries, including medical, automotive, and consumer goods, the system integration of these wires poses a significant challenge, particularly in the context of fully automated mass production. Currently in all known industrial applications, only crimp or splice connectors are employed to connect the wire to its system environment. However, there is no standardized method for systematically designing crimp connectors while considering application-specific requirements. Furthermore, the property rights situation becomes more restrictive, as the protection claim of an expanding number of patents extends beyond the technical design of SMA actuators to their production processes in detail. Nevertheless, crucial process characteristics, particular those related to a crimping process, are undisclosed. In addition, since these documents usually describe specific products, transferring them to other applications remains difficult. To address these challenges, the fundamental connection mechanisms of crimp connectors will be analyzed, and an easily scalable crimping concept will be developed, considering existing intellectual property rights. This crimping concept is then characterized by a parameter study using the Design of Experiments method and static pull-out tests to identify crucial influencing factors and their interactions and to be able to build a mathematical model that maps the parameter- dependent pull-out strength of the connection. Based on the theoretical analysis of the fundamental connection mechanisms and the practical insights into influences and interactions affecting the static pull-out strength of the crimp connection, a systematic method will be devised to facilitate the design of model-based, cycle-resistant crimp connections in accordance with application-specific requirements. © 2024 ASM International® All rights reserved.

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Life cycle assessment of a sensor system for cognitive robots

Life cycle assessment of a sensor system for cognitive robot...

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MikroSystemTechnik Kongress 2023: Mikroelektronik, Mikrosystemtechnik und ihre Anwendungen - Nachhaltigkeit und TechnologiesouveranitatMicroSystems technology Congress 2023: Microelectronics, Microsystems technology and their Applications - Sustainability and technology Sovereignty

作者： Sharma, Priya Zumpe, Martin Stange, Maximilian Al Naser, Ibrahim Fraunhofer Institute for Machine Tools and Forming Technology IWU Germany

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Autonomous assembly and disassembly by cognition using hybrid assembly cells

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International Journal of Mechatronics and Manufacturing Systems 2023年第4期16卷 381-398页

作者： Frieß, Uwe Oberfichtner, Lena Hellmich, Arvid Fritzsche, Rayk Ihlenfeldt, Steffen Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Germany University of Technology Dresden Germany

Current political, economic, and ecological developments put severe pressure on European industries. Significant value chains depend uniliterally on single suppliers for many industrial resources including, raw materials, semi-finished goods as well as whole components. At the very same time, the European industry needs to get carbon neutral within an unprecedented short time frame. To address these challenges, flexibility, adaptivity[...], and resilience based on adaptive assembly and disassembly systems acting autonomously are key. Existing systems lack crucial capabilities as they focus on output volumes and economic criteria excluding part variance. Furthermore, these systems are unsuitable for small and medium batches due to the necessary investment. The paper presents a novel concept for hybrid-autonomous assembly and disassembly systems based on robot cells added to manual stations. A batch-individual allocation of sub-tasks to the autonomous robot-based system and the manual assembly on-site will lead to maximum flexibility while utilising the advantages of both. © 2023 Inderscience Publishers. All rights reserved.

关键词： machine learning

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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 31

Investigation of alternative attention modules in transforme...

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31st CIRP Conference on Life Cycle Engineering, LCE 2024

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

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. © 2024 Elsevier B.V.. All rights reserved.

关键词： Forecasting

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Split CFD-simulation approach for effective quantification of mixed convective heat transfer coefficients on complex machine tool models 16

Split CFD-simulation approach for effective quantification o...

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

作者： Kumar, Tharun Suresh Geist, Alexander Naumann, Christian Glänzel, Janine Ihlenfeldt, Steffen Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany

Estimation of mixed heat transfer coefficients on complex CFD-simulation models of 5-axis machine tools/ machining centers poses a whole new set of challenges. The enclosure around the machine which protects the user from chips and machining-process is also responsible for creation of an additional environment which has coolant supply, chips and moving air due to temperature changes and oil-emulsion exhaust. This results in a highly complex CFD model which has inner and outer environments along with multiphase fluid domains. The computational effort required is extremely large. The split-simulation approach divides the simulation model into internal and external environments. The natural convection is emphasized for external environment model and forced convection for internal multiphase environment model. This division significantly reduces the computational efforts involved by neglecting uninfluential solid bodies, cavities etc. and thereby the model size. The external and internal influences are mapped separately onto natural and forced convection coefficients using neural networks, which can be used to predict the combined heat transfer coefficients for any load cases within the training boundaries. The temperature fields obtained from split-simulation model are validated with thermography and temperature sensor readings taken from the machine in the form of a use-case study. © 2023 Elsevier B.V.. All rights reserved.

关键词： Genetic algorithms

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Overview of methodologies for the lifecycle management of smart product-service systems 34

Overview of methodologies for the lifecycle management of sm...

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34th CIRP Design Conference, CIRP 2024

作者： Mauersberger, Anton Reinhardt, Heiner Alaluss, Mohaned Mahdaviasl, Mahtab Ihlenfeldt, Steffen Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany

Nowadays, companies are operating in increasingly competitive and dynamic markets with rapidly changing customer demands. In order to meet these challenges, digitalization can be leveraged to achieve a transformation in product and service development. As a result, new concepts and methods are emerging, including smart product-service systems (smart PSSs). In combination with smart, connected products (SCPs), added value can be generated for several contracting parties. There are various methodologies available for the development and usage of smart services. However, these are insufficiently applied in practice. Here, an overview of methodologies supporting the various phases of the lifecycle of smart PSSs is presented. In doing so, a classification of these approaches is derived and discussed, while the need for further methodological research is outlined. © 2024 Elsevier B.V.. All rights reserved.

关键词： Smart manufacturing

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Development of Guidelines for the Design of Functionally Integrated Molds for a Novel Vacuum Assisted Resin Infusion Process 2nd

Development of Guidelines for the Design of Functionally Int...

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2nd International Conference Innovation in Engineering, ICIE 2022

作者： Meißner, Sven Falkenhain, Paul Cordeiro, Rafael Scholz, Sebastian Fraunhofer Institute for Machine Tools and Forming Technology IWU Saxony Zittau02763 Germany

ISBN: (纸本)9783031093814

In the present study, a newly developed vacuum assisted resin infusion process (FuVak) is described in which the conventional, disposable multilayer vacuum setup is replaced by reusable silicone vacuum hoods with integrated flow channels. In order to ensure high-quality impregnation of the fiberglass textile structure in a short time, while avoiding the use of disposable layers like flow aids, a suitable design of the flow channel geometry and their positioning on the vacuum hood must be determined. To study the effect of the channel cross-section, an experimental setup with varying geometries in laboratory-scale was designed, constructed, and tested. Optical detection of the flow front during the Infusion process and later examining of porosity distribution on the cured part were performed. The relationship between channel cross-section, flow speed and final part quality (porosity distribution) were determined and discussed. Based on this, an industry-scale, 2 m long part with higher complexity was fabricated with the novel process, validating the process ability to control of the flow front and quality of the composite. © 2023, The Author(s), under exclusive license to Springer Nature Switzerland AG.

关键词： Silicones

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Numerical Method for Highly Accurate Prediction of the Vacuum Assisted Resin Infusion Process Based on Reusable Vacuum Bags with Integrated Flow Channels 1

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3rd International Conference on Innovation in Engineering, ICIE 2024

作者： Kafka, Jiri Meißner, Sven Falkenhain, Paul Scholz, Sebastian Fraunhofer Institute for Machine Tools and Forming Technology IWU Theodor-Koerner-Allee 6 Saxony Zittau02763 Germany

ISBN: (数字)9783031626845

ISBN: (纸本)9783031626838

The current research introduces a recently devised vacuum assisted resin infusion technique (VARI) where the conventional multilayer vacuum system is substituted with reusable silicone vacuum bags featuring built-in resin flow channels. To create functionally integrated molds, an appropriate method for simulating the resin floe process needs to be devised. Numerical resin flow simulations based on Darcy’s law have been established for the design of conventional vacuum-assisted resin infusion processes, allowing accurate prediction of the infiltration of the textile reinforcement structures. The research has demonstrated that the traditional simulation method exhibits poor prediction accuracy, rendering it inappropriate for designing functionally integrated molds. To increase the prediction accuracy, a modified simulation approach with calibrated model parameters was developed. The developed simulation approach was successfully validated by further experimental investigations. It was demonstrated that a reliable simulation approach for the construction of functionally integrated silicone vacuum bags has been developed. © The Author(s), under exclusive license to Springer Nature Switzerland AG 2024.

关键词： Fiber reinforced plastics

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