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

作者： Kies, Alexander D. Abramowski, Johann-Philip Ackermann, Thomas Kux, Fabian Kreppein, Alexander Grunert, Dennis Schmitt, Robert H. Fraunhofer Institute for Production Technology IPT Steinbachstr. 17 Aachen52074 Germany Fraunhofer Research Institution for Battery Cell Production FFB Bergiusstr. 8 Münster48165 Germany Laboratory for Machine Tools and Production Engineering WZL of RWTH University Campus-Boulevard 30 Aachen52074 Germany

In this paper, we introduce a holistic approach to consider quality assurance (QA) for battery cell production (BCP). The framework, the explanation of the individual components as well as their interfaces and dependencies, and a detailed description are presented. Firstly, the level of necessary data (e. g. provided by online and out-of-line measurement systems) for the inspection of quality is presented. The aggregation of the recorded data as well as their tracing are ensured by the realization of a traceability system. Subsequently, by defining a suitable intelligent quality gate system, QA mechanisms are implemented and an active influence on production - e. g. by adaptive process control or identifying and reducing negative influence of cause-effect relationships - is aimed at. Finally, optimization of BCP in terms of product quality and its sustainability will be enabled. The evaluation of the demonstrated approach in practice is outlined based on an exemplary process of BCP. © 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： Battery Cell Production Industry 4.0 Quality Assurance Sustainability Traceability

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A Tactical Planning Approach using Genetic Algorithms and Process Chain Simulation for Closed-Loop Production Systems for high-value components 57

A Tactical Planning Approach using Genetic Algorithms and Pr...

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18th IFAC Workshop on Time Delay Systems, TDS 2024

作者： Dranov, Alexander Juraschek, Max Obst, Birgit Herrmann, Christoph Siemens AG Otto-Hahn-Ring 6 Munich81739 Germany Institute of Machine Tools and Production Technology Sustainable Manufacturing and Life Cycle Engineering Technische Universität Braunschweig Langer Kamp 19b Braunschweig38106 Germany Fraunhofer Institute of Surface Engineering and Thin Films Riedenkamp 2 Braunschweig38108 Germany

The implementation of closed-loop production systems in manufacturing is a promising approach to mitigate environmental impacts and supply chain disruptions, while increasing the value and lifespan of products and materials. These systems integrate forward and reverse material flow activities such as repair, remanufacturing, and recycling within a single facility. However, a major challenge in planning and operating closed-loop production systems is the high uncertainty surrounding material availability and condition. Different process chains may be required depending on the extent and type of wear present in the used products. During the tactical planning phase, factory planners play a crucial role in evaluating and economically assessing various system and process chain configurations. Multiple technology chain and manufacturing equipment options provide different solutions for managing forward and reverse material flows. To address this, this paper introduces a metaheuristic framework based on discrete event simulation and genetic algorithms to evaluate these system configurations. The framework serves as decision-support for factory planners, whether they are planning a greenfield production system or undertaking a brownfield project aimed at transforming linear into circular production systems with both forward and reverse flows. The presented framework is built on data models that incorporate different technology and process chain options for manufacturing and repair, considering the condition of the cores. A manufacturing equipment database contains predefined data models describing machine skills and load profiles, which are utilized to generate various simulation models using different production system configurations. These models are then used to execute predefined scenarios. The main objective is to identify configurations that achieve a beneficial fitness value balancing technical, economic, and environmental key performance indicators for closed-loop p

关键词： Chains

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Generative design in factory layout planning

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Procedia CIRP 2021年 99卷 9-14页

作者： Marian Süße Matthias Putz Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Chemnitz Germany

Planning and optimization of facility layouts have been investigated for decades and manifold approaches are applied for structuring and design of production layouts. However, results heavily depend on the experience and creativity of involved planning experts. Currently, complexity of planning processes constantly increases, e.g. due to further requirements of energy and media supply. Generative Design, hitherto mainly applied in component development, provides opportunities to cope with a much larger solution space and develop creative layout concepts. Thus, based on a structured overview on established planning methods, a concept and first results of factory layout planning with Generative Design are described.

关键词： Generative design Computational design Evolutionary design Factory planning Layout planning Literature search

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Fundamental study on embedded displacement sensor arrays for ultrasonic-assisted ultraprecision machining 22

Fundamental study on embedded displacement sensor arrays for...

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

作者： Uhlmann, E. Polte, M. Bulla, B. Dambon, O. Dicke, C. Hocke, T. Thißen, K. Heper, M. Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Berlin Germany Fraunhofer Institute for Production Systems and Design Technology IPK Berlin Germany Son-x GmbH Aachen Germany

ISBN: (纸本)9781998999118

Ultraprecision machining is a key technology for manufacturing complex steel moulds with dimensional accuracies in sub-micrometer range for mass production of optical components using micro-injection moulding. According to the state of the art, during the machining of carbide-forming metals, such as steel alloys, used single crystal diamond tools suffer from excessive tool wear. In order to overcome this technological und economical limitation, ultrasonic-assisted ultraprecision machining is applied successfully in a broad range of industrial and scientifically applications. Based on the reduction of the contact time between the tool and the workpiece excessive chemical and related tribological tool wear can be avoided. Nevertheless, the cutting speed is strictly limited to deceed critical contact times. Therefore, the monitoring of the tool vibration characteristic and thus the process control is a major challenge and of current industrial and scientifically interest. To overcome these challenges a method for in-situ measurement of the ultrasonic vibration is currently being developed and first results are shown. Using the sophisticated ultrasonic system, developed by SON-X GMBH, Aachen, Germany, up to a frequency fUS= 100 kHz the application of a dedicated eddy current sensor enabled the determination of the real path lines and the exact position of the cutting edge during the whole process with a displacement amplitude AD= 1 µm. The results were subsequently verified by laser vibrometer measurements. As a result of the investigation, an elliptical path movement of the cutting edge in the longitude direction AD,y= ± 1.0 µm and in z-direction AD,z= ± 0.34 µm could be determined using a frequency fUS= 100 kHz. Based on this new measurement method, the vibration characteristic can be specifically varied and adapted to the application. In addition, a comprehensive scientifical knowledge of the process can be gained and used to improve tool wear models. © European Soci

关键词： Vibration analysis

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Software assisted clamping point classification and position optimization for the efficient flexibilization of carbody fixtures using mathematical geometry-based search algorithms

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Procedia CIRP 2021年 99卷 466-471页

作者： Rayk Fritzsche Robert Schaffrath Marcel Todtermuschke Head of group 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 Head of dep. Assembly systems at Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz 09126 Germany

The fraunhofer IWU has been developed specialized clamping robots for production of different car-models on one fixture. One of the challenges with universal clamping of different components is the contact point between part and clamping device. For the optimization of the clamping contours, a software was developed with which the geometries of the clamping points can be automatically analyzed and classified. With target search criteria, the clamping position on the component can be changed so that the clamping contours are geometrically simplified. Thus, a huge reduction in the complexity of the flexible clamping device is possible.

关键词： Body in white Automated device design Analysis software Optimization Product flexibility

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Exposure to industrial noise: Impacts on cognitive performance 50

Exposure to industrial noise: Impacts on cognitive performan...

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50th International Congress and Exposition of Noise Control Engineering, INTER-NOISE 2021

作者： Pereira, Luiz Henrique Mesa Casa Knöfel, Björn Troge, Jan Drossel, Welf-Guntram Klein, Marcel Hübelt, Jörn Fraunhofer Institute for Machine Tools and Forming Technology IWU Nöthnitzer Straße 44 Dresden01087 Germany Mittweida University of Applied Sciences Technikumplatz 17 Mittweida09648 Germany

ISBN: (纸本)9781732598652

Research on the relation between exposure to noise and cognitive performance inside industrial environments is not as broad as on office environments. For a better understanding of the specific industrial noise problems, 23 participants performed arithmetic tests inside a hemi anechoic room while they were exposed to a sequence of sound from five typical industrial noise sources. The subjects also classified how annoying they perceived the noise signals. The effects of noise on the arithmetic test's performance of the 23 participants was found on accuracy and on velocity, although the p-values of a Student t-test are comparable high. Dividing the subjects into a group of more noise annoyed resp. a group of less noise annoyed participants revealed significant influences of the presence of noise compared to an initial test without noise. The more annoyed subjects exhibit a drop of accuracy (-4%, p=0.017) while the less annoyed subjects increase significantly their velocity in the test (+15%, p=0.001). Subjects that evaluated noise as more annoying performed worse in a final arithmetic test (under silence) after being exposed to the noises, indicating a possible cumulative effect of noise on performance. The findings provide a better insight in the cognitive behavior of people who are exposed to industrial noise. Hence, the study will proceed with the specific noise analysis of single industrial workplaces. © INTER-NOISE 2021 .All right reserved.

关键词： Testing

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Life Cycle Gates: Extending the concept of Virtual Quality Gates along circular product life cycles 56

Life Cycle Gates: Extending the concept of Virtual Quality G...

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

作者： Wilde, A.-S. Tonn, K. Abraham, T. Herrmann, Christoph Institute of Machine Tools and Production Technology Technische Universität Braunschweig Langer Kamp 19b Braunschweig38106 Germany Volkswagen AG Wolfsburg38436 Germany Fraunhofer Institute of Surface Engineering and Thin Films Bienroder Weg 54E Braunschweig38108 Germany

Reaching a higher level of sustainability of a products life cycle became a strategic goal for many companies over the past years. To achieve that higher level of sustainability, the transformation of linear product life cycles (cradle to grave) into circular life cycles (cradle to cradle) in the context of a Circular Economy (CE) is one promising approach. However, implementing a circular life cycle results in higher requirements in defining the best fitted strategy at the end of each product use stage depending on economic, environmental and social factors. In order to cope these increased requirements, the whole product life cycle has to become more transparent. This transparency can be reached by a holistic digital representation and virtual quality control of all life cycle stages. To implement a virtual quality control in each stage and enable the monitoring and controlling of the whole life cycle, the concept of Virtual Quality Gates can be extended. Virtual Quality Gates divide a defined manufacturing chain into different virtual, quality-relevant decision points to check the product quality and ensure a defined quality state before further manufacturing steps are approved. This concept can be transferred to each life cycle stage to ensure a holistic optimization of the products life cycle quality and an optimized selection of a strategy at the end of each use stage. This paper presents a framework for the implementation of virtual quality gates into product life cycles. These extended quality gates are defined as Life Cycle Gates, which are virtual decision points to optimize a product life cycle. The demand and applicability of the concept is shown for a mechanical recycling process of automotive parts. © 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 Confe

关键词： Circular Economy Life Cycle Gates Life Cycle Technologies Virtual Quality Gates

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Framework for increasing sustainability of factory systems by generative layout design

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Procedia CIRP 2022年 105卷 345-350页

作者： Marian Süße Steffen Ihlenfeldt Matthias Putz Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Institute of Mechatronic Engineering Technische Universität Dresden Dresden Germany Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Chemnitz Germany

The structure of factory systems has a long-term impact on the productivity and performance of production systems. With an increasing relevance of decentral renewable energy sources, factory planning becomes more complex due to an increase of decision criteria and possible solutions, but ecological impacts are also growingly depending on early structure decisions. However, decisions during planning processes in industry are still based on experience, qualitative assessments and discussions. Thus, planning results may not exploit the potential of the available solution space, nor do they allow quantitative traceability of layout configurations. Generative Design (GD) gained popularity in topology optimization and building construction and provides promising opportunities for complex design tasks. Not least with the increasing relevance of Building Information Modeling (BIM) in manufacturing, new methods and technologies for optimization become available to factory planners. Hence, the paper describes options for enhanced decisions in sustainable factory layout planning. Therefore, it provides a quick overview on optimization and GD in layout planning as well as the relation towards BIM and sustainability assessment. Based on this, possible extensions of optimization targets and boundaries towards energy and sustainability-related criteria is elaborated. Afterwards, necessary and potential data acquisition with the openBIM-related Industry Foundation Classes (IFC) is discussed. The paper concludes with an outlook towards further investigations on the overlap of layout design, BIM and sustainability.

关键词： Factory Planning Sustainable development Generative design Building Information Modeling (BIM)

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Derivation of Solution Bundles in Hybrid Portfolios of Industrial Solution Providers in machinery Engineering

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Procedia CIRP 2024年 128卷 298-303页

作者： Michael Riesener Maximilian Kuhn Carsten Boßmann Sven Schümmelfeder Dennis Hertell Günther Schuh Laboratory for Machine Tools and Production Engineering (WZL) of RWTH Aachen University Campus-Boulevard 30 52074 Aachen Germany Fraunhofer Institute for Production Technology IPT Steinbachstraße 17 52074 Aachen Germany

Companies in the machinery engineering sector are identifying increased demand from their customers for integrated solutions that consist of product, service and software elements tailored to the customers’ specific needs. The companies must therefore transform themselves from classic product providers into industrial solution providers. In addition to the opportunity to differentiate themselves from other competitors, the transformation of the business model to the distribution of customer-specific value propositions provides new revenue opportunities. Progressive digitization and the increasing integration of service and software elements in the value chain are considered to be key enablers of the transformation into an industrial solution provider. In order to realize the transformation successfully, it is necessary to plan the portfolio holistically on the basis of systematized customer requirements and the existing elements in the portfolio. This paper therefore presents a methodology for deriving suitable solution bundles to realize the value propositions. For this purpose, an integrated architecture of the solutions is created, a comparison of the solution elements with the customer requirements is performed, and finally, a staggering of the solutions in the portfolio is conducted.

关键词： Portfolio Planning Solution Provider Servitization

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Experimental analysis on the accuracy of two dimensional curved cuts in wire ECM 15

Experimental analysis on the accuracy of two dimensional cur...

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15th CIRP Conference on Intelligent Computation in Manufacturing Engineering, CIRP ICME 2021

作者： Sous, F. Heidemanns, L. Herrig, T. Klink, A. Bergs, T. Laboratory for Machine Tools and Production Engineering WZL RWTH Aachen University Campus-Boulevard 30 Aachen Germany Fraunhofer Institute for Production Technology IPT Steinbachstraße 17 Aachen Germany

The advantages of sinking ECM like productivity and high surface quality regardless of the mechanical workpiece characteristics are always challenged by increased costs for process development. These costs result from the necessity to design specific tools and complex electrolyte flow devices for each machining task. Instead of using a task specific tool, wire ECM uses a universal tool to perform 2.5 dimensional cuts. However, due to the concentration of the electrical field on edges, machining of small radii and sharp edges on macro scale geometries is challenging and the achievable accuracy with wire ECM needs further investigation. Therefore, this study presents the machining of two-dimensional curved cuts with wire ECM in workpieces made of Inconel 718. In particular, the influence of the wire diameter and various process parameters such as feed rate and working voltage on the achievable cutting radius is investigated. Furthermore, the cutting kerf and resulting machining offset of the machined radii cuts are analyzed. © 2022 The Authors. Published by Elsevier B.V.

关键词： Wire

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