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Computer-based design and development of a fully automated assembly of aircraft doors made of thermoplastic composite material

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Procedia CIRP 2024年 126卷 805-810页

作者： Rayk Fritzsche Erik Jäger Head of group Adaptable assembly systems at Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz 09126 Germany Scientific employeeat Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz 09126 Germany

For production of aircraft doors using innovative lightweight materials, a fully automated assembly process was developed. Therefor a door structure of an overwing-exit-door is to be joined from thermoplastic composite material components. The innovative material enable the use of new joining concepts. The assembly process was virtually simulated in order to forecast production time, process sequence, provision of operating resources and investment costs. Relevant manufacturing equipment was designed and accessibilities of the clamping and joining tools as well as collision areas were determined and optimized. To quality management, process control concept was developed with which geometric deviations of the components can be automatically compensated.

关键词： process automation aircraft production thermoplastic composite material assembly process virtual simulation manufacturing equipment

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New gentle extraction method of hemp bast strips for use as bio-based reinforcing fibers in highly loaded fiber composites

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Procedia CIRP 2024年 125卷 178-183页

作者： Steffen Ihlenfeldt Jens Müller Christoph Peukert Ludwig Rogall TUD Dresden University of Technology Chair of Machine Tools Development and Adaptive Controls (LWM) Dresden 01069 Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz 09126 Germany

Nowadays, fiber composites are among the most important construction materials in lightweight design. Increasingly, attempts are being made to replace fossil raw materials with bio-based materials in order to improve their recyclability and reduce greenhouse gas emissions. While processes suitable for industrial use already exist for the production of biopolymers as matrix materials, there is still a considerable need for research in the production of bio-based reinforcing fibers. For hemp bast strips (HBS), promising utilization options arise due to very good mechanical properties. However, current processes for extracting such raw materials from bast fiber plants result in damage to the fiber structure because they use biochemical decomposition processes and/or squeeze and crush large disordered amounts of stalk along their entire length. This strongly reduces the application potential of the raw materials. A newly developed principle extracts the HBS with minimal impact by dividing single hemp stalks only at one end and then isolating them from the wood core by pulling on the resulting wood fragments. In this manner, the fiber structure and the good mechanical properties are largely retained and the HBS obtained can be stored in parallel alignment for further processing with little effort.

关键词： natural fiber composites hemp decortication mechanical properties industrial application

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Bioinspired approaches for resource-efficient material flow in production – an innovative actuator concept for peristaltic-based transport

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Procedia CIRP 2024年 125卷 249-254页

作者： Henriette Kunze Marcel Lorenz Scientific employee at Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Chemnitz Germany

In automated material flow, in a wide variety of areas, the primary goal is usually to handle a wide spectrum of components as time- and cost-efficiently as possible. In view of the current and future challenges in industrial production, it is becoming apparent that ecological requirements are becoming increasingly important in automation solutions. For example, in form of resource efficiency, transformability and material efficiency. In this context, especially materials handling technology is subject of various optimization approaches, as no value is added to the part handled. The question: "How does material flow occur in nature?" thus offers biologically inspired approaches to thinking about transport in the industrial sector. This paper first presents a selection of concepts or existing mechanisms that are adaptable in materials- handling technology and have been developed based on a biological model. In the second part of this paper, a new concept is presented that is modeled on peristalsis as a transport mechanism. The approach presented here uses tensegrity-structures for assembly, which are characterized by their high material efficiency and flexibility. The transport movement is achieved by peristaltic typical contraction or relaxation of the respective structure parts.

关键词： tensegrity biotensegrity assembly technologies

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Synthetically Generated Images for Industrial Anomaly Detection 29

Synthetically Generated Images for Industrial Anomaly Detect...

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29th IEEE International Conference on Emerging Technologies and Factory Automation, ETFA 2024

作者： Wagenstetter, Marco Gospodnetic, Petra Bosnar, Lovro Fulir, Juraj Kreul, Donovan Rushmeier, Holly Aicher, Thomas Hellmich, Arvid Ihlenfeldt, Steffen Powertrain Production System Planning Bmw Group Germany Synthetic Data Generation Fraunhofer Itwm Germany Yale University Synthetic Data Generation United States Machine tools and forming technology Fraunhofer Iwu Germany

ISBN: (纸本)9798350361230

Automation of inspection for quality control is needed to overcome the errors and delays inherent in manual processes. machine learning methods have the potential to greatly improve automated inspection. However, machine learning techniques require training data that are precisely labeled and reflect the distribution of defects to be detected. Physically collecting suitable training data requires significant time and prolongs the overall time for system development. To address this challenge, a new study is presented that explores synthetic data generation for a state-of-the-art anomaly detection (AD) model in the electric motor housing (EMH) surface inspection. The study successfully demonstrates using synthetic data for anomaly detection and presents a comparison of detection performance by models trained solely on synthetic data and models trained on both synthetic and real data. The study shows that real data combined with synthetic data can increase overall model performance. The study also addresses current challenges in using synthetic data and proposes directions for future work. © 2024 IEEE.

关键词： Adversarial machine learning

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Software support for the development of flexible plant technology in highly automated and high-rate body-in-white production 16

Software support for the development of flexible plant techn...

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

作者： Fritzsche, Rayk Ahrens, Antje Hd. of Grp. Adaptable Assembly Syst. at Fraunhofer Inst. for Mach. Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany Scientific Employee at Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 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. © 2023 Elsevier B.V.. All rights reserved.

关键词： Product design

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Integrating Hybrid Physics-Data Approaches for Enhanced Cutting Force Modeling in Digital Twins of Helical End Mills

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Procedia CIRP 2025年 133卷 358-363页

作者： Yuan Jing Guanchen Gong Albrecht Hänel Steffen Ihlenfeldt Fraunhofer Insitute for Machine Tools and Forming Technology IWU Chemnitz Germany Chair of Machine Tools Development and Adaptive Controls Institute fo Mechatronic Engineering Technische Universität Dresden Dresden Germany

Industry 4.0 has significantly improved data efficiency by leveraging key technologies such as the Internet of Things and machine Learning. Among these key technologies, digital twins stand out by offering a promising approach to intelligently utilize this data. In the virtual representation of a physical asset, data reflects the conditions of the physical entity, while models simulate and predict its behavior. In this paper, a hybrid cutting force model is proposed for digital twins of helical end mills, focusing on cutting force analysis during the utilization phase of the machining process. This model combines a fairly mature physical process modelling approach with a data-driven method, specifically a neural network trained on real process data, to address the limitations inherent in their respective applications. The physics-based model provides meaningful constraints on the neural network’s training, ensuring reliable cutting force prediction, particularly in scenarios with limited process data availability. The cutter’s profile, generated by the geometric model, and the cutter-workpiece engagement maps, derived from the virtual machining model, together serve as inputs for the hybrid cutting force model.

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Case Study of Robot Machining at Different Working Space Locations

Case Study of Robot Machining at Different Working Space Loc...

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MECHATRONIKA International Symposium

作者： Mikuláš Szabari Jan Berhold Jan Vetiška František Bradáč Michal Holub Martin Dix Institute of Production Machines Systems and Robotics Brno University of Technology Brno Czech Republic Cutting Technology Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany

ISBN: (数字)9798350394900

ISBN: (纸本)9798350394917

Machining, 3d printing and robot welding require a minimum difference between simulated and real position of robot (TCP) to facilitate high quality surface finish and fulfil dimension and form tolerance. The solution is the absolute robot calibration, which increases positional accuracy. In this paper, a calibrated direct-measuring robot is used to machine the sample part. In the experiment, the sample part is positioned at different location and machined by different machining processes. Then the produced part is measured on a coordinate measuring machine (CMM). The quality of the surface finish, dimensions and geometric tolerances are evaluated. This experiment showed the effect of calibration on the machining process. Based on the obtained results, further activities will be directed in the field of increasing the geometric accuracy of industrial robots.

关键词： Drilling Accuracy Coordinate measuring machines Service robots Robot kinematics Machining Kinematics Surface finishing Robots Surface treatment

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Methods for the environmental and economic assessment in early product design – a case study-based overview for wind turbines in urban areas

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Procedia CIRP 2024年 122卷 789-794页

作者： Martin Zumpe Maximilian Stange Ahmet Burak Ertem Marian Süße Steffen Ihlenfeldt Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Institute of Mechatronic Engineering Technische Universität Dresden Dresden Germany

The assessment of environmental impacts has become an inevitable necessity for many manufacturing companies – not only from a mere retrospective viewpoint but also for product design decisions. At the same time, economic feasibility must be constantly considered throughout all product design phases. For both dimensions, many different decision-support methods exist. However, there is a lack of combined assessment methods especially in early product design phases, when product characteristics, manufacturing technologies and corresponding data are still uncertain. The paper provides an overview and qualitative evaluation of different methods for economic and ecological assessment in product design stages. Based on this, a generalized procedure for combined economic and ecological decision-making during product design is derived, highlighting possible coping mechanisms for uncertain or insufficient data. Both, the evaluation of available assessment methods as well as the derived procedure are transferred to the specific requirements of wind turbines in urban areas. As a result, open research aspects and the next steps for method development are derived.

关键词： Eco-design methodology LCA Evaluation Environment Wind Turbines

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Structure and Validation of a Kinematic Surface Simulation Model for the ultrashort-pulse Direct-Laser-Writing Process

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Procedia CIRP 2025年 133卷 227-232页

作者： Fabian Wieland Eric Gärtner Sebastian Wieland Fraunhofer Institute for Machine Tools and Forming Technology IWU Department Functional Surfaces and Micromanufacturing Reichenhainer Str. 88 Chemnitz 09126 Germany

This paper presents the development and validation of a kinematic surface simulation model for the prediction of ultrashort-pulsed laser structured surfaces. The simulation is based on an existing kinematic simulation model for short-pulsed laser structuring and utilizes the stepwise Boolean intersection of a machined and digitized single point ablation with the workpiece to reproduce the microstructuring process. The existing short-pulse simulation model was extended by newly integrated description models to allow a more detailed representation of within the process changing influences, e.g. the surface fine-structure to enable a multi-layer processing. In addition, a reorganization of the simulation algorithm resulted in a general improvement of the run time and a resolution-independence. Based on the kinematic simulation principle, the manufacturing process for a wide range of material-machine combinations in the field of laser structuring can be described. The model enables a time-efficient, nanometer-resolved prediction of representative surfaces with a size of up to several square millimeters. Furthermore, complex influences such as material- and temperature-related properties do not need to be considered separately, as they are taken into account by the machined and digitized single point ablation. Compared to artificial intelligence approaches and numerical or multiphysical simulations, the need for preliminary studies is very low. Depending on the chosen laser machining parameters the simulation can reproduce the surface textures macro- and microstructure.

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Combining material flow simulation and optimization for sustainable manufacturing – application in automotive paint shops

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Procedia CIRP 2024年 122卷 659-664页

作者： Marian Süße Xinyi Xie Steffen Ihlenfeldt Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Institute of Mechatronic Engineering Technische Universität Dresden Dresden Germany

The necessity for sophisticated decision support in industrial manufacturing has been described manifoldly and simulation approaches as well as optimization methods are continuously developed. This can be especially promising when it comes to decision-making with multidimensional requirements of economic and ecological efficiency. However, due to the required expert knowledge, there is still a gap between theoretically applicable and industrially applied methods. The paper therefore presents results of two use cases as part of the European project ECOFACT where different approaches for the combination of simulation and (heuristic) optimization were applied with industry partners. An overview of recent works and systematic literature reviews of sustainable manufacturing and the approaches for combining simulation and optimization is given. Correspondingly, the investigated use cases of automobile paint shops refer to the reduction of environmental impacts by optimized heating processes and an improved batching process to minimize paint waste. In the first case, setup times for heating color pools and ovens were shifted to avoid load peaks in a calculation time of less than one minute. In the second use case batch size was increased by around 25%.

关键词： Sustainable manufacturing Energy Simulation Optimization

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