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

作者： Polte, J. Polte, M. Hocke, T. Lahoda, C. Uhlmann, E. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools Factory Management IWF Technische Universität Berlin Germany

ISBN: (纸本)9780995775190

Additive manufacturing enables the production of highly complex metallic components with highest geometrical flexibility in dedicated lightweight construction. For titanium-aluminium alloys, which are used in particular in the aviation industry, powder bed based processes such as the laser powder bed fusion are established. Nevertheless, laser powder bed fusion is limited with regard to the producible surface roughness in a range of 5 µm ≤ Ra ≤ 15 µm. According to the state of the art, the increase of the geometrical accuracy and the reduction of the surface roughness values of the additive manufactured components are realised by different cutting and non-conventional processes. In this investigation, a new approach for the reduction of the surface roughness values by immersed tumbling was realised. Therefore, additively manufactured square bars made of the titanium alloy Ti-5Al-5Mo-5V-3Cr were used as sample geometries. An immersed tumbling machine tool with planetary kinematics for post-processing was applied and the lapping media QZ, HSC 1/500 and M5/400 were evaluated. In addition, the influence of the rotor speed and the holder as well as the depth of immersion were considered as influencing factors. As target values the surface roughness values as well as the rounded edge radius were examined. Within this investigations the surface roughness values could be reduced by more than 90 %. In addition, a targeted rounding of the edges could be obtained, which removed the excess edge height at the part resulting from the laser powder bed fusion process. As a result the immersed tumbling process shows a great suitability as a finishing process for additively manufactured components and is particularly suitable for automated and serial finishing processes. © 2021 Proceedings of the 21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021. All rights reserved.

关键词： Surface roughness

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Particle contact conditions for cutting edge preparation of micro-milling tools by the immersed tumbling process 21

Particle contact conditions for cutting edge preparation of ...

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

作者： Uhlmann, E. Polte, J. Kuche, Y. Landua, F. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools Factory Management IWF Technische Universität Berlin Germany

ISBN: (纸本)9780995775190

For increasing tool life and cutting length of micro-milling tools the cutting edge preparation was successfully established. Using the immersed tumbling process, a reproducible cutting edge preparation with constant cutting edge radii as well as low chipping of the cutting edges can be realised. For a profound understanding of the preparation process and the process mechanisms further knowledge about the particle interactions with cutting tools as well as the particle flow mechanisms needs to be obtained. In this investigation the preparation process of micro-milling tools was analysed and the contact-mechanisms as well as the resulting pressures were investigated by simulation studies. Using the discrete element method (DEM) with the software ROCKY DEM from the company ESSS, Florianópolis, Brasil, the immersed tumbling process could be modelled and particle contacts, particle traces as well as particle interactions with the micro-milling tool can be visualized. Especially the particle-tool interactions were more accurately investigated by analysing the stresses and particles shear work as well as correlations between these parameters to prove the comparability between the process simulation and the real preparation process. © 2021 Proceedings of the 21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021. All rights reserved.

关键词： Milling (machining)

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Simulating flow behaviour of wet particles within the immersed tumbling process 21

Simulating flow behaviour of wet particles within the immers...

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

ISBN: (纸本)9780995775190

For many production chains, it is mandatory to involve special finishing of the manufactured parts for the chipping of the edges as well as the polishing of surfaces. One commonly used method is the immersed tumbling process, where any workpiece is dragged through a particle filled container. In many cases, the immersed tumbling process operates in environments with added liquids, leading to changes in particle-tool interaction and general flow behaviour of the used particles. Whilst the discrete element method for simulating particles is mainly limited to dry particles, the used software ROCKY DEM from ESSS, Florianópolis, Brasil, comes with a built-in liquid-bridge model to simulate water-covered particles and granulate and furthermore an extension for system couplings with Ansys Fluent of the company ANSYS, INC., Canonsburg, Pennsylvania. The latter can be used to create from both software one three-phase-model with higher amounts of actually simulated water. In this study, small amounts of water were added to differently shaped particles using the build-in liquid-bridge model, to analyse and compare the particles flow characteristics in both, wet and dry environments. To gather significant information leading towards precise comparisons, the particles trajectories, velocities and resulting forces against the workpieces can be specifically observed and analysed, whilst this kind of process knowledge could previously never been taken into account without simulation. © 2021 Proceedings of the 21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021. All rights reserved.

关键词： Liquids

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Green incremental learning - Energy efficient ramp-up for AI-enhanced part recognition in reverse logistics

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Procedia CIRP 2023年 116卷 414-419页

作者： Marian Schlüter Robert Schimanek Paul Koch Clemens Briese Vivek Chavan Pinar Bilge Franz Dietrich Jörg Krüger Fraunhofer Institute for Production and Design Technology (IPK) Pascalstr. 8-9 Berlin 10587 Germany Technical University Berlin Institute for Machine Tools and Factory Management Pascalstraße 8-9 10587 Berlin Germany

Artificial Intelligence (AI) has made significant progress in supporting circular economy and reverse logistics by learning from diverse data to predict, e.g., routes or to assist workers in sorting. However, it remains an open question how AI can be integrated and trained into such operational processes, where little to no data has been collected previously. Traditionally, AI models would only be rated by their accuracy. This paper aims to introduce the concept of green incremental learning, i.e. rating AI models not only for their accuracy but to evaluate energy efficiency as well. A ramp-up of a data-driven AI system for part recognition is explored under consideration of energy efficiency. Therefore, we combine online and incremental learning, working with growing data sets to simulate a ramp-up phase. We present experiments of incremental learning on business and image data, partially supported by regular joint training steps. We start local CPU-based machine learning and prediction on business data from the first sample. Finally, we compare incremental learning to traditional batch learning and show energy-saving potential of up to 62 % without a significant drop in accuracy.

关键词： Circular economy reverse logistics incremental learning computer vision machine learning

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Towards Robot-Assisted Data Generation with Minimal User Interaction for Autonomously Training 6D Pose Estimation in Operational Environments 56

Towards Robot-Assisted Data Generation with Minimal User Int...

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

作者： Koch, Paul Schlüter, Marian Thill, Serge Krüger, Jörg Fraunhofer Institute for Production and System Design Technology Pascalstraße 8-9 Berlin10587 Germany Donders Institute for Brain Cognition and Behavior Radboud University Nijmegen6525 HR Netherlands Technical University Berlin Institute for Machine Tools and Factory Management Pascalstraße 8-9 Berlin10587 Germany

Recently, deep neural networks achieved state-of-the-art results in the subject of 6D object pose estimation for robot manipulation. However, those deep learning methods require expensive training data. Current methods for cost reduction use synthetic data, but rely on expert knowledge and suffer from the domain gap when shifting to the real application. Here, we present a proof of concept for a novel approach towards generating annotated training data for 6D object pose estimation. This approach is designed for learning new objects in operational environments while requiring little interaction and no expertise on the part of the user. © 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： 6D Object Pose Estimation Artificial Intelligence Data Generation Robot Cognition Robotic Grasping

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Development of a mechanical, biocide-free method of disinfection for cathodic dip coating processes 21

Development of a mechanical, biocide-free method of disinfec...

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

作者： Uhlmann, E. Hilt, M. Hein, C. Cudazzo, M. Huth-Herms, K. Jahnke, C. Quast, M. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Fraunhofer Institute for Manufacturing Engineering and Automation IPA Germany Institute for Machine Tools Factory Management IWF Technische Universität Berlin Germany

ISBN: (纸本)9780995775190

Technical fluids are often contaminated by bacteria as Burkholderia cepacia (B. cepacia), which is found in different industrial issues and affects manufacturing process chains by the formation of planktonic cell-aggregates and biofilms within the working fluids. B. cepacia is one of nine species of the Burkholderia cepacia complex (Bcc), a group of gram-negative, motile, non-spore-forming, and rod-shaped bacteria. Because of the opportunistic pathogenicity to plants, animals, humans, and the multi-drug and biocide resistance, B. cepacia is difficult to treat. This study aims to provide an application to reduce the germ numbers ng in an eco-friendly and continuous process without the use of biocides. The approach to disinfect technical fluids is to apply high shear forces in a rotor-stator assembly to the fluid. A prototype of the rotor-stator assembly with a variably adjustable shear gap gs and rotor speed srot was constructed. First experiments with a frequency frot 10 Hz ≤ frot ≤ 40 Hz a shear gap gs = 83 µm and gs = 166 µm showed a reduction of germ number ngr = 99.6 %. It concluded that the disinfection of technical fluids by a rotor-stator assembly is a biocide-free alternative. In addition to defined process parameters such as shear gap gS, temperature ϑ, frequency frot and time of machining process tmp, also the peripheral speed vp, rotational speed vrot, flow rate fr and shear stresses τ were used to assess the machining result and to develop an overall concept for disinfection of technical fluids. © 2021 Proceedings of the 21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021. All rights reserved.

关键词： Stators

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Single pass laser vacuum welding of thick steel plates using electromagnetic support.-Invited Paper- 13

Single pass laser vacuum welding of thick steel plates using...

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13th CIRP Conference on Photonic Technologies, LANE 2024

作者： Gumenyuk, Andrey Üstöndag, Ömer Pelz, Till Bakir, Nasim Gerhards, Benjamin Schleser, Markus Rethmeier, Michael Unten den Eichen 87 Berlin12205 Germany LaVa-X GmbH Kaiserstrasse 100 Herzogenrath52134 Germany FH Aachen-University of Applied Science Bayernallee 11 Aachen52066 Germany Technische Universität Berlin Pascalstrasse 8-9 Berlin10587 Germany Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstrasse 8-9 Berlin10587 Germany

The increasing demand for renewable energy produced by offshore wind turbines goes along with an increased demand in the production of offshore wind turbine foundations, so called "monopiles", which are made by joining thick metal sheets. The industrial standard of multi-layer submerged arc welding (SAW) for joining of thick metal sheets is the current bottleneck in the production of monopiles. A possible increase in productivity by the implementation of high-power laser welding in a newly developed mobile vacuum chamber (MoVac) and an electromagnetic root support is the subject of this study. Single run butt welds are performed in flat position on S355 mild steel of thicknesses up to 80 mm using a disc laser system with 1030 nm wavelength and a maximum output of 60 kW. The laser optic is fixed on the MoVac-system which is held and manipulated by an articulated robot. © 2024 The Authors.

关键词： Vacuum welding

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Process strategies for optimizing the cooling behaviour of laser-welded Tailor Welded Blanks made of advanced high strength steels (AHSS) 13

Process strategies for optimizing the cooling behaviour of l...

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13th CIRP Conference on Photonic Technologies, LANE 2024

作者： Lemke, Josefine Höfemann, Matthias Biegler, Max Rethmeier, Michael Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstrasse 8-9 Berlin10587 Germany Unter den Eichen 87 Berlin12205 Germany Institut for Werkzeugmaschinen und Fabrikbetrieb IWF Technische Universität Berlin Strasse des 17. Juni 135 Berlin10623 Germany Salzgitter Mannesmann Forschung GmbH Eisenhöttenstraße 99 Salzgitter38239 Germany

AHSS with 1000 MPa tensile strength show promising properties for the use in Tailor Welded Blanks (TWBs) to locally strengthen car body parts. Challenges in laser beam welding of the sheets are hardness-drops and-peaks in the heat-Affected zone (HAZ) and weld, which cause risks during cold-forming. This happens due to rapid cooling caused by laser welding. A numerical approach aiming for slower cooling rates in the weld region is presented in this article. Laser welded sheets served as reference for setting up a process simulation. Models for pre-heating and a coaxial setup with power split were set up. A correlation between cooling-rate and hardness in the joining zone was established and applied to the modelled strategy. Splitting the power led to a slightly narrower weld seam and experimental pre-heating of the sheets to 600 °C could lower total seam hardening. It achieved a homogenization of the fusion zone. © 2024 The Authors.

关键词： Laser beam welding

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How can the programming of impedance control be simplified?

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Procedia CIRP 2021年 97卷 266-271页

作者： Arturo Bastidas Cruz Marcel Radke Kevin Haninger Jörg Krüger Fraunhofer Institute for Production Systems and Design Technology (IPK) Division of Automation Technology Berlin Germany

Impedance control uses force/torque measurements to adapt a robot’s motion, broadening a robot’s capabilities in contact tasks. However, potential benefits of impedance control are largely not realized in industry, partly due to complexity: it requires a large number of parameters (compliance frame, impedance parameters, reference position/force) and expertise to set these parameters for a specific application. Pre-defined action templates can be used to hide and preset parameters as required for a specific action, potentially reducing the expertise and time required for an integration. However, objectives and methods to design such primitives are not well-established. This paper considers application requirements common in impedance control, and how actions can be designed to support such requirements. Parameter sensitivity and independence are considered, supported experimentally with a ‘hole-in-peg’ assembly task, where the impact of compliance frame and environmental uncertainty are analyzed.

关键词： Impedance control Robotic assembly Action primitives

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Distributed real-time production control for resilient manufacturing systems

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Procedia CIRP 2023年 120卷 1274-1279页

作者： Eckart Uhlmann Julian Polte Christopher Mühlich Technische Universität Berlin Institute for Machine Tools and Factory Management IWF Pascalstraße 8-9 10587 Berlin Germany Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstraße 8-9 10587 Berlin Germany

To enable resilient manufacturing, production control systems must be able to adapt quickly and flexibly to unexpected changes. Motivated by Industrie 4.0, multi-agent systems offer a promising approach to meet these requirements. This paper presents a method for distributed production control that enables production entities to make optimal decisions regarding capacity utilization and the compliance of delivery dates in real-time despite disruptive events. Based on a multi-agent Markov Decision Process, production entities are modeled as autonomous software agents that can solve Flexible Job-Shop Problems through message passing. The performance of the proposed method is evaluated in a simulated production environment.

关键词： Industrie 4.0 resilient manufacturing systems distributed production control multi-agent system Flexible Job-Shop Problem

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