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Implementing human-robot collaboration in highly dynamic environments: Assessment, planning and development

AIP Conference Proceedings 2024年第1期2989卷

作者： A. Bastidas-Cruz T. Jaya G. Thiele J. Krüger Process Automation and Robotics Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstr. 8-9 10587 Berlin Germany Head of Industrial Automation Technology Department Institute of Machine Tools and Factory Management Technische Universität Berlin Pascalstr. 8-9 10587 Berlin Germany

Human-robot collaboration (HRC) applications have been slowly making their path in the industry. Although the required hardware and the methods for the planning and development of collaborative robotic applications are mostly already developed, some industrial branches still struggle to implement HRC. This is the case in motorcycle production, where, unlike car production, the assembly line has been optimized for manual *** on the use case described above, this paper identifies new requirements of HRC for automated screwing assembly operations in flexible production environments. In order to compensate deviations in the position of the tool relative to the workpiece, a screwing strategy based on force control is proposed. Parameter sensitivity is considered and supported experimentally with a screwing task performed by a cobot, where a method for contact detection between the nutrunner and the screw head is analyzed. This paper brings a guideline for experts from the manufacturing system engineering to implement HRC in highly dynamic assembly environments.

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Concept and Architecture for Information Exchange between Digital Twins of the Product (CPS) and the Production System (CPPS)

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Procedia CIRP 2021年 104卷 1292-1297页

作者： Anna Vogt Ralph Klaus Müller Thomas Kampa Rainer Stark Daniel Großmann Technical University of Berlin Chair Industrial Information Technology Pascalstraße 8-9 10587 Berlin Germany Audi AG Auto-Union-Str. 1 85045 Ingolstadt Germany Technische Hochschule Ingolstadt Esplanade 10 85049 Ingolstadt Germany Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstraße 8-9 10587 Berlin Germany

The Digital Twin concept and CPS- and IIoT-based approaches are increasingly important topics concerning future Industry 4.0 architectures. They offer high potential for dynamical aspects in intelligent production planning and control as well as part traceability and documentation. Standardized information exchange is an upcoming requirement among the whole supply chain. This paper presents a concept for a Digital Twin architecture based on motor production in the automotive industry. The key aspect is an information exchange structure for Digital Twins of products and production systems that are combined using principles of Dynamic Aggregation.

关键词： Digital Twin Cyber Physical System Production System Information Model Information Exchange Intelligent Production systems Smart Production

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Advances in Modeling of the Kerf Formation considering the Primary and Deflection Jets for the Abrasive Water Jet technology

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Procedia CIRP 2021年 102卷 156-161页

作者： Eckart Uhlmann Harald Kruggel-Emden Constantin Männel Enrico Barth Darius Markauskas Technische Universität Berlin Institute for Machine Tools and Factory Management (IWF) Pascalstr. 8-9 10587 Berlin Germany Fraunhofer Institute for Production Systems and Design Technology (IPK) Pascalstr. 8-9 10587 Berlin Germany Technische Universität Berlin Mechanical Process Engineering and Solids Processing Ernst-Reuter-Platz 1 10587 Berlin

Processing of difficult to machine materials is a promising application for abrasive water jet kerf cutting and milling. However, due to the large number of interactions of an energy-bound cutting process, a precise prediction of the material removal is crucial for its application. Based on an analytical approach, a material removal simulation model is introduced considering the primary and deflecting jet impacts to rapidly predict various cutting situations. The model describes fundamental cutting mechanisms considering the water jet’s material removal rate and is calibrated for titanium aluminides. The model allows for a comprehensive kerf prediction and thus potentially accelerates the process design improving the productivity and quality for abrasive water jet kerf cutting and milling.

关键词： Waterjet machining Titanium aluminides AWJ milling Modeling AWJ deflection

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Energy efficiency measures for metal forming using hydraulic and mechanical presses

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AIP Conference Proceedings 2024年第1期2989卷

作者： Mandy Preuß Gregor Thiele Jörg Krüger Ökotec Energiemanagement GmbH Torgauer Straße 12 Berlin Germany Fraunhofer IPK Institute for Production Systems and Design Technology Pascalstraße 8-9 10587 Berlin Germany Technical University of Berlin Institute for Machine Tools and Factory Management Pascalstraße 8-9 10587 Berlin Germany

In conventional hydraulic presses only around 13 percent of the energy supplied is converted into the plastic forming of the metal. Mechanical presses achieve an overall efficiency of 13 to 30 percent. A variety of approaches aspire efficiency improvements by tuning process parameters. For the operation engineers it is a crucial task to find measures which are both technical suitable and economical promising. This paper summarizes popular tuning parameters and presents the assessment by seven experts who participated in semi-structured interviews. For hydraulic presses, the most recommend tuning parameter to be adjusted is the pressing force. For mechanical presses the continuous stroke operation is the most popular measure.

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Process data based Anomaly detection in distributed energy generation using Neural Networks

Process data based Anomaly detection in distributed energy g...

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International Conference on Control, Automation and Diagnosis (ICCAD)

作者： Max Klein Gregor Thiele Adalbert Fono Niloufar Khorsandi David Schade Jörg Krüger Fraunhofer Institute for Production Systems and Design Technology IPK Berlin Germany AUCOTEAM GmbH Berlin Germany Institute for Machine Tools and Factory Management Technical University of Berlin Berlin Germany

ISBN: (数字)9781728169996

ISBN: (纸本)9781728170008

The increasing share of renewable energies in the total energy supply includes a growing number of small, decentralized energy generation which also provides control energy. These decentralized stations are usually combined to a virtual power plant which takes over the monitoring and control of the individual participants via an Internet connection. This high degree of automation and the large number of frequently changing subscribers creates new challenges in terms of detecting anomalies. Quickly adaptable, variable and reliable methods of anomaly detection are required. This paper compares two approaches using Neural Networks (NN) with respect to their ability to detect anomalous behavior in real process data of a combined heat and power plant. In order to include process dynamics, one approach includes specifically engineered features, while the other approach uses Long-Short-Term-Memory (LSTM). Both approaches are able to detect rudimentary anomalies. For more demanding anomalies, the respective strengths and weaknesses of the two approaches become apparent.

关键词： Power generation Artificial neural networks Computer architecture Monitoring Anomaly detection Generators Time series analysis

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Automated continuous learn and improvement process of energy efficiency in manufacturing

Automated continuous learn and improvement process of energy...

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Annual Conference of Industrial Electronics Society

作者： Alperen Can Jessica Fisch Philipp Stephan Gregor Thiele Jörg Krüger Mercedes-Benz AG Berlin Germany Fraunhofer Institute for Production Systems and Design Technology IPK Berlin Germany Industrial Automation Technology Group Technische Universität Berlin Berlin Germany

ISBN: (数字)9781728154145

ISBN: (纸本)9781728154152

Optimizing the energy efficiency of machine tools automatically is promising. There are several metrics to be considered when it comes to automated optimization approaches in serial production which are especially quality, technical availability, and cycle time. These are not supposed to be impaired whereas they are indicated as a central obstacle. The measurements and the machine data show the actions happening in the machine which also leads to the data-driven traceability of machine states. This article presents a method to formulate the necessary expert knowledge to optimize the energy efficiency of a machine tool and is basically done by a decision tree which leads to a set of rules which will be explained in this article. This set of rules coordinate an optimization algorithm, which technically manipulates selected variables under the given rules. The development and is a result of a research which was done at the serial production of camshafts at the MB plant in Berlin.

关键词： Optimization Machine tools Production systems Monitoring Process control Tools Data analysis

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Die-sinking EDM of a SiC-boride-composite 19

Die-sinking EDM of a SiC-boride-composite

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19th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2019

作者： Uhlmann, E. Polte, J. Jahnke, C. Wolf, C.-S. Degenhardt, U. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools Factory Management IWF Technische Universität Berlin Germany FCT Ingenieurkeramik GmbH Frankenblick Germany

ISBN: (纸本)9780995775145

Silicon carbide-based composites are highly demanded for industrial applications, like heat exchangers in corrosive environments. In consequence of the mechanical properties like high hardness H and brittleness, cutting processes are still challenging. An opportunity for processing difficult-to-cut materials with sufficient electrical conductivity σ is electrical discharge machining (EDM). In order to develop suitable machining technologies, known parameters for common material combinations can serve as a starting point. Hence, standard technologies from the database of a commercial die-sinking EDM machine tool were applied for machining a silicon carbide-boride-composite. The material removal rate QW and the arithmetical mean deviation Ra for finishing and roughing operations are observed. The formation of cracks and the extend of the typical deposition layer formed at the surface of the workpiece is analysed through scanning electron microscopy. While the material removal rate QW is increasing with higher discharge energies W in this investigation, the arithmetical mean deviation Ra is not dependent on this property. Furthermore, spalling is identified as main material removal mechanism occurring in this process. Overall, the machinability of silicon carbide-boride composites with EDM, applying commercial available parameter technologies, is successfully demonstrated. © 2019 European Society for Precision Engineering and Nanotechnology, Conference Proceedings - 19th International Conference and Exhibition, EUSPEN 2019. All rights reserved.

关键词： Scanning electron microscopy

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Registration of pre- and postoperative surface scans for pediatric neurosurgery

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Current Directions in Biomedical Engineering 2018年第1期4卷 657-660页

作者： Katanacho, Manuel Lack, John-Certus Fehlhaber, Felix Krüger, Jörg Fraunhofer Institute Production Systems and Design Technology IPK Pascalstrasse 8 - 9 Berlin Germany

A software for automatic registration and differential visualization of pre- and postoperative surface scans for use in pediatric neurosurgery is developed and implemented. The core operations of the registration include an automatic head extraction, a rough registration by aligning the main axes, a depth map-based registration for robust determination and registration of feature points in the facial area, and a fine registration. A graphical user interface is implemented for the difference visualization and program control. © 2018 Manuel Katanacho et al.

关键词： Graphical user interfaces

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Dry-ED milling of micro-scale contours with high-speed rotating tungsten tube electrodes

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Procedia CIRP 2020年 95卷 533-538页

作者： E. Uhlmann I. Perfilov S. Yabroudi R. Mevert M. Polte Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Pascalstr. 8-9 Berlin 10587 Germany Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstr. 8-9 Berlin 10587 Germany

This paper presents machining results for dry-ED milling of micro-scale contours by use of a new machine tool, including a relaxation generator, designed for dry-EDM. To implement the dry-ED milling process tungsten tube electrodes were used. The gas is injected through the tubular tool electrode under high pressure. Additionally, a high-speed EDM spindle was used to overcome process instabilities and increase the material removal rate due to better flushing conditions. Further, fluid simulations of the flushing conditions are presented in this paper. It is found that the use of gaseous dielectrics enables much better machining results in terms of shape accuracy and tool wear. The simulations provide new insights in the flushing conditions when using gaseous dielectrics. The calculated fluid flow pattern shows a great agreement with the observed depositions of reattached molten material on the tool and workpiece surface. The results presented as well as the hardware introduced enable the industrial application of dry-EDM for the first time.

关键词： EDM Dry-EDM ED milling CFD flushing

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System identification of a hysteresis-controlled pump system using SINDy

System identification of a hysteresis-controlled pump system...

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International Conference on System Theory, Control, and Computing (ICSTCC)

作者： Gregor Thiele Arne Fey David Sommer Jörg Krüger Fraunhofer Institute for Production Systems and Design Technology IPK Berlin Germany Weierstrass Institute for Applied Analysis and Stochastics Berlin Germany Institute for Machine Tools and Factory Management Technische Universität Berlin Berlin Germany

ISBN: (数字)9781728198095

ISBN: (纸本)9781728198101

Hysteresis-controlled devices are widely used in industrial applications. For example, cooling devices usually contain a two-point controller, resulting in a nonlinear hybrid system with two discrete states. Dynamic models of systems are essential for optimizing such industrial supply technology. However, conventional system identification approaches can hardly handle hysteresis-controlled devices. Thus, the new identification method Sparse Identification of Nonlinear Dynamics (SINDy) is extended to consider hybrid systems. SINDy composes models from basis functions out of a customized library in a data-driven manner. For modeling systems that behave dependent on their own past as in the case of natural hysteresis, Ferenc Preisach introduced the relay hysteron as an elementary mathematical description. In this new method (SINDyHybrid), tailored basis functions in form of relay hysterons are added to the library which is used by SINDy. Experiments with a hysteresis controlled water basin show that this approach correctly identifies state transitions of hybrid systems and also succeeds in modeling the dynamics of the discrete system states. A novel proximity hysteron achieves the robustness of this method. The impacts of the sampling rate and the signal noise ratio of the measurement data are examined accordingly.

关键词： Autoregressive processes Magnetic hysteresis Biological system modeling Nonlinear dynamical systems Hysteresis Relays Data models

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