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Production in the loop – the interoperability of digital twins of the product and the production system

Procedia CIRP 2021年 99卷 561-566页

作者： Anna Vogt Philipp Heiner Schmidt Sebastian Mayer Rainer Stark Audi AG Auto-Union-Str. 1 85045 Ingolstadt Germany Technical University of Berlin Chair Industrial Information Technology Pascalstraße 8-9 10587 Berlin Germany Volkswagen AG Berliner Ring 2 38436 Wolfsburg Germany Technical University of Kaiserslautern Institute for Virtual Product Engineering Gottlieb-Daimler-Straße 44 67663 Kaiserslautern Germany Technische Hochschule Ingolstadt Institute for Innovative Mobility Esplanade 10 85049 Ingolstadt Germany Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstraße 8-9 10587 Berlin Germany

The Internet of Things (IoT) era facilitates new possibilities at the interface between the lifecycle of the product and the manufacturing disciplines allowing to add value and meet growing legal requirements. This work presents use cases from the automobile industry which are analyzed in order to derive requirements for data exchange. The analysis of the use cases shows clearly that we need to focus on the instance level for this purpose. This means that both, a specific unit of the product and the production system, must be considered. As a solution approach, a communication loop is proposed bringing the Digital Twin concept in a new field of usage. The key aspect of the proposed solution is the direct intercommunication between the Digital Twins of the product being produced as a Cyber-Physical System (CPS) and the production resources as Cyber-Physical Production systems (CPPS). This solution enables the aggregation of production-related data within the products Digital Twin and therefore promotes maximal transparency throughout engineering disciplines, phases of the product lifecycle and the whole supply chain.

关键词： Digital twin Digital shadow Digital twin lifecycle Cyber-physical system Intelligent production systems Smart production

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Enterprise Interoperability VII: Enterprise Interoperability in the Digitized and Networked Factory of the Future

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2018年

作者： Kai Mertins Ricardo Jardim-Gonalves Keith Popplewell Joo P Mendona

ISBN: (纸本)9783319809281

A concise reference to the state of the art in systems interoperability, Enterprise Interoperability VII will be of great value to engineers and computer scientists working in manufacturing and other process industries and to software engineers and electronic and manufacturing engineers working in the academic environment. Furthermore, it shows how knowledge of the meaning within information and the use to which it will be put have to be held in common between enterprises for consistent and efficient inter-enterprise networks. Over 30 papers, ranging from academic research through case studies to industrial and administrative experience of interoperability show how, in a scenario of globalised markets, where the capacity to cooperate with other organizations efficiently is essential in order to remain economically, socially and environmentally cost-effective, the most innovative digitized and networkedenterprises ensure that their systems and applications are able to interoperate across heterogeneous collaborative networks of independent organizations. This goal of interoperability is essential, not only from the perspective of the individual enterprise but also in the business structures that are now emerging, such as complex collaborating networks of suppliers and customers, virtual enterprises, interconnected organisations or extended enterprises, as well as in mergers and acquisitions. Establishing efficient and relevant collaborative situations requires the management of interoperability from a dynamic point of view: a relevant and efficient collaboration of organizations may require adaptation to remain in line with changing objectives, evolving resources, unexpected events, etc. Many of the papers contained in this, the eighth volume of Proceedings of the I-ESA Conferences have examples and illustrations calculated to deepen understanding and generate new ideas. The I-ESA16 Conference from which this book is drawn was organized by the Escola de Engenharia da

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Notch impact toughness of laser beam welded thick sheets of cryogenic nickel alloyed steel X8Ni9 11

Notch impact toughness of laser beam welded thick sheets of ...

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11th CIRP Conference on Photonic Technologies, LANE 2020

作者： Gook, S. Krieger, S. Gumenyuk, A. El-Batahgy, A.M. Rethmeier, M. Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstraße 8-9 Berlin10587 Germany Federal Institute for Materials Research and Testing BAM Unter den Eichen 87 Berlin12205 Germany Central Metallurgical R and D Institute CMRDI P. O. Box: 87 Helwan El-Tabbin Cairo Egypt Institut für Werkzeugmaschinen und Fabrikbetrieb IWF Technische Universität Berlin Straße des 17. Juni 135 Berlin10623 Germany

The paper deals with the investigations of the impact toughness of laser beam welded 14.5 mm thick sheets made of cryogenic steel X8Ni9 as a function of preheating. This 9% nickel alloyed steel is widely used in the liquefied natural gas (LNG) industry. An application of highly efficient welding processes such as high-power laser beam welding (LBW) in LNG sector requires an understanding of the interactions between the LBW process parameters and weld properties, in particular the impact toughness. The results show that the original fine-grained martensitic microstructure of the base metal (BM) is significantly changed by melting and crystallization during the LBW, what can lead to a decrease in the impact toughness of the weld metal (WM) below the required level. An optimal preheating temperature range leads to the favorable thermal welding cycle and is of remarkable importance for maintaining the notch impact toughness of laser beam welded joints of these thick steel sheets. A parameter window was identified in which V-notch impact toughness comparable to that of the BM at -196 °C was achieved. © 2020 The Authors. Published by Elsevier B.V.

关键词： Microstructure

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Registration of pre- and postoperative surface scans for pediatric neurosurgery

Registration of pre- and postoperative surface scans for ped...

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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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4 th Industrial Revolution design Through Lean Foundation

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Procedia CIRP 2020年 91卷 306-311页

作者： Nathaniel Davis Aziz Companiwala Bernd Muschard Natalie Petrusch M.Sc Student Technische Universität Berlin Pascalstraße 8-9 10587 Berlin Germany Technische Universität Berlin Pascalstraße 8-9 10587 Berlin Germany Fraunhofer Institute for Production Systems and Design Technology (IPK) Pascalstraße 8-9 10587 Berlin Germany

Industry 4.0 was introduced with the hope of transitioning to the next industrial revolution. I4.0 is a vision of increasing flexibility and efficiency within a system of low complexity. Despite this intention, Industry 4.0 has required users to understand complex information and communication systems, limiting usability and therefore not necessarily satisfying the original vision. However, application of principles from the Lean Production systems originally developed in the 1930’s in combination with Industry 4.0, may help to reach its desired goals. Through a literature review, this paper discusses the current state of art of Industry 4.0 and some Lean Production systems principles. The paper focuses on a model combining Lean Production systems with Industry 4.0, that was created in response to the shortcomings of the anticipated industrial revolution. With a Lean Production System as a foundation, the six design principles of I4.0 of interoperability, virtualization, decentralization, real-time capability, service orientation, and modularity can be better implemented to reach the vision of highly flexible and low complexity systems. In return, horizontal and vertical integration within Industry 4.0 can support and accelerate Lean principles by reducing human error and increasing intercommunications between the systems, resulting in a productive integration. The specific principles of Lean that could boost Industry 4.0 will be discussed, demonstrating why a company should be Lean, meaning value adding processes and stakeholder orientation are at its core.

关键词： Lean Production systems Industry 4.0 Transparency Interoperability Decentralization Stakeholder Orientation

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Constructive compensation of the thermal behaviour for industrial robots

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IOP Conference Series: Materials Science and Engineering 2021年第1期1140卷

作者： Eckart Uhlmann Julian Polte Christian Mohnke Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstraße 8-9 10587 Berlin Germany Institute of Machine Tools and Factory Management Pascalstraße 8-9 10587 Berlin Germany

Industrial robot systems offer a flexible, adaptable basis due to their kinematics and their mobility An influencing variable, which is particularly relevant for processes with long process times, is the thermal heating and the associated thermal drift of the tool center point. The maximum deviation from the actual nominal position can reach up to ΔAPt = 1.5 mm. Currently, there are no procedures and methods established in practice which compensate the effects of thermal drift without expensive calibration measures and system downtime. In these investigations a system was developed which allows the reduction of thermally induced displacement by using controlled heating elements. The aim is to keep the entire robot system at a permanent, balanced temperature level. The heating elements are adapted to the geometry of the respective axis and heat the material to a temperature θ close to the steady state. A comparison of the drift through the heating system with the error occurring in normal operation shows that the drift of the heating system is comparable with the drift of normal heating. With the heating mats, a thermally induced error of ΔAPt = 0.234 mm can be generated within t = 20 min. While normal heating requires up to t = 600 min. The achieved error deviation of the drift of the self-heating to the heated variants is with ΔAP = 0.04 mm only minimal. The results can help to reduce the influence of thermal heating and the associated thermal drift of the TCP without using cost-intensive measures with additional hardware and software on external computers for compensating the errors.

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Constructive methods to reduce thermal influences on the accuracy of industrial robots

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Procedia Manufacturing 2019年 33卷 19-26页

作者： Christian Mohnke Sascha Reinkober Eckart Uhlmann Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstraße 8-9 10587 Berlin Germany Institute of Machine Tools and Factory Management Pascalstraße 8-9 10587 Berlin Germany

Due to their kinematics and their mobility, industrial robot systems offer a flexible, adaptable basis. An influencing variable, which is particularly relevant for processes with long process times, is the thermal heating and the associated thermal drift of the tool center point. The maximum deviation from the actual nominal position can reach up to 1.5 mm. To counteract these displacements, a cooling strategy or a targeted preheating can be installed. Both possibilities were evaluated under constructive, energetic and economic aspects and implemented on at least one axis of an industrial robot. Furthermore, a structural thermal decoupling and optimized design of the respective components were carried out. The results can help to reduce the influence of thermal heating and the associated thermal drift of the TCP by structural support without using cost-intensive measures with additional hardware and software on external computers for compensating the errors.

关键词： Robot Thermal Error Machining

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Ductile machining of brittle materials for manufacturing micro-optic components 18

Ductile machining of brittle materials for manufacturing mic...

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18th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2018

作者： Uhlmann, E. Oberschmidt, D. Rolon, D.A. Kühne, S. Jagodzinski, M. Malcher, M. Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Germany Fraunhofer Institute for Production Systems and Design Technology IPK Germany

ISBN: (纸本)9780995775121

Due to the geometry and specification of micro-optic components, these may not be ground or polished, therefore they demand other manufacturing processes such as ultra-precision (UP) machining with defined cutting edge tools. Despite previous studies, the machining of brittle materials remains a challenge for manufacturing those components in UP processes. For example, ductile machining of silicon is extensively studied, however, ductile machining of materials such as Zerodur®, GaP, U.L.E.® and glass is still a challenge to overcome. Therefore, this paper aims at reporting the ductile or part-ductile machining of silicon and Zerodur® pieces in UP processes. Experiments were carried out using UP-shaping and plane turning processes in an UP-machine tool. Moreover, monocrystalline diamond tools were employed. During UP-turning experiments, the process forces were measured. The machining results were obtained by White Light Interferometer (WLI) of the representative machined surfaces. In order to complement the experiments, simulations were performed in finite element software to comprehend the influences of the rake angle on ductile machining of those materials. After the UP-shaping experiments, the depth of cut was determined for each of the mentioned materials together with the main influence of each process parameter. Furthermore, a reduction of parameter ranges for UPturning experiments was accomplished. Using design of Experiments for UP-turning tests, the main influences of process parameters were observed and detailed, together with tool geometry optimization and recommendation for further experiments. The local optimum of process parameters was found as well as the accomplishment of ductile removal during the machining tests. These results and simulation models are going to be further used for a more detailed process description, as analogous tests and optimization of UP processes such as micro-milling. © 2018 CURRAN-CONFERENCE. All rights reserved.

关键词： design of experiments

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Boron-doped CVD diamond micro-end mills for machining titanium 18

Boron-doped CVD diamond micro-end mills for machining titani...

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18th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2018

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

ISBN: (纸本)9780995775121

In industry micro-milling tools made of cemented carbide are widely used. However, these micro-milling tools suffer from fast and random tool breakage during the machining of hard to machine materials. Therefore, in preliminary work micro-milling tools with cutting edges made of boron doped chemical vapour deposition (bdCVD) diamond were developed. In this work new micro-milling tools were successfully applied for machining titanium grade 2. Comprehensive cutting tests were carried out to analyse the influence of the spindle speed n, the feed per tooth ft, and the depth of cut ap on the surface roughness. Further experiments addressed the wear behaviour of the developed micro-milling tools. After a path length lc of 10 m a maximum width of flank wear land VBmax of 29 μm were observed. © 2018 CURRAN-CONFERENCE. All rights reserved.

关键词： Milling (machining)

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Helical electrodes for improved flushing conditions in drilling EDM of MAR-M247 18

Helical electrodes for improved flushing conditions in drill...

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18th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2018

作者： Uhlmann, E. Yabroudi, S. Perfilov, I. Schweitzer, L. Polte, M. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Germany

ISBN: (纸本)9780995775121

The machining of precision holes in difficult to machine materials or alloys with high aspect ratios φ and under consideration of the cost-effectiveness of the overall process is still a challenge. Electro-discharge machining (EDM) is predestined for such purposes. Flushing is one key factor for the precise machining of bore holes with high aspect ratios φ. Nevertheless, the capabilities of the flushing conditions are often underrated regarding an improved process stability, an increased material removal rate VW, a decreased machining time tero, as well as the tool wear ΔIE. Therefore, the present investigation considers the influence of an outer geometry of cylindrical rod tool electrodes to improve the electro-discharge drilling process. Different electrodes made of brass, with helical flutes along the shank, are compared with the basic geometry, a cylindrical rod electrode, with respect to their flushing capabilities. All electrodes have an outside diameter d = 3 mm. It is suggested that the machining process will stabilise and the material removal rate VW will increase due to improved removal efficiency of erosion particles (debris). Through holes with a total depth h = 16 mm have been machined by use of design of Experiments (DoE) approved process parameters in nickel based superalloy MAR-M247. By use of a helical shaped electrode the machining time tero was reduced by 39 % compared to the cylindrical rod electrode. © 2018 CURRAN-CONFERENCE. All rights reserved.

关键词： Electrodes

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