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International Conference on Control, Decision and Information Technologies (CoDIT)

作者： Gregor Thiele Theresa Johanni David Sommer Martin Eigel Jö rg Krü ger Department for Process Automation and Robotics Fraunhofer IPK Institute for Production Systems and Design Technology Berlin Germany Weierstrass Institute for Applied Analysis and Stochastics Berlin Germany Department for Industrial Automation at the Institute for Machine Tools and Factory Management Technical University of Berlin Germany

The manufacturing sector has witnessed a rapid rise in the importance of energy-efficient operation. For finding optimal set-points for industrial facilities, optimization problems of increasing complexity occur. Key challenges are the leak of derivative information and the curse of dimensionality. For systematic reduction of the search-space by decomposition of the model, a methodology for the inclusion of topology knowledge in the optimization procedure is developed. An implementation of OptTopo (Optimization based on Topology), embedded in a testbed, demonstrates its advantages compared to popular out-of-the-box-optimization. OptTopo could be integrated in energy management software offering advanced set-point control for complex facilities.

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Modeling of the wet immersed tumbling process with the Discrete Element Method (DEM) 18

Modeling of the wet immersed tumbling process with the Discr...

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18th CIRP Conference on Modeling of Machining Operations, CMMO 2021

作者： Uhlmann, E. Fürstenau, J.-P. Kuche, Y. Yabroudi, S. Polte, J. Polte, M. Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Pascalstr. 8-9 Berlin10587 Germany Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstr. 8-9 Berlin10587 Germany CADFEM GmbH Pelikanstr. 13 Hannover30177 Germany

Immersed tumbling is an industrially established process for finishing of components made of metal, ceramic or plastic. In this process, the components are completely surrounded by a wet, abrasive medium, which allows burrs to be removed and surfaces to be polished. In order to gain specific insights into the influence and flow properties of the abrasive media used in this process, numerical approaches using the Discrete Element Method (DEM) with the Rocky DEM software are presented within these investigations. A complete process simulation could be realised by means of a digital machine tool. The immersed tumbling process with cone-shaped polymer abrasive media is implemented by use of a liquid bridge model. The results were validated by experiments with an industrially used immersed tumbling machine tool and for the first time allow sound statements about the contact conditions and interactions of the abrasive media with the workpiece. © 2021 Elsevier B.V.. All rights reserved.

关键词： Finite difference method

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Wear behaviour of various CVD diamond thick film specifications during turning Ti-6Al-4V

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Procedia CIRP 2021年 101卷 266-269页

作者： Eckart Uhlmann Danny Schröter Institute for Machine Tools and Factory Management (IWF) Technische Universität Berlin 10587 Berlin Germany Fraunhofer Institute for Production Systems and Design Technology (IPK) 10587 Berlin Germany

Due to the specific mechanical and thermal properties of Ti-6Al-4V, such as its high heat resistance, the suitability of certain cutting materials is adversely affected. However, the high thermal conductivity and wear resistance of CVD diamond thick films provide the possibility for machining these materials. The present study investigates the wear behaviour of different CVD diamond thick film specifications at various cutting *** particular, differences in the process forces of 53% due to the CVD diamond thick film specifications as well as deviations in tool stability due to process parameter dependent cracks or wear progress were observed.

关键词： diamond tool titanium turning

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AI-enhanced Identification, Inspection and Sorting for Reverse Logistics in Remanufacturing 28

AI-enhanced Identification, Inspection and Sorting for Rever...

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28th CIRP Conference on Life Cycle Engineering, LCE 2021

作者： Schlüter, Marian Lickert, Hannah Schweitzer, Katharina Bilge, Pinar Briese, Clemens Dietrich, Franz Krüger, Jörg Fraunhofer Ipk Institute for Production Systems and Design Technology Pascalstr. 8-9 Berlin10587 Germany Technische Universität Berlin Institute for Machine Tools and Factory Management Pascalstr. 8-9 Berlin10587 Germany Acatech-Deutsche Akademie der Technikwissenschaften Karolinenplatz 4 München80333 Germany

In a circular economy for remanufacturing, after each life cycle used products are returned to a remanufacturer for identification, inspection, sorting and reprocessing. Shortcomings and requirements of the remanufacturing market are identified through expert interviews and process analysis. A concept is proposed to enable an improved identification and a more objective inspection by enhancing the working environment and processes of sorting stations. Digitization and machine learning are applied on business data, using machine vision as well as sensor and actor skills of the worker. With an experimental case study on visual object recognition a positive impact on identification and thus sorting could be demonstrated. © 2021 Elsevier B.V.. All rights reserved.

关键词： Computer vision

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Investigation on stereo-ToF data fusion for the inspection of used industrial parts

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AIP Conference Proceedings 2024年第1期2989卷

作者： Oliver Krumpek Marian Schlüter Johannes Hügle Department of Machine Vision Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstr. 8-9 10587 Berlin Germany

Optical systems for automated or partially automated inspection have been making important contributions to ensure the quality and functionality of technical products for many years. Often used to monitor the quality of newly produced goods, vision systems also aim to play an important role in identification and condition description of used industrial parts such as aged vehicle components. In this work, a passive stereo system and a Time-of-Flight (ToF) sensor of the latest generation were used to create the desired sensor system. In the first step, the pixel-based information of both sensors was exploited to spatially calibrate the transformation between the left stereo camera and the ToF sensor by forming a 2D-3D correspondence set of detected feature points. To compensate for the resolution difference of the sensors, numerous interpolation points were randomly sampled on the reconstructed sparse surface mesh of the ToF sensor to create the missing sub-pixel information. It could be shown that the fused sensor information led to an increase in incompleteness by 7.81% on average for all components examined. The higher noise in the ToF measurement data in the fill-ins could be mitigated by using an adapted median kernel filtering. The average deviation of the measurement from a reference dataset was 1.30mm for the stereo system, 2.51mm for the ToF system, and 1.42mm for the fused result. The result of this work is promising as the quality of the surface mesh could be raised especially for critical surface areas and the underlying RGB data itself can be used for pixel-wise classification and segmentation.

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Single pass laser vacuum welding of thick steel plates using electromagnetic support

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Procedia CIRP 2024年 124卷 418-423页

作者： Andrey Gumenyuk Ömer Üstündağ Till Pelz Nasim Bakir Benjamin Gerhards Markus Schleser Michael Rethmeier Bundesanstalt für Materialforschung und -prüfung (BAM) Unten den Eichen 87 12205 Berlin Germany LaVa-X GmbH Kaiserstrasse 100 52134 Herzogenrath Germany Technische Universität Berlin Pascalstrasse 8-9 10587 Berlin Germany FH Aachen - University of Applied Science Bayernallee 11 52066 Aachen Germany Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstrasse 8-9 10587 Berlin 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.

关键词： high-power laser welding mobile vacuum (MoVac)

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Development of a machining strategy for diamond slide burnishing burnishing tools made of polycrystalline diamond (PCD) 20

Development of a machining strategy for diamond slide burnis...

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20th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2020

作者： Uhlmann, E. Polte, M. Polte, J. Kuche, Y. Wendorf, S. Siebel, D. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools Factory Management IWF Technische Universität Berlin Germany Baublies AG Renningen Germany

ISBN: (纸本)9780995775176

High demands on product quality force companies to reduce production costs. Due to the growing international competition, optical surfaces for tool and mould making need to be produced economically. These surfaces are commonly produced using ultra-precision cutting. However, the efficiency is limited due to low feed velocities vf, small depth of cut ap and associated long process times tPr. An innovative manufacturing process represents diamond burnishing, which can be carried out directly after the high-precision milling process. For this purpose, super-hard materials made of single crystalline diamond (SCD) are currently used as tool materials. Since the material costs are high and the availability is limited, SCD needs to be substituted. An innovative substitution material is polycrystalline diamond (PCD). Within this paper, a machining strategy for the high-precision production of PCD spheres for diamond slide burnishing tools is presented. The processes grinding, polishing and electrical discharge machining (EDM) were applied. Therefore, the manufacturing costs, the surface roughness, the shape accuracy as well as the concentricity accuracy were analysed. Based on these investigations, an efficient and economical machining strategy for the production of high-precision spherical geometries made of PCD can be provided. First results showed that the prefered machining strategy uses a cross-process chain consisting of grinding and polishing. Thereby, the advantages of both processes with the fast manufacturing of the macro-geometry by the grinding process as well as the high surface qualities, which can be achieved by the polishing process, are combined. Copyright © Proceedings of the 20th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2020. All rights reserved.

关键词： Surface roughness

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PowerGrasp - design and evaluation of a modular soft-robotic arm exosuit for industrial applications 52

PowerGrasp - Design and evaluation of a modular soft-robotic...

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52nd International Symposium on Robotics, ISR 2020

作者： Goppold, Jean-Paul Kuschan, Jan Thiele, Gregor Schmidt, Henning Krüger, Jörg Hackbart, Roman Kostelnik, Jan Liebach, Jana Wolschke, Mirko Fraunhofer Institute for Production Systems and Design Technology IPK Berlin Germany Würth Electronics Künzelsau Germany Reha-Zentrum Lübben Lübben Germany

ISBN: (纸本)9783800754298

Absence from work caused by overloading the musculoskeletal system lowers the life quality of the worker and gains unnecessary costs for both the employer and the health system. Classical (rigid link) body-worn exoskeletons can help to reduce critical loading but show many disadvantages, preventing exoskeletons from extensive use in industrial environment. The presented PowerGrasp system is a very robust modular softrobotic arm exosuit sting of robust fabric with embedded rubber tubes as pressure chambers and soft-electronics and who's design is capable to overcome the critical limiting factors of classical exoskeletons. By inflating the tubes via pressure-control valves, it is possible to vary the stiffness of the chambers, which can be effectively used to generate assisting forces and moments at human joints. By using a joint based pressure control, it is possible to decrease the physical demand of overhead working for the wearer. Although the system is designed for industrial overhead assembly, it can also be used in rehabilitation, craftsmanship and construction due to its portable and stand-alone concept. For assessing the impact of the PowerGrasp system, the raise of about 50 percent was shown. Finally, an evaluation study of the overall system has been conducted, showing very high user acceptance and usability. © 2020 VDE Verlag GMBH.

关键词： Musculoskeletal system

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

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Procedia CIRP 2024年 124卷 570-573页

作者： Josefine Lemke Matthias Höfemann Max Biegler Michael Rethmeier Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstrasse 8-9 10587 Berlin Germany Salzgitter Mannesmann Forschung GmbH Eisenhüttenstraße 99 38239 Salzgitter Germany Institut für Werkzeugmaschinen und Fabrikbetrieb IWF Technische Universität Berlin Strasse des 17. Juni 135 10623 Berlin Germany Bundesanstalt für Materialforschung und -prüfung (BAM) Unter den Eichen 87 12205 Berlin 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.

关键词： AHSS laser welding FEM Tailor Welded Blanks hardness HAZ

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DECOMPOSITION OF INDUSTRIAL SYSTEMS FOR ENERGY EFFICIENCY OPTIMIZATION WITH OPTTOPO

arXiv

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arXiv 2022年

作者： Thiele, Gregor Johanni, Theresa Sommer, David Krüger, Jörg Department for Process Automation and Robotics Fraunhofer Institute for Production Systems and Design Technology IPK Germany Faculty of Electrical Engineering and Computer Science Technical University of Berlin Berlin Germany Weierstrass Institute for Applied Analysis and Stochastics Berlin Germany Institute for Machine Tools and Factory Management Technical University of Berlin Berlin Germany

The operation of industrial facilities is a broad field for optimization. Industrial plants are often a) composed of several components, b) linked using network technology, c) physically interconnected and d) complex regarding the effect of set-points and operating points in every entity. This leads to the possibility of overall optimization but also to a high complexity of the emerging optimization problems. The decomposition of complex systems allows the modeling of individual models which can be structured according to the physical topology. A method for energy performance indicators (EnPI) helps to formulate an optimization problem. The optimization algorithm OptTopo achieves efficient set-points by traversing a graph representation of the overall system. © 2022, CC BY.

关键词： Optimization

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