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International Electric Drives Production Conference (EDPC)

作者： Alena Babl Mirko Bach Katrin Schubert Dieter Gerling Verena Kräusel Michaela Gedan-Smolka Chair of Electrical Drives and Actuators Bundeswehr University Munich Neubiberg Germany Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz Germany Institut Polymerwerkstoffe Leibniz-Institut für Polymerforschung Dresden e. V. Dresden Germany

ISBN: (纸本)9781665418102

In the wake of the Paris Climate Agreement and the world wide obligation to reduce CO 2 emissions, products and their manufacturing processes must be optimized in order to reduce resource consumption. This particularly concerns the topic of electric drives and machines. Regarding machines, one possibility to achieve this goal is the use of so-called flux barriers. This working concept offers further possibilities for structural optimization, such as radial lamination of the sheets, which then allows the use of grain-oriented electrical steel. Both mentioned principles increase the efficiency of the machine to a high degree and reduce manufacturing costs, as the iron losses are lessened and the material utilization is raised. This paper presents recent investigations of the use of grain-oriented electrical steel sheets for novel, radially laminated stators for electric motors with concentrated windings and flux barriers. The focus is on the analysis of the electromagnetic properties of the electrical sheets before and after forming, their coating and the operating characteristics of the planned demonstrator machine. Recent findings in the area of the technical implementation of the demonstrator machine and its electromagnetic design with the aid of FEM simulation are presented. Furthermore, challenges are evaluated with regard to eddy currents that arise due the innovative design. Finally, recommendations for further proceeding are derived and the next steps are explained.

关键词： Lamination Windings Production Stators Manufacturing Finite element analysis Steel

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Integration of forming Manufacturing technology into the Component Production of Innovative Electric Motor Concepts

Integration of Forming Manufacturing Technology into the Com...

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International Electric Drives Production Conference (EDPC)

作者： Mirko Bach Alena Babl Dieter Gerling Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz Germany Chair of Electrical Drives and Actuators Bundeswehr University Munich Neubiberg Germany

ISBN: (数字)9781728184586

ISBN: (纸本)9781728196145

Constantly increasing demands on production technology, such as sustainability and climate protection, require continuous optimization or even new development of production processes and designs, including in the field of electrical engineering. For this reason, it is also necessary to exploit the potential of various manufacturing technologies in order to achieve higher efficiency of the running machines. One way to achieve this goal is the application-optimized use of forming technology, which is less material-intensive due to its characteristics compared to, for example, cutting technology. Its use also allows better utilization of the special properties of electrical steel used in electrical machine construction or increases the so-called slot filling factor of electrical ***, motor stators consist of axially stacked, non-grain-oriented electrical steel (ngo), in whose motor slots coils of wound round wire are placed. The grain orientation of the sheets used has an influence on the amount of iron losses of the motor. With the use of round wire for the electric coils, only a slot filling factor of approx. 65 % can be achieved and thus potential for increasing the magnetic field of the coil is available. In order to achieve a higher slot filling factor, it is necessary to adapt the cross-sectional shape of the conductor material to the corresponding installation position by means of *** the present paper a novel approach for stator design with so-called flux barriers and thus the possibility of using radially laminated, grain-oriented plates are presented and the latest research results are shown. In addition current measurement results for the forming technical optimization of the increase of the slot filling factor of electrical coils with adapted conductor cross sections are presented and discussed.

关键词： Coils Electric potential Wires Production Stators Filling Manufacturing

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Comparison of Resistive and Optical Strain Measurement for Early Fracture Detection

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Current Directions in Biomedical Engineering 2020年第3期6卷

作者： Carabello, Alina Neupetsch, Constanze Werner, Michael Rotsch, Christian Drossel, Welf-Guntram Zajonz, Dirk Chemnitz University of Technology Adaptronics and Lightweight Design in Production Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology Iwu Chemnitz/ Dresden Germany Zeisigwaldkliniken Bethanien Chemnitz Germany

To increase learning success in surgical training, physical simulators are supplemented by measurement technology to generate and record objective feedback and error detection. An opportunity to detect fractures following hip stem implantation early can be measurement of occurring strains on bone surface. These strains can be determined while using strain gauges, digital image correlation (DIC) or photoelasticity. In this research strain gauges and DIC were compared regarding their suitability as strain measurement tools for use in physical simulators. Therefore a testing method was described to replicate the implantation of a hip stem. Testing devices modelled on a realistic prosthesis were pressed into prepared porcine femora in a two-step procedure with a material testing machine. The local strains occurring on bone surface were determined using an optical measurement system for DIC and strain gauges. The initial fractures in the tested femora are located medial-anterior in most cases (73,6%). With increasing indentation depth of the test device, the strains on bone surface increase. Comparing the local strains determined by DIC and strain gauges consistencies in curves are noticeable. Maximal determined strains before fracturing amount to 0,69% with strain gauges and 0,75% with DIC. In the range of the fracture gap, strain gradients are determined by using DIC. However the detected surfaces are of low quality caused by gaps and motion artefacts. The results show strains on bone surfaces for early fracture detection are measurable with strain gauges and DIC. DIC is assessed as less suitable compared to strain gauges. Furthermore strain gauges have greater level of integration and economic efficiency, so they are preferred the use in surgical training simulators. © 2020 by Walter de Gruyter Berlin/Boston 2020.

关键词： Image correlation

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Retrieving properties of manufacturing systems from traceability data for performance evaluation and material flow simulation

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Procedia CIRP 2021年 104卷 20-25页

作者： Heiner Reinhardt Marc Münnich Bastian Prell Roman Arnold Fabian Krippner Marek Weber Frank Seifert Matthias Putz Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Chemnitz Germany Technical University of Applied Science Wildau Hochschulring 1 15745 Wildau Germany Volkswagen Sachsen GmbH Motorenwerk Chemnitz Kauffahrtei 47 09120 Chemnitz Germany Chemnitz University of Technology Straße der Nationen 62 09111 Chemnitz Germany

The operation of manufacturing systems is increasingly accompanied by data-driven continuous improvement processes and product traceability is required. Commonly, radio-frequency identification (RFID) technology is applied to track the flow of a uniquely-identifiable workpiece along various stations or waypoints within a factory. Based on an automotive use case, this paper describes how to analyze the resulting traceability data in order to identify several properties of a manufacturing system. The acquired knowledge can support performance evaluation and facilitate model building for material flow simulation as a foundation for digital twins and cyber-physical production systems.

关键词： Knowledge management Algorithm Analysis Condition monitoring Manufacturing system Complexity Man-machine system Pattern recognition

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Comparison of abrasive water jet technologies in terms of performance and kerf geometry accuracy for cutting ceramics

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International Journal of Sustainable Manufacturing 2020年第2-4期4卷 201-215页

作者： Morczinek, Florian Putz, Matthias Dix, Martin Chemnitz University of Technology Reichenhainer Straße 70 Chemnitz09126 Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany

Hard machining of brittle materials such as ceramics is a process-oriented challenge. For the machining of such materials, abrasive water jet cutting is an appropriate alternative to the commonly used diamond grinding and laser cutting processes. In abrasive water jet machining the injection technology is currently used almost exclusively. Due to the realisation of the suspension jet technology a higher cutting performance can be achieved. In this article, the known injection technology and the suspension technology are compared. To do so, the influences on the quality were examined for trimming technical ceramics. The investigation illustrates that suspension technology trims with a higher accuracy than injection technology in matters of kerf geometry but with a lower material removal rate. © 2020 Inderscience Enterprises Ltd.

关键词： Jets

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Development and Validation of Bone Models using Structural Dynamic Measurement Methods

Development and Validation of Bone Models using Structural D...

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作者： Neupetsch, Constanze Hensel, Eric Werner, Michael Meißner, Sven Troge, Jan Drossel, Welf-Guntram Rotsch, Christian Chemnitz University of Technology Professorship for Adaptronics and Lightweight Design in Production Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz/Dresden Germany

Vibration measurement and signal analysis methods are common to evaluate the functionality and characteristics of technical components in different industrial and scientific areas. Modal analysis for example is a standard method to characterize the dynamic behavior of a structure and enables the development of validated bone models. The state of the art of analyzing bone structures does not include the modal damping, although it has a significant influence on the dynamic characteristics. Within the presented investigations, the modal analyses have been performed contactless with respect to excitation and response acquisition, which implies that there are no influences of shakers or sensor couplings. Therefore, an automatic impulse hammer and a 3D Scanning Laser Doppler Vibrometer were used for excitation and response detection. Various supports of the test specimens, surface pretreatments, excitation points and excitation impulses were examined to optimize the measurement setup and process. Experimental modal analysis data were analyzed by curve fitting methods to determine the modal parameters. To evaluate different structures and effects of damping, 3D printed artificial bones and animal in vitro bones were used to perform the measurements. To produce the cortical layer of the artificial bone models, volume models were generated based on medical image data and printed by polyamide-based selective laser sintering. The cancellous bone was represented by different foam fillings for the artificial bones. Thereby, the variation of the porosity was achieved by using different mixing ratios of polyurethane foam and hardener. Furthermore, the modal damping parameters were determined from the measurement of animal bones. The measurement time was optimized during the practical implementation of the parameter determination to minimize the influence of drying and decomposition processes on the measurement results. © 2019 by Walter de Gruyter Berlin/Boston.

关键词： Structural dynamics

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Linked Data Architecture for Assistance and Traceability in Smart Manufacturing

Linked Data Architecture for Assistance and Traceability in ...

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9th EASN International Conference on Innovation in Aviation and Space, EASN 2019

作者： Friedemann, Marko Wenzel, Ken Singer, Adrian 1Fraunhofer-Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany

Traceability systems and digital assistance solutions are becoming increasingly vital parts of modern manufacturing environments. They help tracking quality-related information throughout the production process and support workers and maintenance personnel to cope with the increasing complexity of manufacturing technologies. In order to support these use cases, the integration of information from different data sources is required to create the necessary insights into processes, equipment and production quality. Common challenges for such integration scenarios are the various data formats, encodings and software interfaces that are involved in the acquisition, transmission, management and retrieval of relevant product and process data. This paper proposes a Linked Data based system architecture for modular and decoupled assistance software. Its web-oriented approach allows to connect two usually disparate data sets: semantic descriptions of complex production systems on the one hand and high-volume and high-velocity production data on the other hand. The proposed concept is illustrated with a typical example from the manufacturing domain. The described End-of-Line quality assessment on forming machines is used for traceability and product monitoring. © The Authors, published by EDP Sciences, 2019.

关键词： Linked data

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Influence of a Hydrostatic Pressure Shift on the Flow Stress in Sheet Metal

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Procedia Manufacturing 2020年 47卷 1245-1249页

作者： Sam Coppieters Mathias Jackel Christian Kraus Toshihiko Kuwabara Frederic Barlat KU Leuven Technology Campus Ghent Ghent Belgium Fraunhofer Institute for Machine Tools and Forming Technology IWU Dresden Germany Tokyo University of Agriculture and Technology Tokyo Japan GIFT-POSTECH Pohang Republic of Korea

The stack compression test (SCT) and the strain-rate controlled hydraulic bulge test (HBT) enable to determine the large strain flow curve of sheet metal under an identical deformation mode and balanced biaxial tension. This equivalence should lead to identical flow behavior if plastic yielding is independent of the hydrostatic stress. However, a discrepancy is observed in the flow curves of DP600 steel sheet determined by the SCT and the HBT. In order to avoid uncertainty with respect to dissimilar test conditions, the average strain-rate in both material tests is carefully controlled. Additionally, evidence is provided that friction can be sufficiently minimized yielding a homogeneous SCT up to a true plastic strain of 0.3. Assuming reliable experimental data, the hypothesis that the hydrostatic pressure shift between the stress states in the SCT and the HBT causes the observed difference in flow behavior is scrutinized. Theoretical considerations regarding the effect of a superimposed hydrostatic pressure (i.e. putting a material under a pressure environment for a certain stress state) on the flow stress, as suggested by Spitzig et al. [1] and Spitzig and Richmond [2], are used to understand the effect of a pressure shift between two stress states on the flow stress. Finally, the theoretical considerations are experimentally validated using the discrepancy in flow behavior of DP600 measured by the SCT and the HBT.

关键词： sheet metal stack compression test hydraulic bulge test pressure dependency

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Working Gap Analysis in Electrochemical Precision Machining of External Geometries with Ring Cathodes

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Procedia CIRP 2020年 95卷 662-667页

作者： Ingo Schaarschmidt Matthias Hackert-Oschätzchen Gunnar Meichsner Philipp Steinert Mike Zinecker Andreas Schubert Professorship Micromanufacturing Technology Chemnitz University of Technology 09107 Chemnitz Germany Chair of Manufacturing Technology with Focus Machining Otto von Guericke University Magdeburg 39106 Magdeburg Germany Fraunhofer Institute for Machine Tools and Forming Technology 09126 Chemnitz Germany

Pulsed electrochemical machining (PECM) with oscillating cathode is a non-conventional manufacturing technology to machine complex precision geometries independent from the mechanical properties of the workpiece material. PECM with oscillating cathode is an advanced development of conventional ECM by applying a pulsed electric current in conjunction with an oscillating movement of the cathode. Result is electrochemical precision machining with a more stable process combined with better accuracy and quality. This work focuses on the analysis of the resulting side working gap in electrochemical precision machining of external geometries by applying PECM. Therefore, the height of a ring cathode was varied to adjust the cathode inner surface. The resulting side working gap was studied through multiscale multiphysics simulation applying COMSOL Multiphysics as well as experiments applying a PEMCenter 8000. As main result, the increase of the resulting side working gap as consequence of an increasing cathode inner surface will be analysed in detail.

关键词： Pulsed electrochemical machining (PECM) Side working gap Multiscale multiphysics modelling

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The dynamics of a driven harmonic oscillator coupled to pairwise interacting Ising spins in random fields

arXiv

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arXiv 2020年

作者： Zech, Paul Otto, Andreas Radons, Günter Institute of Physics Chemnitz University of Technology Chemnitz09107 Germany Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz09126 Germany Institute of Mechatronics Chemnitz09126 Germany

In general we are interested in dynamical systems coupled to complex hysteresis. Therefore as a first step we investigated recently the dynamics of a periodically driven damped harmonic oscillator coupled to independent Ising spins in a random field. Although such a system does not produce hysteresis, we showed how to characterize the dynamics of such a piecewise-smooth system, especially in the case of a large number of spins [P. Zech, A. Otto, and G. Radons, Phys. Rev. E 101, 042217 (2020)]. In this paper we extend our model to spin dimers, thus pairwise interacting spins. We show in which cases two interacting spins can show elementary hysteresis and we give a connection to the Preisach model, which allows us to consider an infinite number of spin-pairs. This thermodynamic limit leads us to a dynamical system with an additional hysteretic force in the form of a generalized play operator. By using methods from general chaos theory, piecewise-smooth system theory and statistics we investigate the chaotic behavior of the dynamical system for a few spins and also in case of a larger number of spins by calculating bifurcation diagrams, Lyapunov exponents, fractal dimensions and self-averaging properties. We find that the fractal dimensions and the magnetization are in general not self-averaging quantities. We show, how the dynamical properties of the piecewise-smooth system for a large number of spins differs from the system in its thermodynamic limit. Copyright © 2020, The Authors. All rights reserved.

关键词： Hysteresis

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