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IEEE International Workshop on Robot and Human Communication (ROMAN)

作者： Jayanto Halim Paul Eichler Sebastian Krusche Mohamad Bdiwi Steffen Ihlenfeldt Group Collaborative Robot Systems Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz Germany Departement of Production System and Factory Automation Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz Germany

The programming of industrial robots necessitates specialized expertise and significant time and effort, particularly for small batch sizes. However, with the increasing demand for agility in production, the solutions used for robot programming have evolved significantly. Intuitive robot programming systems based on diverse concepts have been introduced to facilitate rapid deployment of robot systems. One such approved concept is no-code robot programming with finger-based gesture. In this concept, non-expert users draw a robot path via finger movement, which is subsequently translated into robot programming language to facilitate the corresponding movement. A significant challenge associated with this method is the valid replication of the corresponding robot Tool Center Point (TCP) orientation. Reachability issues, non-compliant hand contortions, and sensor occlusions make it difficult to directly derive the robot’s TCP orientation from the finger’s orientation. This work presents two novel approaches for estimating robot orientation using numerical analysis and point cloud information for finger-based robot programming without requiring prior knowledge. The first approach utilizes numerical analysis to estimate the relative robot orientation based on the geometry of the trajectory. In contrast, the second approach uses point-cloud to derive the robot orientation based on the object contour. Input shaping algorithms are employed and evaluated to reduce the divergence in the orientation estimations. Experiments demonstrate the effectiveness of the proposed approach utilizing a low-cost camera as a cost-efficient alternative to existing no-code programming strategies, potentially accelerating the real-world deployment of robotic applications in industrial environments.

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Hem flange bonding: a challenging joining process in automotive body construction 1

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International Congress on Vehicles of Tomorrow, 2019

作者： Jesche, Fred Menzel, Sandra Fraunhofer Institute for Machine Tools and Forming Technology Germany

ISBN: (数字)9783658297015

ISBN: (纸本)9783658297008

Hem flange bonding is widely used in the automotive body shop, especially in the manufacturing of hang-on parts such as doors, hoods and tailgates. By combining the hemming and adhesive bonding processes, components can be joined by material fit and form fit. In this way, new properties are integrated into the assembly, such as higher load-bearing capacity and improved resistance to corrosion. However, both processes also influence each other in the joining pro cess and in the further production process chain, which makes the hem flange bonding process really challenging. The paper gives an overview of the state of the art. For this purpose, based on the structure of the bonded hem flange, the requirements and criteria for quality evaluation are described. The common hemming technologies and adhesive ap plication methods as well as the industrial process chain, in which the hemming operation takes place, are presented. Essential correlations between component/process parameters and the quality in the hem flange bonded joint are discussed. fraunhofer IWU has been researching various aspects of hemming and hem flange bonding for many years and supports the industry in the analysis of assemblies and processes. Our aim is to systematically increase the quality and appearance of hem flange bonded assemblies and the robustness of hem flange bonding processes. Two current examples from research practice will provide a brief insight: Hemming adhesive dimensioning: Adhesive application plays a decisive, quality-defining role in the hemming process. At every point of the circumferential hem seam of an assembly, the adhesive quantity and adhesive position have to match the existing geometry precisely. The paper shows how the adhesive dimensioning can be carried out. Current test results on the effect of glass beads in the adhesive layer to ensure a defined adhesive layer thickness are also discussed. Hem testing: A testing device was developed at fraunhofer IWU to carry out qu

关键词： Joining

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Identifying efficiency and flexibility measures for energy-oriented factory management 29

Identifying efficiency and flexibility measures for energy-o...

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29th CIRP Conference on Life Cycle Engineering, LCE 2022

作者： Münnich, Marc Rein, David Reinhardt, Heiner Ihlenfeldt, Steffen Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Institute of Mechatronic Engineering Technische Universität Dresden Dresden Germany

Recent efforts in climate politics increase the ecological pressure of manufacturing companies in terms of intelligent and efficient usage of resources during operations. Rising energy prices lead to further economic pressure. Especially companies with a high share of energy cost on total costs are forced to continuously improve processes regarding the energy usage. Existing guidelines and methodologies are usually concerned with either of the two dimensions energy efficiency (EnEff), or energy flexibility (EnFlex). While EnEff addresses the reduction of the energy consumption for a defined manufacturing output, EnFlex addresses the advantageous shift, increase, and decrease of energy demand. Although both dimensions address the total reduction of cost, they are usually considered separately in literature. Here, we examine both dimensions while focusing on the provision and usage of electric energy due to its manifold conversion and usability opportunities in factory processes. Therefore, we developed an overview of measures of both dimensions as well as their application characteristics within the factory. To identify EnEff and EnFlex measures, a practicable methodology is introduced. This aims to enable especially companies with few experiences in EnEff and EnFlex measure application to improve energy aware operations. We illustrate our examination by means of an industrial application example. © 2022 Elsevier B.V.. All rights reserved.

关键词： Energy efficiency

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Software support for the development of flexible plant technology in highly automated and high-rate body-in-white production

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Procedia CIRP 2023年 118卷 918-923页

作者： Rayk Fritzsche Antje Ahrens Head of group Adaptable assembly systems at Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz 09126 Germany Scientific employee at Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz 09126 Germany

The remarkly high degree of automation within body-in-white production, with high quality requirements and the increasing demand for product-flexible production form a conflict of objectives. The most significant challenges in making the operating resources of body-in-white manufacturing more flexible arise with the the development of model-flexible geometry fixtures, with the geometric and qualitative requirements being most significant in the production of vehicle doors. For the efficient design of model-flexible fixtures specific methods and software tools for part alignment, clamp point grouping and fixture design have been developed.

关键词： Body in white Automated fixture design Methodical synthesis Analysis software Optimization Product flexibility

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Automated shop floor reconfiguration and process integration: towards product driven manufacturing systems

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Procedia CIRP 2025年 134卷 49-54页

作者： Marcel Albus Florian Duewel Katharina Barbu Jan Eric Huebner Christian Keilig Christian Gollee Fraunhofer Institute for Manufacturing Engineering and Automation IPA Nobelstraße 12 70569 Stuttgart Germany Fraunhofer Institute of Optronics System Technologies and Image Exploitation IOSB Fraunhoferstraße 1 76131 Karlsruhe Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Pforzheimer Straße 7a 01189 Dresden Germany

Flexible manufacturing systems are crucial in today’s rapidly evolving manufacturing landscape, characterized by supply chain disruptions, shorter product lifecycles, and diverse customer demands. Introducing new products necessitates extensive planning efforts, including price estimates, production cost evaluation and ensuring resilience. This paper presents a comprehensive approach through an integrated digital toolchain for reconfiguration planning in manufacturing companies, from production feasibility to shop floor execution. The solution leverages data space connectors to facilitate information exchange between customers and Modular Production (MP) environments. Key features include the STEP decomposition, resource capability matching, automated assembly line reconfiguration and balancing, as well as the automated integration and execution of manufacturing processes on the shop floor. This toolchain aims to enable automated data exchange, coordinated order planning, and efficient shop floor operations, allowing manufacturers to adapt to market changes while maintaining cost-effectiveness and resilience.

关键词： Shop Floor Reconfiguration Automated Process Execution Assembly Line Balancing

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Definition and Description of Matrix Production Systems 57

Definition and Description of Matrix Production Systems

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18th IFAC Workshop on Time Delay Systems, TDS 2024

作者： Ranke, Daniel Trierweiler, Michael Berkhan, Patricia Münnich, Marc Bauernhansl, Thomas Fraunhofer Institute for Manufacturing Engineering and Automation IPA Nobelstr. 12 Stuttgart70569 Germany Institute of Industrial Manufacturing and Management IFF Nobelstr. 12 Stuttgart70569 Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany

The industry's use of adaptable production systems, such as matrix production, is increasing. However, these systems vary in their specific details. The lack of a unified definition, delimitation, and description hinders comparability and the transfer of lessons learned between different systems. This paper aims to propose a comprehensive definition of matrix production and differentiation between different implementation forms. To achieve this, the paper first examines existing approaches to define and describe production systems and their manifestations. Various frameworks and models have been proposed in the literature, but they often focus on specific aspects of production systems, neglecting the complexity of matrix production. The paper identifies common elements and challenges in defining and describing production systems by analyzing these approaches. A second investigation analyzes various existing descriptions of matrix production from the scientific literature. While some definitions focus on the organizational structure, others emphasize operational aspects. By synthesizing these definitions, the paper proposes a comprehensive definition of matrix production encompassing both dimensions. Furthermore, the paper includes cases of industrial implementations as a third investigation. These cases provide insights into the practical application of matrix production systems across different industries. The paper identifies common characteristics, challenges, and benefits associated with matrix production by analyzing these implementation examples. Finally, all three investigations are combined to create a unified definition and a complementary descriptive model. The proposed framework provides a systematic approach to define and describe matrix production systems. It allows for a better understanding and comparison of different implementations, facilitates the transfer of lessons learned, and promotes the exchange of best practices. This framework will enable r

关键词： Production efficiency

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Electrochemical material removal characteristics of a NdFeB permanent magnet 22

Electrochemical material removal characteristics of a NdFeB ...

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22nd International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2022

作者： Petzold, Tom Martin, André Schubert, Andreas Chemnitz University of Technology Institute for Machine Tools and Production Processes Professorship Micromanufacturing Technology Reichenhainer Str. 70 Chemnitz09126 Germany Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Str. 88 Chemnitz09126 Germany

ISBN: (纸本)9781998999118

Electric motors are used in various fields with an ever-increasing demand. In the electromobility sector as an example, a growth of a few hundred thousand motors per year is stated. In many cases, the rotor magnets for electric drives are produced by sintering. Special drives for two-axes positioning with precise movements require individual geometries of the rotor magnets such as spherical shapes. In this case, post-processing of the usually cylindrical or rectangular block shaped bar magnets is necessary. One common technique for post-processing is electrical discharge machining (EDM), which allows the machinability of hard or brittle materials, but also causes thermal impacts, which influence the magnetic properties of the material in a negative way. To overcome this negative effect it is necessary to re-magnetize the rotor magnets after EDM. Additional measurements of the magnetic field strength are required to ensure correct values. Electrochemical machining (ECM) represents an alternative technique for post-processing of rotor magnets, since it offers the possibility to avoid re-magnetization after the shaping process, because machining temperatures are well below the Curie temperature of most materials. In this study, ECM of a NdFeB permanent-magnetic material is presented. The experiments were carried out according to DIN-SPEC 91399. The material-specific removal characteristics indicate an active dissolution with the chosen machining parameters. Comparative measurements of the magnetic field strength before and after ECM indicate that there is no negative influence of the removal process. The results suggest that ECM with pulsed current and oscillating tool cathode is an applicable technique for shaping rotor magnets. © European Society for Precision Engineering and Nanotechnology, Conference Proceedings - 22nd International Conference and Exhibition, EUSPEN 2022. All rights reserved.

关键词： Neodymium alloys

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Incorporating Shape Knowledge into Regression Models

arXiv

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arXiv 2024年

作者： Poursanidis, Miltiadis Link, Patrick Schmid, Jochen Teicher, Uwe Fraunhofer Institute for Industrial Mathematics ITWM Kaiserslautern67663 Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz09126 Germany

Informed learning is an emerging field in machine learning that aims to compensate for insufficient data with prior knowledge. Shape knowledge covers many types of prior knowledge concerning the relationship of a function's output with respect to input variables, for example, monotonicity, convexity, etc. This shape knowledge - when formalized into algebraic inequalities (shape constraints) - can then be incorporated into the training of regression models via a constraint problem formulation. The defined shape-constrained regression problem is, mathematically speaking, a semi-infinite program (SIP). Although off-the-shelf algorithms can be used at this point to solve the SIP, we recommend an adaptive feasible-point algorithm that guarantees optimality up to arbitrary precision and strict fulfillment of the shape constraints. We apply this semi-infinite approach for shape-constrained regression (SIASCOR) to three application examples from manufacturing and one artificial example. One application example has not been considered in a shape-constrained regression setting before, so we used a methodology (ISI) to capture the shape knowledge and define corresponding shape constraints. Finally, we compare the SIASCOR method with a purely data-driven automated machine learning method (AutoML) and another approach for shape-constrained regression (SIAMOR) that uses a different solution algorithm. © 2024, CC BY.

关键词： Contrastive Learning

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Open Source Hardware in Manufacturing – Opportunities and Challenges 9th

Open Source Hardware in Manufacturing – Opportunities and C...

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Production Processes and Product Evolution in the Age of Disruption - Proceedings of the 9th Changeable, Agile, Reconfigurable and Virtual Production Conference CARV2023 and the 11th World Mass Customization and Personalization Conference MCPC2023

作者： Stange, Maximilian Jäpel, Nicole Reichelt, Dirk Ihlenfeldt, Steffen Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Hochschule Für Technik Und Wirtschaft Dresden Dresden Germany Institute of Mechatronic Engineering Technosphere Universität Dresden Dresden Germany

ISBN: (纸本)9783031348204

Manufacturing companies are operating in an environment that is becoming steadily more challenging and uncertain. The most serious risks in developed countries increasingly concern the shortage of skilled workers, growing competition from emerging countries, and ever-shorter development cycles for products that are expected to meet a growing variety of individual customer requirements. In addition, on a macroeconomic level, labour productivity growth is declining. This is a warning sign for the overall economic outlook, which is particularly true for the European economic area. One of the reasons for this is the decreasing diffusion of innovations. A holistic approach is needed to address these challenges. One direction that has been discussed in recent years is the concept of open source hardware. This concept takes up the philosophy of open source software and aims to transfer this open and collaborative approach to physical products. The paper will present the current state of OSH, specifically focusing on its use in manufacturing companies. Based on this, opportunities and risks for the application of OSH to manufacturing companies will be derived. © 2023, The Author(s), under exclusive license to Springer Nature Switzerland AG.

关键词： Open source software

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Modeling the Impact of Laser Powder Bed Fusion on Nd-Fe-B Permanent Magnets

Modeling the Impact of Laser Powder Bed Fusion on Nd-Fe-B Pe...

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Magnetic Conference - Short Papers (INTERMAG Short Papers), IEEE International

作者： Juliane Thielsch Florian Bittner Welf-Guntram Drossel Fraunhofer Institute for Machine Tools and Forming Technology IWU Dresden Germany Institute for Machine Tools and Production Processes Chemnitz University of Technology Chemnitz Germany

Statistical modelling was successfully applied to Laser Powder Bed Fusion (LPBF) of Nd-Fe-B permanent magnets to identify the potential impact of different process parameters and their interactions on resulting magnetic properties. Process models for the magnetic properties coercivity H c , remanence J r as well as for the shape of the demagnetization curve are obtained. The model quality for H c is excellent (R 2 = 0.99). The model for J r only allows a rough statement on the impact of the LPBF process due to a weaker quality of the model (R 2 = 0.77). It will not be possible to maximize H c and J r of LPBF manufactured Nd-Fe-B magnets at the same time due to their contrary dependencies on different LPBF parameters. We have predicted an optimized parameter set with a resulting high H c of 816 kA/m and a maximized J r of 0.65 T. From these properties and the calculated shape of the demagnetization curve we predict a (BH) max of 60.77 kJ/m 3 for a magnet processed on a LPBF machine AconityMINI using MQP™-S powder.

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