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

作者： Schmidt, Torsten Schneider, Jörg Edelmann, Jan Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany

ISBN: (纸本)9780995775176

Extensions of functional ranges and increases in efficiency are among the constant companions in automotive engineering as well as in machine tool industry. In most cases, increased performance requirements meet lower or constant component dimensions, whereby the functional surfaces are exposed to higher loads. These are often components subject to high tribological stress, such as friction bearings or cylinder liners. Against this background, these surfaces are often functionalized by coatings or microstructures in order to meet the increased requirements. For surface micro structuring, a number of processes are known which differ in their suitability for specific applications and series production. Structure rolling offers great potential for the structuring of rotationally symmetric components. With this process the positive structure of the embossing roller is replicated onto the workpiece surface under a defined contact force. This comparatively simple method of structure generation enables a fast and flexible process for transferring different structural geometries to extensive component surfaces. The publication focuses on structure rolling as efficient manufacturing technology. Within the scope of several research projects, various tool concepts have been implemented and advanced, whereby the current tool design is presented and discussed. In addition, the dimensioning and production of the positive structure on the embossing roller by means of laser structuring is described. The potentials of the process are shown by means of an application-oriented example. Copyright © Proceedings of the 20th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2020. All rights reserved.

关键词： Tribology

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Vacuum gripper without central compressed air supply

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Procedia CIRP 2021年 97卷 76-80页

作者： Robert Schaffrath Erik Jäger Georg Winkler Jan Doant Marcel Todtermuschke Fraunhofer Institute for Machine Tools and Forming Technology IWU 09126 Chemnitz Germany

Compressed air operated industrial equipment has been always an important part of car body production. Advantages of compressed air powered tools are their robust construction, low-cost manufacturing as well as high performances especially forces at a minimum of construction size. Disadvantages are high operating costs, due to pressure losses in case of leakage, high installation costs and intricate cabling especially at highly flexible manufacturing systems. As a result, many automobile manufacturers aiming for a reduction of air powered production tools or even air free automobile manufacturing systems. Against this background a new concept of a vacuum grippers will be presented, which does not need central compressed air supply. Results of the development of suction cups will be shown, which are based on mechanical air displacement inspired by artificial muscles. Furthermore, a control of clusters of new suction cups with artificial intelligence is given.

关键词： Automotive Body shop End of arm tooling Gripper Vacuum Sucktion cups Compressed air supply

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Target Costing as an Approach to reduce Costs in closed-loop Agriculture Systems - Application for the Cultivation of Algae in Photobioreactors

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Procedia CIRP 2023年 116卷 372-377页

作者： Maximilian Stange Marc Tieding Gordon Brinitzer Steffen Ihlenfeldt Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Strasse 88 09126 Chemnitz Germany Fraunhofer Institute for Interfacial Engineering and Biotechnology IGB Nobelstrasse 12 70569 Stuttgart Germany Institute of Mechatronic Engineering Technische Universität Dresden 01069 Dresden Germany

The rapidly growing world population, the consequences of climate change and conventional agriculture as well as the limited resources of our planet threaten the food supply of humanity, especially with vital proteins. Therefore, innovation of agricultural systems is crucial for global food security and sustainable development. One proposed system is the cultivation of algae in artificially illuminated photobioreactors, which is a promising technology to limit land and water use. To achieve a competitive position between other agricultural systems and to reduce costs in a systematic and proactive approach, we suggest using Target Costing (TC) at an early stage of development. The paper aims to provide an overview of the state of the art in TC of agricultural systems. The authors identify a suitable approach for the economic evaluation of algae cultivation in bioreactors and adapt it specifically for the extraction of proteins. Based on this, different scenarios are discussed how a cost reduction of the existing systems can be achieved. The focus is on the reduction of energy costs, a suitable site selection and the use of side streams and products.

关键词： Sustainable agriculture Energy costs Target costing Algae

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Data Acquisition Framework for spatio-temporal analysis of path-based welding applications 57

Data Acquisition Framework for spatio-temporal analysis of p...

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18th IFAC Workshop on Time Delay Systems, TDS 2024

作者： Safronov, Georgij Theisinger, Heiko Sahlbach, Vasco Braun, Christoph Molzer, Andreas Thies, Anabelle Schuba, Christian Shirazi, Majid Reindl, Thomas Hänel, Albrecht Engelhardt, Philipp Ihlenfeldt, Steffen Mayr, Peter BMW AG Petuelring 130 München80788 Germany Technical University of Munich Materials Engineering of Additive Manufacturing Freisinger Landstraße 52 Garching bei München85748 Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Nöthnitzer Straße 44 Dresden01187 Germany Nebumind GmbH Willy-Messerschmitt-Straße 1 Taufkirchen82024 Germany

The use of digital technologies in industrial manufacturing reduces operational costs and improves production quality. The "Framework for Spatiotemporal Production Data Acquisition" (PathSense) aims to improve access and usability of production data by applying a common data ecosystem. Through integrating operational technology (OT) and information technology (IT), PathSense supports decision-making and process optimization. The framework uses the concept of digital shadows to collect critical information from sensors within the continuous manufacturing processes, e.g., welding or gluing lines. Spatial and temporal digital shadows are developed in accordance with human spatial cognition to support sophisticated-yet intuitive-human-computer interactions without the need for advanced data science skills. The backbone of the framework consists of robust data pipelines with a setup incorporating modern IT protocols, such as OPC UA and MQTT, to support the efficient acquisition and management of data. The paper addresses the challenges associated with the combination of IT and OT in cyber-physical systems, stressing modern complex data-intensive manufacturing as one exemplary domain to be tackled by scalable and secure data architectures. The paper identifies two major future directions: refining data integration processes and embedding advanced machine learning algorithms to enable automated data analysis and improve process quality monitoring. In summary, PathSense proposes a data-driven approach for quality inspection in manufacturing, which may eventually enhance industry practices and move towards data-driven decisions and increased operational flexibility. © 2024 The Authors.

关键词： Spatio-temporal data

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Mould-integrated mechatronic fixture for error compensation in injection overmoulding of optoelectronic devices 20

Mould-integrated mechatronic fixture for error compensation ...

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

作者： Rentzsch, Hendrik Perz, Stephan Schwarze, Martin Fraunhofer Institut for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany

ISBN: (纸本)9780995775176

Optoelectronic devices consist of electrical and optical components that are usually manufactured separately and assembled subsequently. To further enhance functional quality and at the same time shorten the production process, a new approach combines both steps by over-moulding the electric components with the lens material using injection moulding. During this process, aligning the electric components (e.g. LEDs) towards the lens geometry is a critical factor allowing for only very small tolerances. The accuracy of positioning the functional components on the printed circuit board (PCB) often does not fulfil the requested demands so that there is a need for compensating misalignment errors. For that purpose, a mould-integrated mechatronic fixture was developed, allowing for measurement-based alignment of optoelectronic components towards lens geometries within the injection-moulding tool. Principle concepts were derived incorporating functional requirements as well as boundary conditions for mould integration, resulting in a 3-DOF mechatronic fixture based on a compliant mechanism with piezo actuators. Model-based dimensioning and design of the prioritized principle as well as capabilities of the developed system will be discussed within the paper. Copyright © Proceedings of the 20th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2020. All rights reserved.

关键词： Injection molding

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In-process evaluation of the grinding process using a new Barkhausen noise method

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Procedia CIRP 2021年 99卷 202-207页

作者： Maximilian Rößler Matthias Putz Carsten Hochmuth Jens Gentzen Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Strasse 88 09126 Chemnitz Germany

While the achievement of size and form tolerances is already state of the art for grinding, there are hardly any industrial solutions to identify thermo-mechanical process loads such as grinding burn. A system was developed, presented, and tested, which allows for the first time the in-process measurement of Barkhausen noise to indicate changes of the boundary zone’s state using a novel kind of sensor. The system enables tactile and non-contact measurement at sampling rates of up to 10 ms. During investigations on hardened shafts of 100Cr6, relevant influences on the in-process Barkhausen noise were identified and evaluated. Furthermore, cause-effect relationships between microstructural effects and the Barkhausen noise were detected.

关键词： Grinding In-process measurement Barkhausen noise

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Vacuum gripper without central compressed air supply 8

Vacuum gripper without central compressed air supply

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8th CIRP Conference of Assembly technology and Systems, CATS 2020

作者： Schaffrath, Robert Jäger, Erik Winkler, Georg Doant, Jan Todtermuschke, Marcel Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz09126 Germany

关键词： Compressed air

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Towards the forming of concentrated Windings with trapezoidal Cross Sections for Increasing the Slot Filling Factor

Towards the Forming of concentrated Windings with trapezoida...

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International Electric Drives Production Conference (EDPC)

作者： Mirko Bach Maik Linnemann Markus Bergmann Verena Psyk Verena Kräusel Niclas Pohl Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz Germany

ISBN: (纸本)9781665418102

The steadily growing use of industrial electric motors worldwide, combined with the need for improved efficiency, require advanced technologies that are beneficial with regard to resource efficiency and productivity. One possibility for saving raw materials is to reduce the size and weight of motors while maintaining the same performance. This can be achieved through an increase of the so-called slot filling factor, which has substantial influence on the torque generation in the electric machine. One way of increasing the slot filling factor is to shape the respective conductors in such a way that the cross sections correspond to their position. The focus of this paper lies on the description of interactions in the forming process of tooth coils with trapezoidal cross section geometry of the individual turns. In particular, the shaping of the coil heads of coils produced by sequential forming and subsequent bending is characterized via FEM forming simulation. Furthermore, the contribution presents a possibility for manufacturing coils of different geometries at high output rate by using flexible forming operations. Compared to manufacturing process chains suggested earlier, this approach allows considerable shortening and optimization of the process chain.

关键词： Coils Geometry Torque Shape Windings Wires Bending

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Developments in Powder Mixed EDM and its perspective Application for targeted Surface Modification

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Procedia CIRP 2022年 113卷 100-119页

作者： Andreas Schubert Viet D. Bui Ingo Schaarschmidt Thomas Berger André Martin Chemnitz University of Technology Professorship of Micromanufacturing Technology Reichenhainer Strasse 70 09107 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Str. 88 09126 Chemnitz Germany

Although widely studied over the few decades, there are conflicting theories on the discharge mechanisms of powder mixed electrical discharge machining (PMEDM). Additionally, the dielectric flow plays a vital role in the distribution of powder particles in the machining gap, which significantly affects the powder deposition to the modified surface. In this paper, the literature on PMEDM surface modification is thoroughly reported. The conflicting mechanisms and the effects of PMEDM main machining conditions, such as powder and electrical parameters on improving mechanical and antibacterial properties as well as biocompatibility of the surface, have been discussed. To verify the separation mechanism of the discharge in PMEDM, single discharge investigations have been performed when silver nano-powder is mixed into the hydrocarbon-based dielectric fluid to modify Ti6Al4V surfaces. Surface topography, chemical composition as well as the deposited silver content and distribution over the crater surface when using positive and negative polarities are analyzed and discussed. Current waveforms of PMEDM and EDM without powder at varying discharge energies as well as with and without ultrasonic vibration assistance are recorded and analyzed. For the transfer of fundamental results to a perspective application, CFD simulation is used to calculate the flow field of the dielectric fluid and analyze the velocity and distribution of the nano-powder within the working gap of a setup with internal flushing. The results show that PMEDM is a potential technology for machining medical devices with simultaneous antibacterial surface modification.

关键词： Powder mixed EDM Surface modification Single discharge CFD simulation Antibacterial

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Toward an Efficient Industrial Implementation of W-temper forming for 7xxx Series Al Alloys 13th

Toward an Efficient Industrial Implementation of W-temper Fo...

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13th International Conference on the technology of Plasticity, ICTP 2021

作者： Trân, Ricardo Kertsch, Lukas Marx, Sebastian Hebbar, Shreyas Psyk, Verena Butz, Alexander Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany Fraunhofer Institute for Mechanics of Materials IWM Wöhlerstraße 11 Freiburg79108 Germany

ISBN: (纸本)9783030753801

Manufacturing technologies for parts made from ultra-high-strength 7xxx series aluminum sheet material have been the focus of research in recent years. A promising approach is W-temper forming, where sheet material is cold formed after heat treatment. Conventional heat treatment routes are very time-consuming and inefficient. In this study, a new more efficient and industry-orientated transfer tool concept has been developed. Heating and cooling of the sheets take place in separate contact tempering stages, which allow superior heating and cooling rates in comparison to conventional methods. To analyze the influences of temperature rates and deformation on microstructure and mechanical behavior, thermo-mechanical experiments in a Gleeble simulator were carried out. The results prove the great potential of the transfer tool concept with inline heat treatment for series production. The process-dependent mechanical properties determine a suitable process window for the industrial application of the W-temper forming of the analyzed alloys. © 2021, The Minerals, Metals & Materials Society.

关键词： Industrial research

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