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European Wind Energy Association Conference and Exhibition 2014, EWEA 2014

作者： Domínguez, Diego Pröhl, Marco De Troyer, Tim Feng, Guoying Werner, Markus Runacres, Mark Department of Engineering Technology Vrije Universiteit Brussel Brussels Belgium Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany

Vertical axis wind turbines have experienced a renewed impulse during the last few years, with important research efforts focused on them. This work is focused in the development of new blade designs capable of notably reduce their manufacturing cost and, consequently, improve global profitability. Thanks to the aerodynamic and structural analyses that have been carried out, a final blade design has been achieved. It is based on the use of hydroforming manufacturing techniques with metal sheets, creating 3 meters blades to be used in a turbine capable of produce about 1kW. First estimations show that with the positive effects of a mass use and production (economies of scale), such metal blades have a 90 % reduction potential in their production costs compared to fibre-reinforced ones for single turbines.

关键词： Turbomachine blades

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Characterisation of tool coatings for press hardening

Characterisation of tool coatings for press hardening

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6th International Conference on Tribology in Manufacturing Processes and Joining by Plastic Deformation, ICTMP 2014

作者： Müller, Roland Mosel, André Fraunhofer-Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Chemnitz Germany Chemnitz University of Technology Machine Tools and Forming Technology Straße der Nationen 62 09107 Chemnitz Germany

ISBN: (纸本)9783038351276

Hot sheet metal forming is gaining in importance in many fields, because of its capability to produce more complex components than possible with cold forming. Hot forming is also used to influence the final material properties with the hot forming of manganese-boron steels being a good example. One of the major challenges in hot forming is the tribological conditions between the tool and sheet material at the required high temperatures. This article will discuss the influence of different tool material coatings, ranging from PVD to mechanically bonded ceramic coatings, on the tribological conditions during forming. It will also shed light on how these coatings influence the heat transfer between the component´s material and the tool material. © (2014) Trans Tech Publications, Switzerland.

关键词： Heat transfer

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Fabrication Method for Series Production of Sheet Metal Parts with Integrated Piezoelectric Transducers

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Procedia technology 2014年 15卷 494-502页

作者： Matthias Nestler Welf-Guntram Drossel Sebastian Hensel Roland Müller Fraunhofer Institute for Machine Tools and Forming Technology IWU 09126 Chemnitz Germany

The paper presents a high volume compatible production method for the fabrication of sheet metal parts with integrated piezoelectric transducers. The functionality of the integrated piezomodule is shown on a wing assembly, consisting of two sheet metals shaped with roll bending and three point bending operations. The stimulation of the structure is performed with a shaker, the reduction of the acoustic noise was realized with the integrated piezomodule and monitored with vibrometer measurements. Impedance measurements were performed for health monitoring of the multiple bolted joint. Furthermore, a simulation of the structure was used for the determination of resonance frequencies. The results show a good correlation between experiment and simulation.

关键词： piezo-metal-compound adhesive MFC piecoelectic transducer vibration compensation health monitoring

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Tempered forming of Magnesium Alloys Using the Example of Roll forming

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Materials Today: Proceedings 2015年 2卷 S60-S66页

作者： K. Richter R. Haase F. Schieck D. Landgrebe Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 09126 Chemnitz Germany

The sheet metal forming of magnesium alloys requires an adaption of the forming processes utilized. Due to limited formability at room temperature, heating above a temperature of 200 to 225 °C is necessary in order to activate additional gliding planes. By the example of roll forming, the temperature regime and implementation of heating equipment into the forming process is illustrated. On account of the progressive feed of sheet material necessary for roll forming, a transverse flux induction heating was used in the experimental setup. Results of experimental design and experimentation with AZ31 alloy will be presented in this paper.

关键词： Magnesium Alloys AZ31 Roll forming Inductive Heating

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Integrated Sensors System for Human Safety during Cooperating with Industrial Robots for Handing-over and Assembling Tasks

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Procedia CIRP 2014年 23卷 65-70页

作者： Mohamad Bdiwi Department of Joinging and Assembling Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany

Human safety is the main concern which prevents performing some tasks requiring physical interaction between human and robot. Therefore, the safety concept was previously based on eliminating contact between human and robots. This paper will propose a robot system which integrates different types of sensors to ensure human safety during the physical human robot interaction. The implemented sensors are vision, force and sensitive skin. Using vision system, the robot will be able to detect and recognize human face, loadfree human hand and any object carried by human hand (active hand). Furthermore, it will help the robot to define in which directions the force should be applied and what are the dangerous directions for human safety. The force sensor will help the robot to react to the motion of the human hand during the handing-over or assembling task. The sensitive skin will prevent any collision between the human and the robot arm. The proposed system is supported with a voice system for informing human about the actual status of the system.

关键词： Human-robot interaction Human-safety visual servoing force control handing-over and assembly tasks

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High Performance of Machining Processes by Applying Adaptronic Systems

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Procedia CIRP 2014年 14卷 500-505页

作者： W.-G. Drossel A. Bucht C. Hochmuth A. Schubert A. Stoll J. Schneider R. Schneider Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 09126 Chemnitz Germany Technische Universität Chemnitz Institute for Machine Tools and Production Processes Reichenhainer Str.70 09126 Chemnitz Germany

Manufacturing processes are constantly facing the demand for higher efficiency regarding time, costs and resource consumption. In addition, challenges arise from the use of new materials and stricter requirements concerning the efficiency of the final product in use. Besides the economic perspective of realizing a highly efficient production and sustainable products, a new level of standards is set by politics and industry. To meet these demands, it may no longer suffice to improve processes by optimizing process parameters. Instead, advanced machine and tool concepts will be necessary and therefore have to be developed. An innovative approach to enhance the cutting process is the integration of adaptronic systems. This integration can happen at different levels, from no close loop control to using additional feed drives and in the cutting tool or in the machine. The paper presents examples from research at fraunhofer iwu for the application of adaptronic systems in machining processes, such as ultrasonic assisted machining, adaptronic form honing and adaptive spindle support for precision finishing of cylinder bores. Properties of the actuators and the adaptronic systems are described and the effects on both, the efficiency of the machining process and the final product performance, are discussed.

关键词： Adaptronic form honing Adaptive spindle support Ultrasonic assisted machining Hybrid processes

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Integration of vision/force robot control for transporting different shaped/colored objects from moving circular conveyor

Integration of vision/force robot control for transporting d...

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International Workshop on Robot Sensing (ROSE)

作者： Michael Jokesch Mohamad Bdiwi Jozef Suchý Robot Systems Chemnitz University of Technology Chemnitz Germany Tools and Forming Technology IWU Fraunhofer Institute for Machine Chemnitz Germany Technische Universitat Chemnitz Chemnitz Sachsen DE

This paper will propose algorithms for transporting different objects from moving circular conveyor with the help of vision/force robot control. Poses and speeds of the objects are calculated from sequential images captured by 3D-camera mounted on the hand of the robot. In the conveyor there are 4 slots which contain four differently formed and coloured objects. The cross sections of these objects are the square, the rectangle, the triangle and the circle. The required object will be segmented and then recognized with the help of fast image processing algorithm depending on its colour and shape. Furthermore, this paper will improve algorithm for grasping and pulling-out the required object from slot with tight clearance. For this task two different kinds of simple force control have been developed. The objects will be grasped by a 6-DoF robot with a primitive two-finger-gripper as end-effector. In the first experiment the proposed system will follow the required object until the movement of the conveyor stops. After that it will start to pull-out the object. In more complicated case, the robot will pull-out the object while the conveyor is moving. In other words, the movement of the robot will be synchronized with the movement of the object and it should grasp it at a convenient time and pose without any prior knowledge about its velocity. This paper will be supported with real experiments presenting promising results which illustrate the capability of grasping a stuck moving object with the help of vision/force robot control.

关键词： Force Grippers Trajectory Grasping Robot kinematics Cameras

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Closed loop control for shape memory alloy actuators

Closed loop control for shape memory alloy actuators

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IEEE SSD International Multi-Conference on Systems, Signals and Devices

作者： Christian Auerswald Björn Senf Jan Mehner Welf-Guntram Drossel Chair of Microsystems and Precision Engineering Technische Universität Chemnitz Chemnitz Germany Adaptronics and Acoustics Fraunhofer IWU Institute for Machine Tools and Forming Technology Chemnitz Germany

This paper describes design considerations of a control circuit for adaptive hybrid structures. These consist of a fiber-reinforced lightweight structure with a thermoplastic matrix and additional shape memory alloy wires, which can be used both as actuators and sensors. In order to use their properties, a control circuit able to heat the actuator wires and to measure their electrical resistance when used as a sensor is needed. In contrast to most references using expensive lab test equipment, a small sized, stand-alone control box is presented. It combines advantages of precision linear current sources for resistance measurement with high efficiency switch-mode converters delivering the wire heating current.

关键词： Heating Electrical resistance measurement Voltage measurement Resistance Optical fiber devices Matrix converters Magnetic properties

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A Reconfigurable Tooling System for Producing Plastic Shields

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Procedia CIRP 2014年 17卷 853-858页

作者： Dominik Simon Lisa Kern Julia Wagner Gunther Reinhart Fraunhofer Institute for Machine Tools and Forming Technology (IWU) Project Group Resource-efficient Mechatronic Processing Machines Beim Glaspalast 5 86153 Augsburg Germany Technische Universität München (TUM) Institute for Machine Tools and Industrial Management (iwb) Boltzmannstrasse 15 85748 Garching Germany

State of the art for producing 3-dimensional formed plastic shields is the use of mould blocks that are milled on machining centers. This paper describes the replacement of traditional mould blocks by a novel automated reusable mould and tooling system that produces good forming results at low investment costs. The reconfigurable tooling system replaces commonly used mould blocks. Two major issues will be addressed. The first aim is to identify principles for low tooling costs, while the second focuses on the improvement of a forming process suitable for the system so that this can be used for a broad range of products.

关键词： flexible forming reconfigurable tooling system thermoforming plastic shields

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Structural Integration of PZT Fibers in Deep Drawn Sheet Metal for Material-integrated Sensing and Actuation

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Procedia technology 2014年 15卷 658-667页

作者： M. Müller B. Müller S. Hensel M. Nestler S.F. Jahn V. Wittstock A. Schubert W.-G. Drossel Professorship for Adaptronics and Lightweight Design in Production Technische Universität Chemnitz 09107 Chemnitz Germany Professorship Micromanufacturing Technology Technische Universität Chemnitz 09107 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 09126 Chemnitz Germany Professorship Machine Tools and Forming Technology Technische Universität Chemnitz 09107 Chemnitz Germany

Today, adaptive sheet metal parts are manufactured by surface bonding of sensors and actuators on shaped structural parts. This paper presents a technology for direct structural integration of lead-zirconate-titanate (PZT) fibers in flat sheet metal and subsequent shaping. Microcavities are microformed into the surface of the metal sheet in which piezoceramic fibers are inserted and joined. After that, the composite is shaped by deep drawing into a complex 3D surface. The production technology is discussed in detail with regard to the limits of each process step. Functional shaped prototypes with ten interconnected parallel piezoceramic fibers were fabricated. The function as transducer and sensor for lamb waves is demonstrated and the degradation due to the shaping is compared for different parameters of the deep drawing process. The composite shapes are cups with a double curvature radius of 100 mm and 250 mm respectively. As a result, degradation of the piezoelectric function varies as a consequence of the process parameters. In the best case, a degradation of the transducer function of 33% was shown in the experiments. The cause of the decreased performance after shaping is discussed and explained by debonding mechanisms. Results of numerical simulations show good agreement with the experimental findings of the optimum process parameters.

关键词： Functional integration direct integration piezoceramic microforming microassembly deep drawing simulation function test sensor

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