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Cause-Effect Relationships in Battery Cell Production - Data based validation of expert knowledge in electrode production

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Procedia CIRP 2023年 120卷 469-474页

作者： A. Fitzner J.-P. Abramowski A. Schmetz J. Krauß K. Borzutzki M. Eckstein K. Pouls C. Baum R.H. Schmitt A. Kampker Fraunhofer Research Institution for Battery Cell Production FFB Bergiusstr. 8 48165 Münster Germany Fraunhofer Institute for Production Technology IPT Steinbachstr. 17 Aachen 52074 Germany Laboratory for Machine Tools and Production Engineering WZL of RWTH University Campus-Boulevard 30 52074 Aachen Germany Production Engineering of E-Mobility Components PEM of RWTH University Bohr 12 52072 Aachen Germany

The advancing climate change requires a shift from conventional energy sources to renewable ones, which is accompanied by the indispensability of an efficient and sustainable storage of electrical energy. The production of lithium-ion battery cells comprises an enormous complexity, as it consists of several interlinked process steps, each with different quality requirements for the (intermediate) products and the processes itself. This complexity means that a supposedly insignificant process parameter can lead to errors and deviations in the manufactured products via complex cause-effect relationships, that are not fully known. The missing knowledge of the processes and inter-process interdependencies lead to difficulties in the setup of a suitable quality assurance in battery cell production to reduce scrap rates. Beside these potentials in planning and optimizing the process chain of the battery cell factory of tomorrow are impeded. We developed a method to build up a relevant knowledge base on cause-effect relationships for battery cell production. Expert knowledge based on experience and intuition has been collected and quantitative cause-effect relationships are established. This knowledge is used to set up the initial data acquisition, ensuring relevant data being available for analysis. Afterwards, the data analysis, that validates and extends this expert knowledge, is defined. This approach is applied to real-world use-cases including machinery and laboratory equipment in battery cell production. The electrode production is selected as the basis for validation. The found inter-relationships either validate the qualitative expert knowledge, contradict this prior knowledge or else add new insights about the battery cell electrode production process that have not been considered in the qualitative expert knowledge. Methods used include correlations and a predictive power score for non-linear interdependencies. The cause-effect relationships are constantly updat

关键词： battery cell production cause-effect relationships digital factory

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The development of a digital twin for machining processes for the application in aerospace industry 53

The development of a digital twin for machining processes fo...

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53rd CIRP Conference on Manufacturing Systems, CMS 2020

作者： Hänel, Albrecht Schnellhardt, Thorben Wenkler, Eric Nestler, Andreas Brosius, Alexander Corinth, Christian Fay, Alexander Ihlenfeldt, Steffen Institute of Manufacturing Technology Technische Universität Dresden Dresden01062 Germany Institute of Mechatronic Engineering Technische Universität Dresden Dresden01062 Germany Institute of Automation Technology Helmut Schmidt University Hamburg22043 Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Dresden01187 Germany

This paper describes a method for creating a digital twin based on planning and process data for machining processes by using the example of components in the aerospace industry. This development is based on an information model that combines the properties and relationships of relevant information and data involved in the manufacturing process. This system integrates mathematical (technical-technological) models and algorithms for the determination of process parameters as well as planning-relevant information from the machining process. The technology of the digital twin makes it possible to recognize problems directly in the machining process, e.g. deviations from the planning specifications and to derive targeted measures for quality assurance and optimization of the machining process. © 2020 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://***/licenses/by-nc-nd/4.0/) Peer-review under responsibility of the scientific committee of the 53rd CIRP Conference on Manufacturing Systems

关键词： Machining centers

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Numerically Assisted Design For Electromagnetically Driven tools

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Procedia Manufacturing 2020年 47卷 1334-1338页

作者： Maik Linnemann Christian Scheffler Verena Psyk Fraunhofer Institute for Machine Tools and Forming Technologies Reichenhainer Str. 88 09126 Chemnitz Germany

The use of high-speed forming technologies can contribute to satisfying current social and political demands on production technology such as sustainability and climate protection in manufacturing. These technologies have a very high potential for shaping complex, sharp-edged parts and constitute a key means of reducing a component’s weight. One exemplary high-speed forming technology is electromagnetic forming. It uses the energy density of pulsed magnetic fields to impose forces on electrically conductive materials, which leads to plastic deformation after exceeding the yield stress of the material. However, for very thin sheet materials this effect could result in an uncontrolled deformation of the work piece. In order to overcome this effect, the use of electromagnetically driven tools can be appropriate. An additional benefit is that this process is no longer restricted to electrically highly conductive work piece materials. In order to achieve an efficient process and high work piece quality, it is necessary to design an electromagnetically driven tool, adapted to the forming task and considering the electrical properties of the machine. For this reason, a numerically supported design strategy is presented within this paper and the challenges that arise during this process are highlighted.

关键词： electromagnetic forming high speed forming finite element method (FEM) design method

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Introduction of decision support systems for failure management in manufacturing

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Procedia CIRP 2024年 130卷 1549-1555页

作者： Linda Waldscheck Robin Günther Sebastian Beckschulte Sebastian Baumann Julian Haller Martin Wende Maximilian Dresemann Robert H. Schmitt Fraunhofer Institute for Production Technology IPT Steinbachstraße 17 52074 Aachen Germany Laboratory for Machine Tools and Production Engineering WZL of RWTH Aachen University Campus-Boulevard 30 52074 Aachen Germany DATAbility GmbH Karlsbader Straße 10 64295 Darmstadt Germany KRONE Business Center GmbH & Co. KG Heinrich-Krone Straße 10 48480 Spelle Germany

Data-driven approaches are essential for optimizing failure management in manufacturing. However, there is no systematic approach that serves as a blueprint for data-driven failure management and thus data is predominantly used for custom-tailored and standalone solutions. Identifying and integrating cross-value chain data along the product lifecycle remains challenging. This complicates constructing comprehensive failure knowledge and prioritizing quality-centered measures. This paper proposes a systematic approach to implementing data-enabled failure management within the value chain, requiring adapted organization and strategic alignment across all business levels. A guideline is presented for organizing data-enabled failure management. Firstly, an understanding of data-enabled failure management is established based on a reference structure. Secondly, structures and utilized data are analyzed. The paper examines how added value can be generated and utilized from existing information, as well as from AI-supported models, to derive optimization and failure prevention processes. Subsequently, implementation potentials and areas for improvement are identified. The focus in developing cross-value chain failure management is on achieving direct added value for the company throughout the build-up phase of establishing AI use cases. This methodology, initially developed for the commercial vehicle industry, is evaluated and refined through use cases involving field data, production process data, and configuration data. The presented results serve as a basis to further improve failure culture and understanding, as well as to introduce employee incentive programs in future research activities. This research establishes a framework for achieving a cohesive decision support system for failure management. By outlining the organizational setup, including the definition of an idealistic representation on the strategic orientation, scope of the project and a status quo analysis,

关键词： Data-driven failure management cross-value chain integration organizational alignment manufacturing optimization

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Influence of the stiffness of burnishing tools on process force and surface quality of EN AW-2007 and C45 workpieces

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Procedia Manufacturing 2020年 43卷 635-641页

作者： Rico Stöckmann Marco Posdzich Philipp Klimant Matthias Putz Chemnitz University of Technology Institute for Machine Tools and Production Processes (IWP) Reichenhainer Str. 70 09126 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology (IWU) Reichenhainer Str. 88 09126 Chemnitz Germany

Burnishing is a highly efficient surface finishing process, which is also more sustainable compared to grinding. Such processed surfaces are characterized by a low roughness and an increased hardness. In recent years, the interest in the process grew due to the steady adoption on flat and free-form surfaces. Especially the latter may benefit from a soft burnishing tool, due to the nearly constant burnishing force and therefore a less strong interaction with geometric imperfections of the free-form surface. In this paper, the influence of the burnishing tool stiffness on the surface features indent, bulge and roughness are shown. Several low and one high stiffness burnishing tool were investigated. As evaluation data, the burnishing force and the finished surface were measured. As shown in this paper, soft tools result in a constant force and can improve surface quality.

关键词： Manufacturing process Surface modification Burnishing

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Geometric empirical modelling of forces influenced by the cutting edge microgeometry in orthogonal cutting of unidirectional CFRP

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Procedia CIRP 2021年 102卷 25-30页

作者： Konstantin Sauer Alexander Nowak Joachim Regel Rafael Wertheim Martin Dix Chemnitz University of Technology Professorship Production Systems and Processes Reichenhainer Strasse 70 09126 Chemnitz Germany Chemnitz University of Technology Professorship Machine Elements and Product Development Reichenhainer Strasse 70 09126 Chemnitz Germany Fraunhofer Institue for Machine Tools and Forming Technology Reichenhainer Strasse 88 09126 Chemnitz Germany

In optimising the cutting of carbon fibre reinforced plastics (CFRP), increasing emphasis is placed on the cutting edge microgeometry. A significant challenge lies in understanding the engagement conditions between tool and workpiece, influencing tool wear mechanisms and performance. This paper aims to provide a more in-depth insight into the influence of cutting parameters on process forces when applying ideally rounded cutting edges in orthogonal cutting. A geometric empirical process model is developed for calculating the cutting force and the passive force, considering the cutting edge radius, the uncut chip thickness, and the fibre cutting angle. As a result, the minimum uncut chip thickness was determined, and process forces were calculated.

关键词： composite cutting edge modelling orthogonal cutting

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Improving dynamic process stability in finishing of thin-walled workpieces by optimal selection of stock shape

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Procedia CIRP 2024年 126卷 372-377页

作者： Pascal Kienast L. Taner Tunç Recep Koca Ozan Ölgü Philipp Ganser Thomas Bergs Fraunhofer Institute for Production Technology IPT Steinbachstr. 17 52074 Aachen Germany Manufacturing Research Lab Faculty of Engineering and Natural Sciences Sabanci University 34956 Istanbul Türkiye TUSAS Engine Industries Inc. (TEI) 26210 Eskişehir Türkiye Laboratory for Machine Tools and Production Engineering (WZL) RWTH Aachen University Campus-Boulevard 30 52074 Aachen Germany

In 5-axis milling of thin-wall parts, flexibility of the in-process-workpiece (IPW) governs static and dynamic deflections, especially at the semi-finishing and finishing stages. Thus, the near net shape preform, i.e. the stock shape left for semi/finishing is crucial for chatter stability. In this study, a methodology is presented to design the stock shape for improved stability. Coupled process simulation, which includes material removal, finite element analysis (FEA) and process stability simulations, is used to show the effect of stock shape on chatter stability. Spindle speed is optimized along the toolpath based on the varying process dynamic behavior for selected cutter locations (CL). The proposed method is experimentally demonstrated on case studies.

关键词： milling 5-axis process stability chatter vibration, in-process workpiece, machining strategy, coupled process simulation

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An investigation of abrasive waterjet machining of cubic boron nitride (CBN) with a softer abrasive material

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Procedia CIRP 2020年 95卷 6-11页

作者： F. Morczinek M. Putz Institute for Machine Tools and Production Processes (IWP) Chemnitz University of Technology Reichenhainer Str. 70 09126 Chemnitz Germany Fraunhofer Institute for Machine Tools an Forming Technology IWU Reichenhainer Str. 88 09126 Chemnitz Germany

For an effective machining of high-performance materials, high-strength cutting materials, e.g. cubic boron nitride (CBN), with high resistance to any kind of wear are used. However, these materials must also be able to be machined in order to produce geometric elements such as chip breakers or chip grooves. According to the current state of the art, grinding and laser beam technology are used for this purpose. In this paper, an attempt was made to use the erosive removal mechanism of abrasive water jet technology to cut a harder material with a softer abrasive. Within the framework of a full factorial test plan, the removal rate, the macroscopic kerf geometry on CBN were investigated by means of abrasive water jet machining. It could be proven that it is possible to remove a harder material with a softer abrasive by means of abrasive water jet technology.

关键词： Abrasion Cubic Boron Nitrid (CBN) Hardness Machining Material removal Removal rate Waterjet machining

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Simulation-based digital twin for the manufacturing of thermoplastic composites 31st

Simulation-based digital twin for the manufacturing of therm...

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31st CIRP Design Conference 2021, CIRP Design 2021

作者： Hürkamp, André Lorenz, Ralf Ossowski, Tim Behrens, Bernd-Arno Dröder, Klaus Technische Universität Braunschweig Institute of Machine Tools and Production Technology Langer Kamp 19b Braunschweig38106 Germany Leibniz Universität Hannover Institute of Forming Technology and Machines An der Universität 2 Garbsen30823 Germany Open Hybrid LabFactory Hermann-Münch-Straße 2 Wolfsburg38440 Germany

The bond strength between a thermoformed fibre reinforced thermoplastic sheet and an injected polymer is the limiting factor for the structural integrity of overmoulded thermoplastic composites. In this contribution, a simulation based digital twin of the thermoforming process is presented. From numerical parametric studies a reduced order model based on Proper Orthogonal Decomposition (POD) is developed. The combination with machine learning methods enables the real-time computation of arbitrary physical reliable temperature fields with sufficient accuracy to be used for design purposes and as inline quality gates. © 2021 Elsevier B.V.. All rights reserved.

关键词： Finite element method

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Investigation of the gap bridgeability at high-power laser hybrid welding of plasma-cut thick mild steels with AC magnetic support 10

Investigation of the gap bridgeability at high-power laser h...

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10th International Conference on Beam Technologies and Laser Applications, BTLA 2021

作者： Üstündag, Ömer Bakir, Nasim Gumenyuk, Andrey Rethmeier, Michael Unter den Eichen 87 Berlin12205 Germany Fraunhofer Institute for Production Systems and Design Technology Pascalstraße 8-9 Berlin10587 Germany Institute of Machine Tools and Factory Management Technische Universität Berlin Pascalstraße 8-9 Berlin10587 Germany

One of the challenges of the high-power hybrid laser welding of thick steels is the sensitivity of the process of the process to manufacturing tolerances. This usually leads to a time-consuming preparation of the welding edges, such as milling. The study deals with the influence of the edge quality of milled and plasma-cut steel made of S355J2 with a wall thickness of 20 mm on the laser hybrid welded seam quality. Furthermore, the gap bridgeability and the tolerances towards edge misalignment was investigated. An AC magnet was used as backing support to prevent sagging and positioned under the workpiece, to generate an upwards directed electromagnetic pressure. The profiles of the edges and the gap on the top and root side were measured using a digital camera. Single-pass laser hybrid welds of plasma-cut edges could be welded using a laser beam power of just 13.7 kW. A gap bridgeability up to 2 mm and misalignment of edges up to 2 mm could be achieved successful. Additionally, the independence of the cutting side and the welding side was shown, so that samples were welded to the opposite side to their cutting. For evaluation of internal defects or irregularities, X-ray images were carried out. Charpy impact strength tests were performed to determine the toughness of the welds. © 2021 institute of Physics Publishing. All rights reserved.

关键词： High power lasers

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