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39th Annual Meeting of the American Society for Precision Engineering, ASPE 2024

作者： Sordon, Fabian Lahoda, Christian Polte, Mitchel Uhlmann, Eckart Maas, Jürgen Mechatronic Systems Lab EMK Technische Universität Berlin Germany Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Germany Fraunhofer Institute for Production Systems and Design Technology IPK Germany

ISBN: (纸本)9781887706612

Cutting edge preparation is a critical step in the fabrication of micro-milling tools, helping to remove grain chipping and to reduce tool wear. In our previous research, we explored the use of magnetorheological fluids for directed immersed tumbling under magnetic excitation, demonstrating its potential through significant and precise material removal rates and reduced processing times. This study expands on that work by examining how the composition of the abrasive magnetorheological fluid affects surface quality and the long-term performance of the fluid. Various compositions of magnetorheological fluid samples were tested on high-speed steel specimens using a custom-designed test bench, which enables the variation of the magnetic field. The microgeometry of the cutting edges, including the maximum chipping, was recorded before and after processing. Results indicate that compositions yielding larger abrasive particles, combined with high magnetic and abrasive particle volume fractions lead to improvements in surface quality and material removal rate. © 2024 Proceedings - ASPE 2024 Annual Meeting. All rights reserved.

关键词： Magnetorheological fluids

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F5G OpenLab: Enabling Twin Transition through Ubiquitous Fiber Connectivity 23

F5G OpenLab: Enabling Twin Transition through Ubiquitous Fib...

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23rd International Conference on Transparent Optical Networks, ICTON 2023

作者： Balanici, Mihail Shariati, Behnam Safari, Pooyan Chojecki, Paul Chemnitz, Moritz Przewozny, David Fischer, Johannes Karl Freund, Ronald Heinrich-Hertz-Institut Fraunhofer Institute for Telecommunications Einsteinufer 37 Berlin10587 Germany Fraunhofer Institute for Production Systems and Design Technology Pascalstr. 8-9 Berlin10587 Germany

ISBN: (纸本)9798350303032

The paper introduces a new open laboratory, the F5G OpenLab, which aims at fostering the advancement of fiber-based solutions for everything. F5G OpenLab intends to aid in creating a sustainable and eco-friendly ICT industry and accelerate the digital transformation through autonomous networking solutions that are secure and trustworthy. In particular, the purpose of the F5G OpenLab is to establish an ecosystem for the validation of optical networking solutions that facilitate twin transition, provide a vendor-neutral platform for the assessment of vertical use cases, and enable the development of fiber-based solutions. It provides a platform to verify and unify next-gen networking solutions, access to early hardware and software releases, and unique testing and measurement facilities. Finally, the F5G OpenLab supports the development of blueprints for a green and digital transformation, capitalizing on the benefits of fiber technology for all industry sectors. We present its architecture as well as key features and capabilities. Moreover, we report several proof-of-concept demonstrations focused on industry 4.0 vertical use-cases. © 2023 IEEE.

关键词： Fibers

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Planning of Time-Efficient Trajectories for Mobile Robots with Differential-Drives

Planning of Time-Efficient Trajectories for Mobile Robots wi...

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International Conference on Emerging Technologies and Factory Automation (ETFA)

作者： Philipp Lelidis Axel Vick Production Machinery and Equipment Management Fraunhofer Institute for Production Systems and Design Technology IPK Berlin Germany Process Automation and Robotics Fraunhofer Institute for Production Systems and Design Technology IPK Berlin Germany

ISBN: (数字)9798350361230

ISBN: (纸本)9798350361247

To effectively utilize the capacities of the production facilities, flexible and fast transport, and manipulation technology is essential. Current path planning methods use simple paths without exploiting the physical limitations of mobile robots. This paper deals with the time-efficient kinematic planning of path and velocity trajectories for autonomous mobile robots equipped with a differential-drive, used to load and unload machine tools. For a close parking position next to the machine tools, the mobile robot must approach practically straight without the necessity of turning at the end. After a brief definition of the kinematics of a mobile robot with nonholonomic constraints, a Bezier-curve is combined with multiple jerk-limited velocity trajectories considering the initial and final state as well as the physical limitations. For a time-efficient acceleration and deceleration the maximum acceleration of the mobile robot is used and differentiated into the radial and tangential acceleration. This allows a quickly reached close parking pose next to a machine tool. The algorithm is tested with simulations in RVIZ in combination with Gazebo and ROS2 as well as with the real mobile robot Tend-o-Bot.

关键词： Kinematics Turning production facilities Trajectory Planning Machine tools Mobile robots Manufacturing automation Load modeling Autonomous robots

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DEM Simulation of Abrasive Brushing Processes on Additively Manufactured Workpieces 20

DEM Simulation of Abrasive Brushing Processes on Additively ...

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20th CIRP Conference on Modeling of Machining Operations in Mons, CIRP CMMO 2025

作者： Hoyer, Anton Uhlmann, Eckart Technische Universität Berlin Pascalstr. 8-9 Berlin10587 Germany Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstr. 8-9 Berlin10587 Germany

Brushing with bonded abrasives is a finishing process mainly used for deburring, edge rounding, and surface roughness reduction. The brushing tools consist of flexible polymer filaments embedded with abrasive grains, allowing them to adapt to complex workpiece shapes. However, interactions between filaments lead to complex motion, chipping, and wear behaviors, making it difficult to predict work results. The discrete element method (DEM) has been shown to be effective in simulating process forces, contact areas, and filament interactions on flat workpieces. Consequently, this article focuses on processing geometrically complex workpieces, particularly additively manufactured turbine fan blades (Ni-Cr-Co), using round brushes with bonded silicon carbide. First, a vectorized iterative method is introduced to generate artificial filament patterns, enhancing DEM simulation accuracy compared to state-of-the-art filament pattern models. Subsequently, dry brushing experiments are carried out on a fan blade feature demonstrator, aiming to achieve homogeneous roughness reduction. The qualitative analysis of the contact surface suggests that results from DEM simulations can reduce the need for costly technological investigations and prototypes. © 2025 The Author(s).

关键词： Nickel alloys

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Corporate Climate Protection Measures to Improve the Carbon Footprint in production: A Systematic Development of a Toolbox with Climate Protection Actions for the Reduction of Greenhouse Gas Emissions in Small and Medium-Sized Enterprises 19th

Corporate Climate Protection Measures to Improve the Carbon ...

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19th Global Conference on Sustainable Manufacturing, GCSM 2023

作者： Budde, Felix Kohl, Holger Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstraße 8-9 Berlin10587 Germany Technische Universität Berlin Pascalstraße 8-9 Berlin10587 Germany

ISBN: (纸本)9783031774287

Individual climate protection measures are already being successfully implemented by many companies. But often, there is a lack of comprehensive information for selecting and implementing the right measures that fit the individual company’s emissions profile. This paper presents the systematic development of a toolbox of climate protection actions for small and medium-sized enterprises in order to reduce greenhouse gas emissions. The development process followed a four-step methodological approach: conducting intensive research on climate protection measures in applied and practical literature, reducing and grouping the measures into their corresponding emission categories, structuring and categorizing the measures into specific types of areas, and providing detailed profiles and descriptions of each measure. The resulting list of climate protection actions follows underlying basic principles (i.e. improvement of the emission factor, reduction of emission-generating activities and behavioral changes) which allow an individual derivation of measures. In its final version, the toolbox provides small and medium-sized enterprises with a comprehensive and accessible resource for identifying and implementing effective climate protection actions according to their emissions profile. © The Author(s) 2025.

关键词： Greenhouse gas emissions

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technology Radar for a Sustainable Biological Transformation in the Manufacturing Industry 19th

Technology Radar for a Sustainable Biological Transformation...

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19th Global Conference on Sustainable Manufacturing, GCSM 2023

作者： Mügge, Janine Berkhahn, Magda Knauf, Tobias Stark, Rainer Faßbender, Lynn Lange, Annika Riedelsheimer, Theresa Lindow, Kai Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstraße 8-9 Berlin10587 Germany Technische Universität Berlin Pascalstraße 8-9 Berlin10587 Germany

ISBN: (纸本)9783031774287

Bio-inspired, bio-integrated, bio-intelligent product and production systems are new research approaches aimed at achieving sustainability in manufacturing. For the industrial application of new technological solutions, it is crucial to convey their added value from not only an economic but also an environmental perspective. The evaluation of their technological readiness plays an important role in implementation. This paper presents a technology radar developed and evaluated within German research project BioFusion 4.0 involving 13 industry and research partners. The paper outlines the development approach and its application by means of three technological examples. The technologies are categorized and assessed using four significant attributes of an effective biological transformation: (1) the mode of action (bio-inspiration, bio-integration, and bio-interaction);(2) the transformative character and (3), the technology—and (4) Sustainability Readiness Level. The technology radar comprises a step-by-step procedure to assess a technology by each criterion to enable different stakeholders, such as production planners or product developers to evaluate and identify suitable technologies according to their needs and business strategy. The application of the technology radar is demonstrated on the exemplary technologies of a digital twin with integrated life-cycle assessment, situation awareness monitor for networked production systems and bio-based 3D printing. © The Author(s) 2025.

关键词： Biotic

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Sustainable Product Lifecycle Management – Implementation of a Digital Twin of a Biologically Transformed Product-Ecosystem

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Procedia CIRP 2024年 125卷 30-35页

作者： Sebastian Wehking Anne Seegrün Theresa Riedelsheimer Kai Lindow Fraunhofer-Institute for Production Systems and Design Technology IPK Pascalstr. 8-9 10587 Berlin Germany

Biological transformation is the transfer of principles of natural systems to technical materials, processes and systems. The essential concepts of biological transformation - inspiration (learning from the observation of nature for the adaptation of technology), integration (symbiosis of technical systems based on biological principles) and interaction (interweaving of nature with technology) - can be transferred to Industry 4.0 solutions. One of these solutions is the Digital Twin, which can be used to provide transparency of an individual product’s environmental impact and to positively influence it throughout all lifecycle phases. A Digital Twin can be seen a digital ecosystem that inherits various biological principles itself, but also serves as an enabler of biologically transformed products. The application of the principles of biological transformation to Industry 4.0 helps achieve sustainable value creation. Manufacturing and operating companies, leveraging operational data with the help of Digital Twins, are equipped to better understand a product ecosystem’s performance and identify constraining resources that determine its lifecycle sustainability. This paper demonstrates the concept development of a Digital Twin for a biologically transformed product-ecosystem with integrated sustainability assessment focused on the production phase and its corresponding user interface.

关键词： Biologicalisation Industry 4.0 Biological Transformation Sustainability Sustainable Manufacturing Digital Twin

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Developing Digital Twins for energy efficiency in the production phase of products

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Procedia CIRP 2024年 122卷 933-938页

作者： Sebastian Wehking Theresa Riedelsheimer Cansu Tanrikulu Kai Lindow Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstraße 8-9 10587 Berlin Germany

The relevance of digital solutions to enable sustainable value creation, the monitoring and ultimately the reduction of the environmental footprint has increased. New information technologies and increased data availability along a product's lifecycle offer more tools to assess product sustainability than ever before. This paper presents how a Digital Twin needs to be designed to help monitor product-level energy efficiency and how such a Digital Twin can be implemented. State-of-the-art research on Digital Twins and their development, lifecycle assessment, and energy efficiency are introduced. There is a lack of evaluated implementations of methodical DT development in different scenarios, especially for the evaluation of product-level energy efficiency during production. Results of a research project with the focus on the development and implementation of Digital Twins are presented. The use case is set within the scenario of the sequential development of a product simultaneously with the development of the Digital Twin. The focus is put on the implementation of an energy consumption prediction and product carbon footprint analytics module as part of the Digital Twin. The development approach is presented and recommendations for the development of future Digital Twins are derived.

关键词： Digital Twins Sustainability Lifecycle Assessment Energy efficiency

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Integrated Consideration of Data Flows and Life Cycle Assessment in Vehicle Dismantling processes 31

Integrated Consideration of Data Flows and Life Cycle Assess...

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31st CIRP Conference on Life Cycle Engineering, LCE 2024

作者： Mügge, Janine Seegrün, Anne Faßbender, Lynn Riedelsheimer, Theresa Staufenbiel, Philip Lindow, Kai Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstraße 8-9 Berlin10587 Germany LRP-Autorecycling Leipzig GmbH Priesterstraße 6 Krostitz04509 Germany

The pursuit of environmental sustainability and resource conservation has underscored the growing significance of the circular economy paradigm across industries. This transformation is particularly pertinent within the automotive industry, necessitating a profound restructuring of the value chain, with a specific focus on end-of-life considerations. Significant potential for circular economy arises from the thorough examination of end-of-life vehicles and processes, involving strategies such as component reuse, material recycling and primary resource reduction. Providing process-, product-, component-, and material-specific information at the end-of-life of automotive vehicles can improve decision-making regarding circular strategies. It also demands for new digital solutions. This paper addresses an integrated approach of data flow analysis and Life Cycle Assessment (LCA) to enable a comprehensive monitoring of the environmental impact of these processes. First, the use case of end-of-life dismantling processes is presented - including pyrotechnics neutralization, vehicle dehydration, disassembly of reuse components as well as vehicle compaction. Secondly, the data demand respective information and material flows is depicted. As a main result, the LCA data flow model specifically tailored to the end-of-life vehicle dismantling processes is described. This model serves as a fundamental basis for analyzing the environmental impact of end-of-life processes combined with the underlying data flow. © 2024 Elsevier B.V.. All rights reserved.

关键词： Life cycle

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Injection mould measurement system for increasing manufacturing control and production quality 23

Injection mould measurement system for increasing manufactur...

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23rd International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2023

作者： Uhlmann, Eckart Trabasso, Luís Gonzaga Bolz, Robert Schweitzer, Luiz Hein, Christoph De Souza, Diego Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Germany SENAI Innovation Institute for Manufacturing Systems and Laser Processing Brazil

ISBN: (纸本)9781998999132

Tool and mould making is one of the most important sectors of industrial manufacturing. Currently, over a third of polymer products are manufactured by injection moulding or stamping. These processes are complex, as the melted or heated polymers are subject to thermomechanical changes. Since injection moulding and stamping are mostly used for mass production, process repeatability and quality of the final product are very important. Improper adjustments of process variables lead to various defects in the final product along with high amount of waste and rejects. The need for measurement and control of the process is mandatory. Frequently, the tool is not operated by the owner of the mold or the end user of the plastic components, respectively, but by an injection molding service provider within the supply chain. Consequently, it is impossible for the tool owner to trace the quality of parts regarding the parameters applied for processing. This is crucial information to connect parts outside the tolerances to the respective process characteristics. The increase of quality in the production is achievable through correlating the processing parameters applied with the produced components. Therefore, the aim of the research herein is to develop an autonomous sensor system for monitoring injection moulding and stamping processes. The system comprises an external component of the tool in order to record and document the parameters applied such as tool temperature, pressure, number of machined parts and geolocation among others. In conjunction with a connected laser marking system for injection moulding, the unique identification of the components and the unchangeable connection of the production parameters with an individual component is enabled. The direct technological added value is given by the fact that the customer is able to monitor the production at any time, any place, comparing the actual production with the agreed and specified conditions. Furthermore, this info

关键词： Injection molding

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