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Product-specific Identifiers and Data Aggregation for Enabling Traceability in Battery Cell Production

Procedia CIRP 2023年 120卷 1262-1267页

作者： Alexander D. Kies Ferdinand Siegert Thomas Ackermann Jonathan Krauß Dennis Grunert Robert H. Schmitt Fraunhofer Institute for Production Technology IPT Steinbachstr. 17 52074 Aachen Germany Fraunhofer Research Institution for Battery Cell Production FFB Bergiusstr. 8 48165 Münster Germany Laboratory for Machine Tools and Production Engineering WZL of RWTH University Campus-Boulevard 30 52074 Aachen Germany

In the context of the ongoing energy transition from fossil fuels to renewable energies, suitable energy storage systems play a major role. An important aspect here is sustainable battery cell production itself, but also the generation of transparency about the battery life cycle, e. g. in form of a battery passport. To remain competitive and to ensure sustainable production, high product quality with low scrap rates during production has to be achieved. This is possible with process optimization and digitalization. One underlying requirement lies in a traceability system. To enhance quality of battery cells as well as to minimize scrap, tracing at the finest granularity serves as a key enabler. A broadly applied traceability solution has not yet been fully explored and central challenges lie in the linking of continuous and discrete production steps — both from a digital and physical perspective. In this paper, we propose a concept for realizing a traceability system in battery cell production based on a product-specific identifier (ID) and the underlying data aggregation. The procedure for tracing an ID through the production steps of a battery cell, the assignment of relevant production data and the prototypical implementation, are presented. For this purpose, concept for battery cell production is introduced, which uses an object-oriented approach to link the different stages of the product ID with the respective production progress. The data generated in the process is aggregated and stored in a database, with the ID enabling unique assignment. Existing dependencies between individual entities of components to be traced and the assignment of corresponding data are shown by means of entity-relationship diagrams. Finally, the application of the concept and the validation are demonstrated using the first processes of electrode production.

关键词： Traceability Battery Cell Production Industry 4.0 Digitalization

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Holistic Approach for Digitalized Quality Assurance in Battery Cell Production

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Procedia CIRP 2023年 120卷 1250-1255页

作者： Alexander D. Kies Johann-Philip Abramowski Thomas Ackermann Fabian Kux Alexander Kreppein Dennis Grunert Robert H. Schmitt Fraunhofer Institute for Production Technology IPT Steinbachstr. 17 Aachen 52074 Germany Fraunhofer Research Institution for Battery Cell Production FFB Bergiusstr. 8 Münster 48165 Germany Laboratory for Machine Tools and Production Engineering WZL of RWTH University Campus-Boulevard 30 52074 Aachen Germany

In this paper, we introduce a holistic approach to consider quality assurance (QA) for battery cell production (BCP). The framework, the explanation of the individual components as well as their interfaces and dependencies, and a detailed description are presented. Firstly, the level of necessary data (e. g. provided by online and out-of-line measurement systems) for the inspection of quality is presented. The aggregation of the recorded data as well as their tracing are ensured by the realization of a traceability system. Subsequently, by defining a suitable intelligent quality gate system, QA mechanisms are implemented and an active influence on production 3 e. g. by adaptive process control or identifying and reducing negative influence of cause-effect relationships 3 is aimed at. Finally, optimization of BCP in terms of product quality and its sustainability will be enabled. The evaluation of the demonstrated approach in practice is outlined based on an exemplary process of BCP.

关键词： Battery Cell Production Industry 4.0 Sustainability Quality Assurance Traceability

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Surface integrity in high-feed roughing of Inconel 718 with SiAlON end mills 6th

Surface integrity in high-feed roughing of Inconel 718 with ...

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6th CIRP Conference on Surface Integrity, CSI 2022

作者： Zimmermann, Richard Michel-Angeli, Niklas Welling, David Ganser, Philipp Bergs, Thomas Makino Europe GmbH Karl-Friedrich-Straße 60 Aachen52072 Germany Fraunhofer-Institute For Production Technology Ipt Steinbachstraße 17 Aachen52074 Germany Laboratory For Machine Tools And Production Engineering Rwth Aachen University Campus Boulevard 30 Aachen52074 Germany

Conventional machining processes for hard-to-machine nickel-based alloys involve carbide tools, which exhibit low productivity at high tool wear rates. Novel tool concepts such as SiAlON-ceramic high-feed end milling tools show great potential to reduce the time required for the roughing process. However, these cutting processes feature high cutting speeds while avoiding cutting fluids, which leads to high thermomechanical loads. Since an unaffected rim zone must be ensured, this paper investigates the surface integrity effects on Inconel 718 machined with SiAlON-ceramic end mills. Particularly, the cutting forces, surface temperature, microhardness and microstructural damages in the cross-section are evaluated. In the selected slot milling operation, surface temperatures of up to 1,250 °C were measured and plastic deformations could be identified up to a depth of 35.5 μm in the bottom of the slot. The side walls are affected up to a depth of 69.6 μm from the surface. Microhardness measurements of the bottom of the slot show a hardening of the machined surface of 17.9 %, which does not reach deeper than 150 μm into the basic structure. © 2022 The Authors.

关键词： Milling (machining)

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Material substitution to reduce the environmental impacts in construction of car body manufacturing plants

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Procedia CIRP 2024年 122卷 157-162页

作者： Tobias Wallrapp Felix Wanielik Felipe Cerdas Max Juraschek Christoph Herrmann Markus Rössinger Volkswagen AG Berliner Ring 2 38440 Wolfsburg Germany Institute of Machine Tools and Prodcution Technology (IWF) Chair of Sustainable Manufacturing and Life Cycle Engineering Technische Universität Braunschweig Langer Kamp 19b 38106 Braunschweig Germany Fraunhofer Institute of Surface Engineering and Thin Films Riedenkamp 2 38108 Braunschweig Germany

The efficient use of resources is a key driver for reconciling nature and technology in the automotive manufacturing process. Resource efficiency not only considering the final product but also the construction of the manufacturing system is therefore essential for achieving the sustainability goals pursued by global automotive manufacturers. In this context, the substitution of energy-intensive primary materials with renewable raw materials represents a significant potential for reducing the environmental impacts of automotive plant engineering. However, the use of new materials often leads to conflicting objectives in terms of environmental and economic aspects as well as technical feasibility. To ensure an effective contribution to sustainability, it is necessary to evaluate the entire product life cycle of the substitute material, to localize the resulting secondary effects and to develop target-oriented solution concepts. Against this background, an approach is presented for the implementation of material substitution. The feasibility is demonstrated with a case-study on the substitution of energy-intensive steel with renewable wood material for the structural elements of a vertical conveyor pallet in the car body construction. The technical development and series testing is described and subsequently a comparative environmental and economic evaluation is carried out to analyze the potential benefits compared with the status quo while considering the resulting secondary effects. Finally, a potential assessment is made based on a reference body shop.

关键词： Material substitution environmentally compatible materials profound wood material car body plant construciton environmental impacts

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A Tactical Planning Approach using Genetic Algorithms and Process Chain Simulation for Closed-Loop Production Systems for high-value components

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Procedia CIRP 2024年 130卷 1575-1582页

作者： Alexander Dranov Max Juraschek Birgit Obst Christoph Herrmann Siemens AG Otto-Hahn-Ring 6 81739 Munich Germany Institute of Machine Tools and Production Technology Chair of Sustainable Manufacturing and Life Cycle Engineering Technische Universität Braunschweig Langer Kamp 19b 38106 Braunschweig Germany Fraunhofer Institute of Surface Engineering and Thin Films Riedenkamp 2 38108 Braunschweig Germany

The implementation of closed-loop production systems in manufacturing is a promising approach to mitigate environmental impacts and supply chain disruptions, while increasing the value and lifespan of products and materials. These systems integrate forward and reverse material flow activities such as repair, remanufacturing, and recycling within a single facility. However, a major challenge in planning and operating closed-loop production systems is the high uncertainty surrounding material availability and condition. Different process chains may be required depending on the extent and type of wear present in the used products. During the tactical planning phase, factory planners play a crucial role in evaluating and economically assessing various system and process chain configurations. Multiple technology chain and manufacturing equipment options provide different solutions for managing forward and reverse material flows. To address this, this paper introduces a metaheuristic framework based on discrete event simulation and genetic algorithms to evaluate these system configurations. The framework serves as decision-support for factory planners, whether they are planning a greenfield production system or undertaking a brownfield project aimed at transforming linear into circular production systems with both forward and reverse flows. The presented framework is built on data models that incorporate different technology and process chain options for manufacturing and repair, considering the condition of the cores. A manufacturing equipment database contains predefined data models describing machine skills and load profiles, which are utilized to generate various simulation models using different production system configurations. These models are then used to execute predefined scenarios. The main objective is to identify configurations that achieve a beneficial fitness value balancing technical, economic, and environmental key performance indicators for closed-loop p

关键词： Closed-loop production system Genetic algorithm Discrete Event Simulation Process chain simulation

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Machinability study in orthogonal cutting of additively manufactured Inconel 718 with specifically induced porosity

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Procedia CIRP 2024年 121卷 168-173页

作者： S.A.M. Schneider Y. Li J. Boseila P. Ganser T. Bergs J.H. Schleifenbaum Fraunhofer Institute for Production Technology IPT Steinbachstrasse 17 52074 Aachen Germany Chair of Digital Additive Production RWTH Aachen University Campus-Boulevard 73 52074 Aachen Germany Laboratory for Machine Tools and Production Engineering (WZL) of RWTH Aachen University Campus-Boulevard 30 52074 Aachen Germany

In comparison to conventional manufacturing technologies, additive manufacturing (AM) offers great design freedom, the integration of functions into components, new lightweight design concepts and high material efficiency. In aerospace and turbomachinery, this technology is increasingly coming into focus, especially the laser-based powder bed fusion of metals (PBF-LB/M) process. PBF-LB/M is already used for some aerospace components, which are often exposed to high thermal and mechanical loads. Dependent on the component geometry, support structures are required for AM, which then usually have to be removed by machining. One suitable support structure is the use of material with specifically induced porosity. This ensures good heat dissipation and thus homogeneous component properties, high retention forces and short process times in PBF-LB/M. However, the machinability of porous, additively manufactured material has hardly been researched so far. One preliminary investigation of milling porous, additively manufactured Inconel 718, though, showed significantly poorer machinability of the porous material compared to the dense material. To further examine this phenomenon, this paper presents the results of fundamental machinability studies with porous, additively manufactured Inconel 718 in orthogonal cutting. The investigations with tungsten carbide cutting tools on a special fundamental test rig include the analysis of the cutting force, the chip geometry, the chip temperature and the surface quality. The research results provide explanations for the poorer machinability of the porous material and derived approaches for improving the machinability in future studies.

关键词： LPBF PBF-LB/M SLM additive manufacturing AM porous porosity Inconel 718 alloy 718 machining support structure orthogonal cutting

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Surface optimization of dental implants with laser surface texturing and silver coating 22

Surface optimization of dental implants with laser surface t...

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

作者： Uhlmann, E. Brehmer, A. Schneider, Peter Hein, C. Schweitzer, L. Fraunhofer Institute for Production Systems and Design Technology Berlin Germany Institute for Machine Tools and Factory Management Technische Universität Berlin Germany Department of Orthopedics and Orthopedic Surgery University Medicine Greifswald Germany Laser Mikrotechnologie D. Kieburg GmbH James-Franck-Straße 15 Berlin12489 Germany

ISBN: (纸本)9781998999118

The risk of bacterial inflammation at the interface between implant and tissue exists following the implantation of a dental prosthesis. Nearly half of implants are at risk of colonisation by pathogenic bacteria, which is associated with the occurrence of peri-implant mucositis. This disease can develop into peri-implantitis and thereby trigger a severe inflammatory process. The occurrence of peri-implantitis includes different phases. The initial attachment of microorganisms is only possible by pioneer bacteria, such as the gram-positive streptococci. Since the pathogenic cannot form a biofilm unless attached to a surface, the attachment of the pioneer bacteria is crucial for the onset of peri-implantitis. Due to the flexibility and contact free process, laser material processing is used for the surface structuring of several materials. In the biomedical field, laser-based surface texturing enables the production of implants with improved biological reaction surfaces to positively influence protein adsorption and cell adhesion. This paper presents laser texturing and silver coating to reduce initial biofilm formation on Ti6Al4V. The laser processing includes the manufacturing of LIPSS (Laser Induced Periodic Surface Structures), which enables the functionalisation of the surface. Furthermore, the surfaces are coated with silver to act as an inhibitor of biofilm formation. The implant material undergoes an in vitro culture of the microorganism Streptococcus salivarius in order to determine the biofilm formation applying both techniques. The analysis was realized by fluorescence microscopy with the application of 4', 6-diamidino-2-phenylindole (DAPI) on the adhered biofilm. Results show that the surface modification plays a major role in the inhibition of biofilm formation. © European Society for Precision Engineering and Nanotechnology, Conference Proceedings - 22nd International Conference and Exhibition, EUSPEN 2022. All rights reserved.

关键词： Bacteria

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Constructive compensation of the thermal behaviour for industrial robots 13

Constructive compensation of the thermal behaviour for indus...

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13th International DAAAM Baltic Conference and 29th International Baltic Conference, BALTMATTRIB 2021

作者： Uhlmann, Eckart Polte, Julian Mohnke, Christian Fraunhofer Institute for Production Systems Design Technology IPK Pascalstraße 8-9 Berlin10587 Germany Institute of Machine Tools and Factory Management Pascalstraße 8-9 Berlin10587 Germany

Industrial robot systems offer a flexible, adaptable basis due to their kinematics and their mobility An influencing variable, which is particularly relevant for processes with long process times, is the thermal heating and the associated thermal drift of the tool center point. The maximum deviation from the actual nominal position can reach up to ΔAPt = 1.5 mm. Currently, there are no procedures and methods established in practice which compensate the effects of thermal drift without expensive calibration measures and system downtime. In these investigations a system was developed which allows the reduction of thermally induced displacement by using controlled heating elements. The aim is to keep the entire robot system at a permanent, balanced temperature level. The heating elements are adapted to the geometry of the respective axis and heat the material to a temperature ϑ close to the steady state. A comparison of the drift through the heating system with the error occurring in normal operation shows that the drift of the heating system is comparable with the drift of normal heating. With the heating mats, a thermally induced error of ΔAPt = 0.234 mm can be generated within t = 20 min. While normal heating requires up to t = 600 min. The achieved error deviation of the drift of the self-heating to the heated variants is with ΔAP = 0.04 mm only minimal. The results can help to reduce the influence of thermal heating and the associated thermal drift of the TCP without using cost-intensive measures with additional hardware and software on external computers for compensating the errors. © 2021 DAAAM International. All rights reserved.

关键词： Industrial robots

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Comparison of Resistive and Optical Strain Measurement for Early Fracture Detection

Comparison of Resistive and Optical Strain Measurement for E...

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作者： Carabello, Alina Neupetsch, Constanze Werner, Michael Rotsch, Christian Drossel, Welf-Guntram Zajonz, Dirk Chemnitz University of Technology Adaptronics and Lightweight Design in Production Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology Iwu Chemnitz/ Dresden Germany Zeisigwaldkliniken Bethanien Chemnitz Germany

To increase learning success in surgical training, physical simulators are supplemented by measurement technology to generate and record objective feedback and error detection. An opportunity to detect fractures following hip stem implantation early can be measurement of occurring strains on bone surface. These strains can be determined while using strain gauges, digital image correlation (DIC) or photoelasticity. In this research strain gauges and DIC were compared regarding their suitability as strain measurement tools for use in physical simulators. Therefore a testing method was described to replicate the implantation of a hip stem. Testing devices modelled on a realistic prosthesis were pressed into prepared porcine femora in a two-step procedure with a material testing machine. The local strains occurring on bone surface were determined using an optical measurement system for DIC and strain gauges. The initial fractures in the tested femora are located medial-anterior in most cases (73,6%). With increasing indentation depth of the test device, the strains on bone surface increase. Comparing the local strains determined by DIC and strain gauges consistencies in curves are noticeable. Maximal determined strains before fracturing amount to 0,69% with strain gauges and 0,75% with DIC. In the range of the fracture gap, strain gradients are determined by using DIC. However the detected surfaces are of low quality caused by gaps and motion artefacts. The results show strains on bone surfaces for early fracture detection are measurable with strain gauges and DIC. DIC is assessed as less suitable compared to strain gauges. Furthermore strain gauges have greater level of integration and economic efficiency, so they are preferred the use in surgical training simulators. © 2020 by Walter de Gruyter Berlin/Boston 2020.

关键词： Image correlation

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Metal Foams with Ceramic Inserts for Security Applications 11th

Metal Foams with Ceramic Inserts for Security Applications

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11th International Conference on Porous Metals and Metallic Foams, MetFoam 2019

作者： Vogel, René Drebenstedt, Claudia Szyniszewski, Stefan Bittner, Florian Fras, Teresa Blanc, Ludovic Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany University of Surrey Guildford United Kingdom Fraunhofer Institute for Wood Research Wilhelm-Klauditz-Institut WKI Hannover Germany Saint-Louis France

ISBN: (纸本)9783030427979

Protective performance and a low weight of armour plates are the most important objective in security applications. Metallic foams can provide a high level of protection without an extensive mass and were used as a part of various laminated armour systems in the past. Embedding small ceramic parts in metallic foam combines the hardness of ceramics with the flexibility of the lightweight cellular matrix. The material has an extreme cutting resistance against mechanical tools such as angle grinder, drill bits, or other cutting devices. In several testing campaigns, aluminium foams were combined with different internal layouts of stacked or integrated ceramics. The cellular core was foamed directly to steel cover sheets or was bonded to different steel alloy faceplates. In additional tests, blast wave propagation of the metallic foam ceramic composite (MFCC) panels was evaluated. Furthermore, several ballistic tests were performed and compared to state-of-the-art armour materials. It was possible to achieve better performance in this comparison to standard armoured steel at a lower overall weight. © 2020, The Minerals, Metals & Materials Society.

关键词： Metals

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