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Requirements for a methodology for the assessment and selection of technologies of digitalization for lean production systems

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Procedia CIRP 2019年 79卷 198-203页

作者： Georg Hoellthaler Stefan Braunreuther Gunther Reinhart Fraunhofer Research Institution for Casting Composite and Processing Technology (IGCV) Provinostr. 52 86153 Augsburg Germany Augsburg University of Applied Sciences An der Hochschule 1 86161 Augsburg Germany Institute for Machine Tools and Industrial Management (iwb) Technical University of Munich Boltzmannstr. 15 85748 Garching Germany

Since the beginning of lean production there have been two implementation waves. The first one failed as manufacturing companies implemented methods of lean production isolated from each other, whereas in the second wave these companies learned from this experience. Ever since then lean production has been used for production organization and waste reduction but has not evolved, even though markets are more demanding due to individualization and volatility. Digitalization offers methods to adapt lean production to such aggravated market conditions by expanding its abilities. Therefore, digitalization has the potential to initiate a third wave within the philosophy of lean production.

关键词： Lean production systems Technologies of digitalization Methodology Assessment Selection Interdependency

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Thermal and Mechanical Joining of Basalt Fiber Reinforced Thermoplastic Laminates

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IOP Conference Series: Materials Science and Engineering 2020年第1期947卷

作者： A Al-Obaidi P Rochala M Kroll T Hahn V Kräusel Chemnitz University of Technology Institute for Machine Tools and Production Processes Professorship for Forming and Joining 09107 Chemnitz Germany Nordmetall GmbH –Materials and Impact Engineering Adorfer Hauptstraße 16 09221 Neukirchen/Adorf Germany

In this paper, quasi-isotropic basalt fiber reinforced polyamide PA6 was joined to aluminum sheets using three different joining technologies. The joints were manufactured by means of nut and bolt (NAB) as well as two-piece hollow riveting (TPHR) as current state of the art processes. Furthermore, additional joints were established by the new inductive contact joining (ICJ) technology. The obtained specimens were compared by means of tensile shear tests and by analysis of the fractured surfaces. It was found that the joints produced by ICJ are superior in comparison to joints manufactured by TPHR with regard to joint strength. In addition, during ICJ, the fibers of the polymer material are not damaged and the strength of the base material is maintained. Further optimization potential of the ICJ process was discovered during the investigations, so that potentially higher joint strengths as well as shorter process times can be expected, making the process interesting for future industrial applications.

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Automated quality assurance as an intelligent cloud service using machine learning

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Procedia CIRP 2019年 86卷 185-191页

作者： M. Schreiber J. Klöber-Koch J. Bömelburg-Zacharias S. Braunreuther G. Reinhart Fraunhofer Research Institution for Casting Composite and Processing Technology (IGCV) Provinostr. 52 86153 Augsburg Germany Hochschule Augsburg University of Applied Sciences An der Hochschule 1 86161 Augsburg Germany Institute for Machine Tools and Industrial Management (iwb) Technical University of Munich Boltzmannstr. 15 85748 Garching Germany

The amount of data generated in production systems increases continuously due to the integration of cyber-physical systems and additional sensors. This data contains potentially useful knowledge that can be used to improve production processes and product quality. machine learning algorithms offer the potential of improvements for quality assurance. However, companies often do not have the necessary know-how to extract this knowledge. This publication therefore presents a service-based system for optical quality assurance using machine learning algorithms. The intelligent cloud service is tested and validated by an industrial use case for transparent injection molded parts.

关键词： methodology quality assurance machine learning

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Mechanical Properties of Single-pass Hybrid Laser Arc Welded 25 mm Thick-walled Structures Made of Fine-grained Structural Steel

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Procedia Manufacturing 2019年 36卷 112-120页

作者： Ömer Üstündağ Sergej Gook Andrey Gumenyuk Michael Rethmeier Fraunhofer Institute for Production Systems and Design Technology Pascalstraße 8-9 10587 Berlin Germany Bundesanstalt für Materialforschung und -prüfung (BAM) Unter den Eichen 87 12205 Berlin Germany Institute of Machine Tools and Factory Management Technische Universität Berlin Pascalstraße 8-9 10587 Berlin Germany

The presented study deals with the performing and mechanical testing of single pass hybrid laser-arc welds (HLAW) on 25 mm thick plates made of steel grade S355J2. One of the challenges have to be solved at full penetration HLAW of thick plates is the drop formation occurring due to the disbalances of the forces acting in the keyhole and on the melt pool surface. Such irregularities mostly limit the use of high-power laser beam welding or HLAW of thick-walled constructions. To overcome this problem, an innovative concept of melt pool support based on generating Lorentz forces in the weld pool is used in this work. This method allows to perform high quality welds without sagging even for welding of 25 mm thick plates in flat position at a welding speed of 0.9 m min -1 . For the obtain of full penetrated welds a laser beam power of 19 kW was needed. A high V-impact energy of up to 160 J could be achieved at the test temperature of 0 °C. Even at the most critical part in the weld root an impact energy of 60 J in average could be reached. The tensile strength of the weld reaches that of the base material. An introduce of the HLAW process with electromagnetic support of the melt pool in the industrial practice is an efficient alternative to the time- and cost-intensive arc-based multi-layer welding techniques which are established nowadays for joining of thick-walled constructions.

关键词： hybrid laser-arc welding thick-walled structures high-strength steel mechanical properties electromagnetic weld pool support

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Planning for Digitalisation in SMEs using tools of the Digital Factory

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Procedia CIRP 2018年 72卷 179-184页

作者： Johannes Stoldt Thies Uwe Trapp Stefan Toussaint Marian Süße Andreas Schlegel Matthias Putz Fraunhofer Institute for Machine Tools and Forming Technologies IWU Reichenhainer Straße 88 09126 Chemnitz Germany Robert Bosch GmbH Bexbacher Straße 72 66424 Homburg (Saar) Germany

Digitalisation offers ways as well as means for manufacturers to adapt their production systems to handle diversifying and rapidly changing market demands. Yet, small and medium sized enterprises are often overwhelmed by the speed of development of ICT solutions as well as ICT business schemes. This paper discusses how tools of the Digital Factory enable decision-makers to assess digitalisation measures during the planning process to take full advantage of newly available technologies. Potentials and prerequisites for the application of available tools are argued and illustrated considering an in-depth example on the simulation of an automotive supplier’s tool management process.

关键词： Manufacturing system Simulation Digitalisation

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IT-based Architecture for Power Market Oriented Optimization at Multiple Levels in Production Processes

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Procedia CIRP 2019年 81卷 618-623页

作者： Philipp Seitz Eberhard Abele Lukas Bank Thomas Bauernhansl Eduardo Colangelo Gilbert Fridgen Johannes Schilp Paul Schott Johannes Sedlmeir Nina Strobel Thomas Weber Fraunhofer Institute for Manufacturing Engineering and Automation IPA Nobelstrasse 12 70569 Stuttgart Germany Institute of Production Management Technology and Machine Tools Technische Universität Darmstadt Otto-Berndt-Straße 2 64287 Darmstadt Germany Fraunhofer Research Institution for Casting Composite and Processing Technology IGCV Beim Glaspalast 5 86153 Augsburg Germany Fraunhofer Institute for Applied Information Technology FIT Wittelsbacherring 10 95444 Bayreuth Germany University of Augsburg Chair of Digital Manufacturing Department of Applied Computer Science Universitätsstraße 2 86159 Augsburg Germany FIM Research Center University of Bayreuth Wittelsbacherring 10 95444 Bayreuth Germany

Given the increasingly volatile prices on the power markets, it becomes economically more and more important for companies to develop and realize flexible strategies for energy consumption. A steady adaption of production processes which considers current power prices can take place on several levels of the automation pyramid, where each level has its own characteristics and requirements. In this paper, we present an optimization architecture based on an IT-platform which meets the challenges of complex multilayered production processes. We introduce layer-specific optimization strategies as well as an associated information flow, which facilitates creating holistic and well-coordinated optimizations.

关键词： Energy flexibility Demand Response Production process optimization

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Publisher Correction: Non-cuttable material created through local resonance and strain rate effects

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Scientific reports 2020年第1期10卷 19103页

作者： Stefan Szyniszewski Rene Vogel Florian Bittner Ewa Jakubczyk Miranda Anderson Manuel Pelacci Ajoku Chinedu Hans-Josef Endres Thomas Hipke Durham University Durham United Kingdom. s.szyniszewski@***. Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany. Fraunhofer Institute for Wood Research Wilhelm-Klauditz-Institut WKI Hannover Germany. Leibniz University Hannover Institute of Plastics and Circular Economy IKK Garbsen Germany. University of Surrey Guildford United Kingdom. University of Stirling Stirling United Kingdom.

An amendment to this paper has been published and can be accessed via a link at the top of the paper.

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Metrological analysis of a mechatronic system based on novel deformation sensors for thermal issues in machine tools

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Procedia CIRP 2018年 77卷 517-520页

作者： Christian Brecher Michel Klatte Tae Hun Lee Filippos Tzanetos Laboratory for Machine Tools and Production Engineering (WZL) of RWTH Aachen University Aachen Germany Fraunhofer Institute of Production Technology Aachen Germany

The precision as well as the production rate of machine tools are starkly dependent on thermal issues. In order to minimize this influence, manufacturers are bound to warm-up procedures before production can begin, so that the machine tool thermal state has stabilized. On the other hand, design optimization and cooling techniques cannot eliminate all errors and call for higher investment costs for the machine tool user. Either through acquiring a new, thermally stable machine or through higher energy consumption, these measures are also not always applicable. Hence, it remains the task for a mechatronic system to capture as much information as possible about the thermal state of the machine tool and take corrective measures during production. A novel mechatronic system that measures directly the thermally induced deformations has been developed to fulfil this task. The measurement uncertainty, as well as the reliability of this mechatronic system are the two crucial properties that define whether this can be applied successfully in the industry. This paper summarizes the investigations on the measurement uncertainty of the proposed system, both analytical and experimental. The functionality of the system was verified on a second test rig, as well as on a vertical machining center, which build the basis for future reliability analyses.

关键词： Thermal Issues machine tools Metrology Sensors Reliability

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Requirements and Tasks for Active Energy Management Systems in Automotive Industry

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Procedia Manufacturing 2017年 8卷 175-182页

作者： Franz, Enrico Erler, Felix Langer, Tino Schlegel, Andreas Stoldt, Johannes Richter, Mark Putz, Matthias Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Strasse 88 Chemnitz 09126 Germany ACOD GmbH Schillerstraße 5 Leipzig 04109 Germany

The “2020 climate and energy package” enacted by the EU aims to reduce emission of greenhouse gases, to increase the share of renewable energy and to improve overall energy efficiency. These goals are forwarded to the industry using regulations or funding opportunities. Taking a deeper look e.g. into automotive industry the companies reflect these goals to their plants across Europe. Energy efficiency is a plant-related KPI to gain customer satisfaction, enhance greener production and optimise internal costs. Current developments especially deal with base load reduction for production plants. In order to achieve this, all resources within the factory, interconnected by processes or by energy flows, have to be actively managed. This paper deals with the requirements on energy management systems stemming from the task to control production, infrastructure as well as technical building systems (TBS) simultaneously with focus on specifics of the automotive industry. © 2017

关键词： automotive energy management system energy storage management flexibility production planing and control

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Finite element simulations on the relation of microstructural characteristics and the formation of different types of adiabatic shear bands in a β-titanium alloy

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IOP Conference Series: Materials Science and Engineering 2019年第1期480卷

作者： S Winter S Pfeiffer T Bergelt M F-X Wagner Institute of Materials Science and Engineering Materials Science Group Chemnitz University of Technology 09125 Chemnitz Germany now at Fraunhofer Institute for Machine Tools and Forming Technology IWU 09126 Chemnitz Germany

Deformation at high strain rates in combination with local thermal softening can lead to the formation of so-called adiabatic shear bands. These shear bands occur when the macroscopic deformation is concentrated in microscopic areas. The fundamental thermomechanical processes and micromechanical mechanisms acting during adiabatic shear band formation are not fully understood yet. In particular, the influence of different initial microstructures on shear band formation has not sufficiently clarified. In an earlier investigation, adiabatic shear bands formed in a β-titanium alloy with different initial microstructures were characterized in detail. It was shown that different volume fractions of the α-phase result in the formation of different types of shear bands. In the present study, a simple modeling approach based on the finite element (FE) method is used to investigate in a systematic parameter study (with a special focus on mechanical and thermal variables) how these different types of adiabatic shear bands can occur in the same material. The FE simulations clearly show that microstructural characteristics – such as size and volume fraction of the α-phase in the β-titanium alloy – have a strong influence on shear band formation. This study contributes to a more detailed understanding of the microstructural and thermomechanical mechanisms leading to the formation of different types of adiabatic shear bands in titanium alloys.

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