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Highly modular and generic control software for adaptive cell processing on automated production platforms

Procedia CIRP 2018年 72卷 1245-1250页

作者： Sven Jung Jelena Ochs Michael Kulik Niels König Robert H. Schmitt Fraunhofer Institute for Production Technology IPT Steinbachstr. 17 Aachen 52074 Germany Laboratory for Machine Tools and Production Engineering WZL of RWTH Aachen University Campus-Boulevard 30 Aachen 52074 Germany

The expansion of patient derived stem cells requires adaptive processing protocols that consider the growth behavior. In order to minimize human errors and enhance reproducibility, the industry moves towards automated platforms. This bears several challenges for a control software, such as coping with non-deterministic processes and the prevalent heterogeneity of device interfaces. We have developed a service-oriented approach to meet the demand for flexibility while at the same time giving maximum control over data and devices. Hardware modules are integrated via agents into the control software following a plug-and-produce approach. This generic software is also easily adaptable for other applications.

关键词： production control software service oriented architecture flexibility adaptivity agents modularity

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Automatic Adjustment of Car Body Fixtures Using Artificial Intelligence

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Procedia CIRP 2017年 62卷 600-605页

作者： R. Fritzsche A. Richter M. Putz Head of group assembly systems at Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz 09126 Germany Scientific employee at Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz 09126 Germany

In car-body production, the fixtures used for fixing the car-body panels during the joining pro-cesses predominantly consist of rigid constructions that require a time-consuming manual set-up process. To automate the adjustment process and reduce ramp up times, different adjustment modules have been developed at the fraunhofer IWU in order to meet specific requirements. Because of high quality requirements, produced components will be checked against an adjustment database. The exactly positioning for each clamping point will be derived, with the aid of mathematical algorithms and modern methods of artificial intelligence, based on measured values and the knowledge of the template technicians.

关键词： Quality management Body in white Ramp up Artificial intelligence Neuronal network Database

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A characterization of quality of sheared edge in fine blanking using edge-computing approach

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Procedia Manufacturing 2018年 15卷 578-583页

作者： Daniel Trauth Joachim Stanke Andreas Feuerhack Thomas Bergs Patrick Mattfeld Fritz Klocke Laboratory for Machine Tools and Production Engineering WZL of RWTH Aachen University Steinbachstr. 19 52074 Aachen Germany Fraunhofer Institute for Production Technology IPT Steinbachstr. 17 52074 Aachen Germany

In fine blanking the sheared edge’s quality is of major importance. As the sheared edge needs to transmit process forces and precisely align parts, attributes like die rolls, tears and tear-offs need to be eliminated. Currently, these attributes are manually determined at the end of the process chain, which makes a complete correlation between influencing factors and the attributes hardly possible. If it would be possible to create a real-time evaluation of the attributes, not only unknown correlations would be found, also an instant process adaption could be made, optimizing the quality of the sheared edge. Therefore, this contribution focusses on the development of an edge computing approach.

关键词： Fine blanking Sheared edge’s quality Image processing Edge computing Deep learning

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Modeling and Simulation of the Microstructure Evolution of 42CrMo4 Steel During Electrochemical Machining

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Procedia CIRP 2018年 68卷 505-510页

作者： F. Klocke S. Harst M. Zeis A. Klink Laboratory for Machine Tools and Production Engineering (WZL) of RWTH Aachen University Steinbachstraße 19 52074 Aachen Germany Fraunhofer-Institute for Production Technology IPT Steinbachstraße 17 52074 Aachen Germany

Machining independently of mechanical material properties like hardness or high temperature strength is one mayor advantage of the electrochemical machining process (ECM). Additionally, high material removal rates can be achieved in combination with best surface integrities. Nevertheless, one limiting factor in the resulting surface integrity can be a significantly varying dissolution rate of material phases in a multi phase material during ECM. These differences in the dissolution rates determine the surface topography as well as the achievable surface roughness. However, this behavior cannot be forecasted up to now. For that reason, this paper presents a model for the prediction of the microstructure evolution as well as simulation results regarding the influence of the electrochemical machining process on resulting surface topography for the ferritic perlitic steel 42CrMo4 in a passivating electrolyte system. With the help of the model, the evolution of surface topography can be predicted and will be analyzed for different process parameters and various initial microstructures.

关键词： ECM Microstructure Process Signature 42CrMo4 Process Simulation

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A Novel Modeling Approach for the Simulation of Precise Electrochemical Machining (PECM) with Pulsed Current and Oscillating Cathode

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Procedia CIRP 2018年 68卷 499-504页

作者： Fritz Klocke Lukas Heidemanns Markus Zeis Andreas Klink Laboratory for Machine Tools and Production Engineering (WZL) of RWTH Aachen University Steinbachstr. 19 52074 Aachen Germany Fraunhofer-Institute for Production Technology IPT Steinbachstr. 17 52074 Aachen Germany

Simulation in electrochemical machining (ECM) offers the capability to distinctly reduce time and costs of the design process and, thereby, increase the economic potential of the manufacturing technology. In recent years, different models for the simulation of ECM with direct current (DC-ECM) have been introduced and successfully applied to varying geometries. Furthermore, first approaches to model the effect of ECM with pulsed current have been presented. However, state of the art machine tools additionally apply an oscillation of the cathode to further improve surface quality and machining precision. To date there exists no validated model for this precise ECM (PECM) process. Therefore, this paper outlines the challenges emerging from considering cathode oscillation in ECM simulation models. Based on an overview of existing models for ECM with pulsed current, conclusions are drawn which concepts can be adopted for the modeling of precise ECM and which phenomena require the introduction of new approaches. Lastly, a model for the simulation of precise ECM is presented. This model accounts for the flow field of the electrolyte, the evolution of temperature in the machining gap as well as the resulting electrical field and finally the material removal.

关键词： simulation of ECM PECM oscillating cathode short-cut mehtods

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Affordance Based Approach to Automatic Program Generation for Industrial Robots in Manufacturing

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Procedia CIRP 2018年 76卷 133-137页

作者： Oliver Heimann Jörg Krüger Fraunhofer Institute for Production Systems and Design Technology Pascalstr 8-9 10587 Berlin Germany Technische Universität Berlin Institute for Machine Tools and Factory Management Pascalstr 8-9 10587 Berlin Germany

Due to the increasing demand for flexible and low-cost production, manufacturing solutions involving human robot interaction have become much sought-after. Robotic manufacturers meet the demand with a rising number of low cost robots specifically designed around safety and usability. However, the programming is still based on a tool centric teach-in. This paper discusses an affordance based approach for process programming in industrial manufacturing. Using low level feature detection and a consecutive evaluation, a fast programming method for industrial applications is presented. The paper presents the concept and a prototypic implementation for a welding process. Using the affordance detection, the system is able to identify relevant seams based on an image of the work space. The identified seams are then presented to the user for review with the means of augmented reality. Lastly, the system derives a welding program based on the detected seams. First experiments show promising results concerning programming speed and path accuracy for different work piece shapes and task definitions. Finally, based on the experience gained with the prototype, the outlook discusses the possibilities and further fields for future work.

关键词： Robot Welding Programming

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Human robot collaboration - using kinect v2 for ISO/TS 15066 speed and separation monitoring

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Procedia CIRP 2018年 76卷 183-186页

作者： Martin J. Rosenstrauch Tessa J. Pannen Jörg Krüger Fraunhofer Institute for Production Systems and Design Technology Pascalstr 8-9 10587 Berlin Germany Technische Universität Berlin Institute for Machine Tools and Factory Management Pascalstr 8-9 10587 Berlin Germany

The use of industrial robots within assembly workstations where human and robot should be able to collaborate or even cooperate involve high safety requirements. One out of four possibilities outlined in the current technical specification ISO/TS 15066 for ensuring safety is speed and separation monitoring. Here the robot motion speed in- or decreases dynamically depending on the distance between operator and robot. This paper introduces an approach of a speed and separation monitoring system with the help of a time of flight sensing. After introducing this safety ensuring method, a Microsoft Kinect V2 is used to continuously detect human worker within a shared workspace. With the help of the robots joint angles from the robot control it is possible to compute the distances between all robot joints and the human worker. The shortest distance, which is at the same the critical distance time, is determined and as a consequence the velocity and acceleration values of the robot were set to safe values according to ISO/TS 15066. As it is not necessary to visually detect also the robot, but only human workers, this approach is very resilient. Afterwards the introduced setup is tested by a real detected human in front of a Kinect and a simulated industrial robot (Universal Robot UR5) in the robot operating system ROS. Measurements show that depending on the position of the worker the robots speed adapts to recommended safety values up to a complete halt if necessary. Conclusively all results are discussed and an outlook for possible fields of applications is given.

关键词： human robot collaboration safety ISO/TS 15066 kinect v2

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Decentralized Data Analytics for Maintenance in Industrie 4.0

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Procedia Manufacturing 2017年 11卷 1120-1126页

作者： Uhlmann, Eckart Laghmouchi, Abdelhakim Geisert, Claudio Hohwieler, Eckhard Fraunhofer Institute for Production Systems and Design Technology – IPK Berlin Germany Institute for Machine Tools and Factory Management IWF - Technische Universität Berlin Germany

Due to the increased digital networking of machines and systems in the production area, large datasets are generated. In addition, more external sensors are installed at production systems to acquire data for production and maintenance optimization purposes. Therefore, data analytics and interpretation is one of the challenges in Industrie 4.0 applications. Reliable analysis of data (e.g. internal and external sensors), such as system-internal alarms and messages produced during the operation, can be used to optimize production and maintenance processes. Furthermore, information and knowledge can be extracted from raw data and used to develop data-driven business models and services, e.g. offer new availability contracts for production systems. This paper illustrates an approach for decentralized data analytics based on smart sensor networks. © 2017 The Authors

关键词： algorithms classifier data analytics Industrie 4.0 production systems

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Smart Life Cycle Monitoring for Sustainable Maintenance and Production – An example for Selective Laser Melting machine

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Procedia Manufacturing 2017年 11卷 711-717页

作者： Uhlmann, Eckart Pontes, Rodrigo Pastl Laghmouchi, Abdelhakim Geisert, Claudio Hohwieler, Eckhard Fraunhofer Institute for Production Systems and Design Technology – IPK Berlin Germany Institute for Machine Tools and Factory Management IWF - Technische Universität Berlin Germany

Smart linking, evaluation and provision of information over the life cycle of a product are becoming growingly important. The use of information extracted from combination of monitoring data, product data, maintenance information, and from product utilisation data can increase the availability of production machines and reduce the costs and resources cause by machine downtime. Especially for new manufacturing technologies such as Selective Laser Melting, the storage and management of such information are crucially important to develop knowledge and improve the quality of the machines and their products. By acquiring data from the machine, processing them and calculating proper key performance indicators, the critical region where the failures are most commonly found and the critical subsystems responsible for the failures are identified. Moreover, using the historical data, the tolerances for those subsystems can be defined. © 2017 The Authors

关键词： data analysis life cycle monitoring selective laser melting Smart linking

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Manufacturing of carbide tools by Selective Laser Melting

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Procedia Manufacturing 2018年 21卷 765-773页

作者： Eckart Uhlmann André Bergmann Robert Bolz Fraunhofer Institute for Production Systems and Design Technology (IPK) Pascalstraße 8-9 Berlin 10587 Germany Technische Universität Berlin – Institute for Machine Tools and Factory Management (IWF) Pascalstraße 8-9 Berlin 10587 Germany

Application fields of electrical discharge machining (EDM) are limited due to given process conditions. When producing structures of high aspect ratios or using multi-axis machining, removed particles assemble at the machining zone, leading to process instabilities and increasing tool wear. A promising approach to improve EDM process conditions is the utilization of flushing channels in the tool electrode. However, with increasing complexity of the electrode geometry and the local integration of the mentioned flushing channels, conventional electrode manufacturing reaches its limitations. By applying Selective Laser Melting (SLM), these limitations are eliminated. An additional benefit is the efficient use of material during SLM, where nearly no waste is produced, because remaining powder can be used for the next SLM-process. The appropriate integration of flushing channels, even for complicated electrode geometries, improves process conditions during EDM in a variety of applications, leading to a higher material removal rate V W and reduced tool wear ϑ compared to machining without flushing. Additionally, the number of required tool electrodes can be reduced, as SLM enables an efficient integration and miniaturization of all features in a single electrode, what results in a far more sustainable process chain. Of particular interest in the field of EDM is carbide. Because of its wear resistance and stability, it is an ideal electrode material, which is commonly applied in µEDM. Tungsten carbide-cobalt is representative for this group of materials, which is already used in tool manufacturing. Several tests show a general suitability of carbide tool electrodes made by SLM for EDM-processing. However, the SLM process parameters and the composition of the carbide-cobalt show significant impact to the EDM results. A lower proportion of cobalt leads to reduced material removal rates, whereas the level of tool wear remains at a similar level. In order to benefit from the a

关键词： additive manufacturing selective laser melting electrical discharge machining tungsten carbide

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