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Cluster identification of sensor data for predictive maintenance in a Selective Laser Melting machine tool

Procedia Manufacturing 2018年 24卷 60-65页

作者： Eckart Uhlmann Rodrigo Pastl Pontes Claudio Geisert Eckhard Hohwieler 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

Selective laser melting has become one of the most current new technologies used to produce complex components in comparison to conventional manufacturing technologies. Especially, existing selective laser melting machine tools are not equipped with analytics tools that evaluate sensor data. This paper describes an approach to analyze and visualize offline data from different sources based on machine learning algorithms. Data from three sensors were utilized to identify clusters. They illustrate the normal operation of the machine tool and three faulty conditions. With these results, a condition monitoring system can be implemented that enables those machine tools for predictive maintenance solutions.

关键词： Selective laser melting sensor data machine learning clustering predictive maintenance

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Concept of Sustainable Data for a Selective Laser Melting machine

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Procedia Manufacturing 2018年 21卷 655-662页

作者： Eckart Uhlmann Rodrigo Pastl Pontes Abdelhakim Laghmouchi André Bergmann 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

Due to increased digitalization in the production environment, data, information, and sustainable management approaches should be developed in order to enable production machines for data acquisition, data exchange and data analysis. Especially for additive manufacturing technologies, those approaches are extremely important to detect and avoid failures in the manufacturing process. A critical failure during the manufacturing process could lead to a defective workpiece, wasting resources. Within this context, this work addresses the concept of sustainable data for a selective laser melting machine tool. The selective laser melting process is one of the additive manufacturing technologies that is capable of producing lighter and more complex functional workpieces in comparison to conventional manufacturing technologies. Beyond the use of the machine tool system internal data (e.g. process data, internal sensors), additional information such as energy consumption and data provided using external sensors are required to detect the current condition of production process. In order to observe if the considered data sources are capable of identifying abnormal conditions of the machine tool, failures from five subsystems were inserted during a manufacturing process of a reference workpiece. Four of the five data sources detect failures that influenced the layer quality while they are occurring. Thus, the results could be used to allow the operator to take measures to save energy and resources.

关键词： Production SLM machine data management information analysis

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[POSTER] Industrial Augmented Reality: Transferring a Numerical Control Connected Augmented Realty System from Marketing to Maintenance

[POSTER] Industrial Augmented Reality: Transferring a Numeri...

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IEEE International Symposium on Mixed and Augmented Reality Workshops (ISMARW)

作者： Christian Kollatsch Marco Schumann Philipp Klimant Mario Lorenz Institute for Machine Tools and Production Processes Chemnitz University of Technology IWU Fraunhofer Institute for Machine Tools and Forming Technology Department of Orthopedics Trauma and Plastic Surgery

ISBN: (纸本)9781538614549

Connecting third party systems like machine controls and product data management systems with Augmented Reality (AR) support applications is crucial for their industrial success. We present a marketing use case of a Virtual Press demonstrator where the connection to a machine control was successfully implemented. The realization of this application utilized the AR framework ARViewer that is introduced in this paper. Subsequent, an outlook is given how this framework can be extended using three examples of AR maintenance applications.

关键词： Augmented reality

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Smoothed Particle Hydrodynamics simulation of the machining process of Inconel 718

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Procedia Manufacturing 2018年 18卷 1-11页

作者： Eckart Uhlmann Enrico Barth Fraunhofer Institute for Production Systems and Design Technology (IPK) Pascalstr. 8-9 10587 Berlin Germany Institute for Machine Tools and Factory Management (IWF) Technische Universität Berlin Pascalstr. 8-9 10587 Berlin Germany

The Smoothed Particle Hydrodynamics (SPH) is a meshfree simulation method which allows to describe the machining process of the nickel-based alloy Inconel 718. This paper analyses the accuracy of a developed simulation model for an orthogonal turning process. The simulation results show the occurring process forces. Subsequently, the model is extended with a variable chip thickness to consider the different engagement condition during a peripheral down milling process. The model allows to investigate the influence of geometry parameters of the cutting edge for possible tools designs with little economic and financial expenses.

关键词： nickel-based alloys milling tool Smoothed-particle hydrodynamics, simulation machining process tool development cutting forces

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Multi-functional battery housing for electric vehicles

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Lightweight Design worldwide 2017年第5期10卷 26-31页

作者： Schmerler, Rico Gebken, Tobias Kalka, Sebastian Reincke, Tobias Fraunhofer Institute for Machine Tools and Forming Technology IWU Wolfsburg Germany Technische Universität Braunschweig Germany Fraunhofer Institute for Wood Research WKI Hannover Germany

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Enabling Human-Robot-Interaction via Virtual and Augmented Reality in Distributed Control Systems

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Procedia CIRP 2018年 76卷 167-170页

作者： Jan Guhl Johannes Hügle Jörg Krüger Institute for Machine Tools and Factory Management Technische Universität Berlin Pascalstraße 8-9 10587 Berlin Germany Fraunhofer Institute for Production Systems and Design Technology Pascalstraße 8-9 10587 Berlin Germany

Production and assembly lines are nowadays transforming into flexible and interconnected cells due to rapidly changing production demands. Changes are, for example, varying locations and poses for the processed work pieces and tools as well as the involved machinery like industrial robots. Even a variation in the combination or sequence of different production steps is possible. In case of older involved machines the task of reconfiguration and calibration can be time consuming. This may lead, in addition with the expected upcoming shortage of highly skilled workers, to future challenges, especially for small and medium sized enterprises. One possibility to address these challenges is to use distributed or cloud-based control for the participating machines. These approaches allow the use of more sophisticated and therefore in most cases computationally heavier algorithms than offered by classic monolithic controls. Those algorithms range from simple visual servoing applications to more complex scenarios, like sampling-based path planning in a previously 3D-reconstructed robot cell. Moving the computation of the machine’s reactions physically and logically away from the machine control complicates the supervision and verification of the computed robot paths and trajectories. This poses a potential threat to the machine’s operator since he/she is hardly capable of predicting or controlling the robot’s movements. To overcome this drawback, this paper presents a system which allows the user to interact with industrial robot and other cyber physical systems via augmented and virtual reality. Captured topics in this paper are the architecture and concept for the distributed system, first implementation details and promising results obtained by using a Microsoft HoloLens and other visualization devices.

关键词： Augmented reality Robot Human-machine interaction

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Evaluation of Shape Memory Alloy Bulk Actuators for Wear Compensation in Ball Screw Drives

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IFAC-PapersOnLine 2016年第21期49卷 88-94页

作者： Drossel, Welf-Guntram Junker, Tom Bucht, André y de Sosa, Iñaki Navarro Pagel, Kenny Fraunhofer Institute for Machine Tools and Forming Technology IWU Department Mechatronics Dresden01187 Germany Technische Universität Chemnitz Department of Machine Tools and Forming Technology Chemnitz09107 Germany

In this paper we present an approach to reset a preload loss in ball screw drives which enables to compensate losses of positioning accuracy due to wear over lifetime. The main purposes are reduced maintenance, longer service life and improved workpiece quality by regenerating the desired preload conditions which leads to a higher profit for manufacturers. For this purpose, a novel shape memory alloy (SMA) bulk actuator module for ball screw drives is designed. The device is developed to be implemented in standard drives without major changes in component design. It is installed between flanged nut and counter nut and replaces a spacer usually needed to set a defined preload. To achieve the required actuator performance SMA bulk actuators are investigated in detail. This covers their basic design and activation concepts. A prototype is designed and experimentally investigated; measurements show the proof of the concept. © 2016

关键词： Ball screws Drives machine tools Rigidity Shape memory effect Actuator modules Actuator performance Ball screw drives Basic designs Component design Positioning accuracy Shape memory alloys(SMA) Wear compensation

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Measurement of in-mould shear rates by x-ray particle image velocimetry 17

Measurement of in-mould shear rates by x-ray particle image ...

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17th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2017

作者： Uhlmann, E. Hein, C. Oberschmidt, D. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Germany

ISBN: (纸本)9780995775107

The manufacturing of large quantities of polymeric optical and micro-optical components becomes more and more important regarding industrial applications as MEMS devices, customer electronics or micro imaging systems. The relevant parameters for the qualification of polymeric micro optics as surface roughness, shape and positional tolerances, refractive index, molecular orientation, injection moulding process induced deviations and their connection to injection moulding parameters are largely known. The manufacturing of micro optics by micro injection moulding and associated with that, micro injection moulding machine tools with highly complex plastification and injection systems is far less understood. In particular, the influence of shear loads and temperature deviation on replication quality has not been fully investigated. The occurring shear rates during injection moulding lead to mechanical damage of the polymer on a molecular level and reduced optical functionality. This work presents an approach for in mould shear rate measurement by the use of a metrological computed tomography system. Using metal powder with a particle size 3 μm ≤ dp ≤ 5 μm as tracer particles, Polyetheretherketon (PEEK) as mould material, a Zeiss Metrotom 800 computer tomography system and a Babyplast injection unit, streamlines of polymer flow could be visualized. In accordance to optical particle image velocimetry (PIV), for each frame a matrix including particle position was calculated. The temporal shift of these positions lead to velocity gradients that allow the calculation of shear-rates. By reproducing relevant elements of injection units and mould structures, this works enables the profound investigation of fluid dynamics regarding micro injection moulding and the correlation between shear loads and polymer characteristics.

关键词： Injection molding

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Utilization of Product Lifecycle Data from PLM Systems in Platforms for Industrial Symbiosis

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Procedia Manufacturing 2017年 8卷 369-376页

作者： Halstenberg, Friedrich A. Lindow, Kai Stark, Rainer Institute for Machine Tools and Factory Management Technische Universität Berlin Germany Department for Virtual Product Creation Fraunhofer Institute Production Systems and Design Technology Berlin Germany

Industrial Symbiosis represents a promising approach to foster the transformation towards a circular economy. To involve businesses in Industrial Symbiosis, online platforms and input-output matching tools for facilitating the exchange of by-products have been provided by industry organizations and facilitators. Regarding the discrete parts and product manufacturing industry (DPPM), little success is being reported for such platforms and tools. Within the scope of this research, a list of Input-Output matching tools was analysed regarding data sources which are currently used for input-output Matching. Specifications of by-products in the DPPM industry were reviewed in order to identify a list of requirements for data sources. Shortcomings of the currently existing input-output matching tools were identified and suggestions for additional data sources used for input-output matching in IS in DPPM were given. Results show that datasets currently used do not include organisational data sources such as Product Data Management (PDM) systems, Enterprise Resource Planning (ERP) systems, Supply Chain Management (SCM) systems, and or Manufacturing Execution Systems (MES). © 2017 The Authors

关键词： Industrial Ecology Industrial Symbiosis Product Lifecycle Management (PLM)

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Liquid covered micro-milling 17

Liquid covered micro-milling

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17th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2017

作者： Uhlmann, E. Oberschmidt, D. Polte, M. Polte, J. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Germany

ISBN: (纸本)9780995775107

Micro-milling tools made of cemented carbide suffer from fast tool wear and random tool breakage during the machining process. The cutting material cemented carbide is composed of a hard material phase made of tungsten carbide and a binder phase made of cobalt. An allotropical crystal lattice transformation of the binder phase at a temperature υ = 420 °C leads to increased tool wear. Commonly minimum quantity lubrication (MQL) is used as cooling lubricant technology in micro-milling. In this work a new liquid covered cooling lubricant (LCCL) technology and the commonly used MQL technology were compared regarding tool wear of cemented carbide tools for machining the steel STAVAX ESU. In the LCCL technology the cutting process is completely covered with cutting lubricant. It could be concluded that the new LCCL technology offers a high potential to reduce the tool wear in micro-milling of steel with cemented carbide micro-milling tools.

关键词： Wear of materials

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