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AI-driven force torque control strategies for further automate flexible high-precision, contact-intensive assemblies

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Procedia CIRP 2024年 130卷 348-354页

作者： Yunqi Gu Ruth Maria Otto Martin Naumann Leutrim Gjakova Rico Löser Martin Dix University of Applied Sciences Munich Lothstr. 34 80335 Munich Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU 09126 Chemnitz Germany Chemnitz University of Technology 09111 Chemnitz Germany

Robotic assembly processes are integral to industrial manufacturing, traditionally relying on pre-programmed sequences that exhibit limited adaptability to uncertain conditions. Recent advancements propose AI-enhanced vision systems as viable solutions to mitigate uncertainty in automated tasks. Despite the potential of vision, contact-intensive, high-precision assembly processes need customized force-torque feedback strategies to perform the task. Parametrization for setup and adaption of force-torque processes are time consuming, but decisive for quality. This work outlines an AI-driven force-torque control strategic solution for peg-in-hole assembly task, which employs object detection algorithm to grasp the workpiece and determine flexible assembly position, with force-torque-informed DNN algorithm for error correction in terms of position, and digital twin to monitor the process and collect virtual data.

关键词： Robotic Assembly Force-torque control Deep-Neural-Network Cognitive Robotics

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Incremental micro-forming for surface finishing with piezoelectrically actuated hammering tool with coupling unit 21

Incremental micro-forming for surface finishing with piezoel...

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21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021

作者： Fiedler, Maik Kolouch, Martin Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 Chemnitz09126 Germany

ISBN: (纸本)9780995775190

machine hammer peening can be referred as an incremental mechanical surface treatment procedure, which can be realized by using various tools being based on various actuator principles. For the purpose of high productivity, a high-performance drive for generating vibrations in the tool of a high frequency is desired. Therefore, this paper presents a new hammer peening tool with a piezoelectric actuator. In order to facilitate this actuator principle for practical applications, a coupling unit is necessary being installed between the tool and the machine. This coupling unit insulates the process vibration at the machine (e.g. a machine tool or an industrial robot) and changes the operating mode of the hammer peening process from position controlled to force controlled. In such way, the accuracy of the positioning movement as well as the accuracy of the workpiece are not the issue anymore and the piezoelectrically actuated tool with a low stroke of 120 µm can be deployed for practical applications. This tool together with the coupling unit can reach hammering frequencies in the range from 800 to 1300 Hz. These frequencies enable higher feed rates and productivity of the hammer peening process than tools with pneumatic or electromagnetic actuators being available on the market. For the purpose of demonstration of the tool potential, some experimental tests are presented in this paper. Here, workpiece being milled like in die making were treated by the hammer peening process with the new tool. The surface were smoothed from Ra 1.18 μm to Ra 0.10 μm. © 2021 Proceedings of the 21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021. All rights reserved.

关键词： Piezoelectric actuators

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Influence of the cutting edge preparation of carbide punching tools for punching of ultra-high strength steel strips

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Procedia CIRP 2024年 123卷 268-273页

作者： Nermin Redžić Sven Winter Elmar Galiev Sarah Baron Christian Stein Markus Höfer Joachim Regel Verena Kräusel Martin Dix Chemnitz University of Technology Institute for Machine Tools and Production Processes IWP Reichenhainer Str. 70 09126 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 09126 Chemnitz Germany Fraunhofer Institute for Surface Engineering and Thin Films IST Riedenkamp 2 38108 Braunschweig Germany

In order to ensure a robust punching process of ultra-high strength steel spring strips using carbide punching tools, a high stability of the cutting edge is required. Here the cutting edge preparation process has a significant influence. In the presented study, high-pressure abrasive water jet technology for cutting edge preparation was designed, investigated and analysed. For defining the optimal cutting edge shape regarding stresses, a numerical analysis using LS-DYNA was conducted. Within this analysis, the influence of the cutting edge rounding and symmetry was numerically tested and evaluated. Based on the results, two cutting edge shapes were selected and prepared using the high-pressure abrasive water injection jet technology. The tools were applied in the punching process up to 50,000 strokes in order to analyse the cutting performance and tool wear. With regard to a highly wear resistant tool for punching, a combination of the abrasive water injection jet preparation routine and a CVD diamond coating are under further investigation and first insights are presented additionally.

关键词： Punching Carbide Tool geometry Waterjet machining Ultra-high strength steel

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Experimental validation of characteristic diagram-parameterization for environment-induced thermal interactions on machine tools in a climate chamber 14

Experimental validation of characteristic diagram-parameteri...

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14th CIRP Conference on Intelligent Computation in Manufacturing Engineering, CIRP ICME 2020

作者： Kumar, Tharun Suresh Glänzel, Janine Tehel, Robert Putz, Matthias Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 Chemnitz09126 Germany

Thermal gradients created by environmental influences on machine tools cause considerable non-linear thermo-elastic deformations whether the machine is in operation or in idle mode. When a machine tool is subjected to changes in environmental influences such as ambient air temperature, velocity or direction, then flow (CFD) simulations are necessary to effectively quantify the thermal behavior between the machine tool surface and the surrounding air. The conventional two-step simulation procedure consisting of coupled CFD and thermo-elastic simulation is highly time-consuming especially when complex geometries are considered. Decoupling of CFD and thermo-elastic simulation can be achieved by introducing a Clustering Algorithm (CA) and Characteristic Diagrams (CDs) within the simulation workflow. Using training data obtained from a limited number of CFD simulations, the CDs can predict the heat transfer coefficients (HTCs) based on the parameterized environmental influences. This paper attempts to validate the experimental temperature and displacement readings obtained at selected positions on a machine tool using a wide range of metrological equipment such thermography camera, temperature and displacement sensors with the decoupling approach based on parameterized CDs. For investigation, the machine tool is positioned in a climate chamber, which facilitates the variation of environmental influences such as ambient temperature, flow velocity and flow direction. Initially, a precise coupled simulation model is created which is later on converted to a decoupled system using parameterized CDs. © 2021 The Authors. Published by Elsevier B.V.

关键词： machine tools

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Acoustic process monitoring for ultrasonic-assisted deep drilling 27

Acoustic process monitoring for ultrasonic-assisted deep dri...

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27th International Congress on Sound and Vibration, ICSV 2021

作者： Georgi, Oliver Rüger, Carlo Rentzsch, Hendrik Hochmuth, Carsten Putz, Matthias Dix, Martin Papsdorf, Gunther Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany SINUS Messtechnik GmbH Leipzig Germany

ISBN: (纸本)9788378807995

Regarding deep drilling, problems in terms of chip formation and removal, burrs, tool vibrations as well as process reliability occur. Modern scientific approaches face these problems and aim to improve productivity, quality and reliability to reduce manufacturing costs. At the same time, there is a trend to use in-process monitoring and control in terms of adaptive machining processes in order to operate cutting processes close to the limits of stability. The application of ultrasonic assistance for drilling and deep drilling processes enables multiple advantages like reduced tool wear and burr formation as well as enhanced chip breaking behaviour. Moreover, ultrasound enables the use of previously unused physical effects to obtain information from the process zone and identify process conditions. In this context, the paper presents an approach of using modulation phenomena to evaluate dynamic process stability, using ultrasound as a carrier signal for low-frequency vibrations related to the deep drilling tool. In addition, the resonant coupling of ultrasonic system and cutting operation is used to draw direct conclusions about the load behaviour of the machining process from characteristics of the resonant vibration system. This directly leads to the possibility to perform in-process monitoring of tool wear. The article covers the theoretical basics, the hardware realization as well as experimental investigations regarding acoustic process monitoring for ultrasonic-assisted deep drilling. © "Advances in Acoustics, Noise and Vibration - 2021" Proceedings of the 27th International Congress on Sound and Vibration, ICSV 2021. All rights reserved.

关键词： Process monitoring

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A Hybrid Approach of No-Code Robot Programming for Agile Production: Integrating Finger-Gesture and Point Cloud

A Hybrid Approach of No-Code Robot Programming for Agile Pro...

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IEEE International Workshop on Robot and Human Communication (ROMAN)

作者： Jayanto Halim Paul Eichler Sebastian Krusche Mohamad Bdiwi Steffen Ihlenfeldt Group Collaborative Robot Systems Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz Germany Departement of Production System and Factory Automation Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz Germany

ISBN: (数字)9798350375022

ISBN: (纸本)9798350375039

Industrial robot programming necessitates specialized expertise and significant time commitment, particularly for small-batch productions. In response to the escalating demand for production agility, novel approaches have emerged in intuitive robot programming. These inventive systems, rooted in diverse conceptual frameworks, are designed to expedite the deployment of robot systems. A prominent innovation in this domain is adopting no-code robot programming through finger-based gestures. A robot program can be generated by capturing and tracking non-expert users’ finger movements and gestures, converting 3D coordinates into an executable robot programming language. However, accurately determining finger positions for 3D coordinates and precise geometrical features presents an ongoing challenge. In pursuit of heightened trajectory precision and reducing more significant effort for the users, we propose a hybrid methodology that amalgamates finger-gesture programming with point cloud data. This synergistic integration demonstrates promising outcomes, substantiating its potential to facilitate the precise and adaptive generation of robot paths within robot applications.

关键词： Point cloud compression Technological innovation Three-dimensional displays Service robots Tracking Robot kinematics Welding Trajectory Robots Robot programming

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Generative design in factory layout planning 14

Generative design in factory layout planning

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14th CIRP Conference on Intelligent Computation in Manufacturing Engineering, CIRP ICME 2020

作者： Süße, Marian Putz, Matthias Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany

Planning and optimization of facility layouts have been investigated for decades and manifold approaches are applied for structuring and design of production layouts. However, results heavily depend on the experience and creativity of involved planning experts. Currently, complexity of planning processes constantly increases, e.g. due to further requirements of energy and media supply. Generative Design, hitherto mainly applied in component development, provides opportunities to cope with a much larger solution space and develop creative layout concepts. Thus, based on a structured overview on established planning methods, a concept and first results of factory layout planning with Generative Design are described. © 2021 The Authors. Published by Elsevier B.V.

关键词： Plant layout

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A No-Code Approach for Intuitive Robot Programming for Agile Welding Application

A No-Code Approach for Intuitive Robot Programming for Agile...

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International Workshop on Robot Sensing (ROSE)

作者： Jayanto Halim Mohamad Bdiwi Steffen Ihlenfeldt Group Collaborative Robot Systems Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz Germany Department of Production System and Factory Automation Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz Germany

ISBN: (数字)9798350362367

ISBN: (纸本)9798350362374

Agile manufacturing paradigms have revolutionized a new era of production processes, offering unparalleled flexibility and adaptability to the ever-changing landscape of product variations and smaller batch sizes. In response to this dynamic environment, the robotic industry has undergone a significant transformation, presenting a range of versatile robotic systems capable of swiftly deploying diverse applications. This transformative shift accelerates manufacturing processes and showcases the ability to accommodate product specifications and batch size variations. Welding is a notable example of robotics playing a crucial role in agile production. This work presents a novel approach combining no-code robot programming and an intelligent vision-based welding system. By leveraging this framework, even non-expert users can seamlessly instruct welding trajectories through intuitive interactions. These trajectories are meticulously crafted using advanced welding seam extraction algorithms, considering various welding joint types and inputs from heterogeneous sensors. Consequently, robot-specific parameters can be parametrized, and the generated robot code can seamlessly translate into robotic movements in the real world. Validation of this approach through real-world experiments underscores its potential for deployment in agile welding applications. The promising results affirm this novel methodology's efficacy, paving the way for its practical implementation in real-world scenarios. By effectively bridging the divide between advanced robotics and agile manufacturing, this approach can potentially elevate industrial robotic applications to new levels of efficiency and adaptability.

关键词： Agile manufacturing Service robots Welding Semantics Production Robot sensing systems Mathematical models

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Software assisted clamping point classification and position optimization for the efficient flexibilization of carbody fixtures using mathematical geometry-based search algorithms 14

Software assisted clamping point classification and position...

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14th CIRP Conference on Intelligent Computation in Manufacturing Engineering, CIRP ICME 2020

作者： Fritzsche, Rayk Schaffrath, Robert Todtermuschke, Marcel Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany

The fraunhofer iwu has been developed specialized clamping robots for production of different car-models on one fixture. One of the challenges with universal clamping of different components is the contact point between part and clamping device. For the optimization of the clamping contours, a software was developed with which the geometries of the clamping points can be automatically analyzed and classified. With target search criteria, the clamping position on the component can be changed so that the clamping contours are geometrically simplified. Thus, a huge reduction in the complexity of the flexible clamping device is possible. © 2021 The Authors. Published by Elsevier B.V.

关键词： Product design

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Ultrasonic assistance to reduce and monitor tool wear in deep drilling 21

Ultrasonic assistance to reduce and monitor tool wear in dee...

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21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021

作者： Georgi, Oliver Rüger, Carlo Rentzsch, Hendrik Putz, Matthias Dix, Martin Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 Chemnitz09126 Germany

ISBN: (纸本)9780995775190

In deep drilling, the large aspect ratio of hole depth to diameter causes problems in terms of chip formation and removal as well as tool vibrations. In addition, tool wear leads to a deterioration of process properties and decreasing process reliability. Therefore, scientific approaches aim to improve productivity and quality via a reduction of tool wear. Furthermore, methods for monitoring process conditions, specifically known as tool condition monitoring, contribute to an increase in performance. Superimposing ultrasonic vibrations to the conventional process is known as an approach with various potentials like reduced tool wear and burr formation or enhanced chip breaking behaviour. Aiming to realize in-process measurements to identify tool conditions, ultrasonic assistance enables the application of new monitoring techniques. In this context, the paper introduces a new approach to monitor tool wear using characteristic values of the resonant ultrasonic system coupled with the machining process. Experimental investigations considering deep drilling in steel 1.2311 show prove of the positive influence of ultrasonic assistance on the progress of tool wear. Furthermore, in-process measurements demonstrate that the new approach is able to monitor tool wear. © 2021 Proceedings of the 21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021. All rights reserved.

关键词： Aspect ratio

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