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Tool-holder integrated printed piezoceramic sensors for process state classification and tool-wear progress evaluation in turning

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Procedia CIRP 2025年 133卷 382-387页

作者： Miguel Panesso Jan Berthold Lucas Hamm Zongshuo Li Welf-Guntram Drossel Thomas Bergs Fraunhofer Institute for Machine Tools and Forming Technology Nöthnitzer Str. 44 01187 Dresden Germany Manufacturing Technology Institute (MTI) of RWTH Aachen University Campus-Boulevard 30 52074 Aachen Germany

Tool condition monitoring strategies in turning processes, using multiple sensor sources to measure dynamic quantities (e.g., force, acoustic emissions, acceleration), has gained significant attention in conjunction with machine learning methods. As a novel approach, the introduction of printed piezoceramic thick films in machine tools allows the customization of sensor shape and placement, optimized to fit the tool holder’s geometry and process boundary conditions. This work proposes integration concepts using two configurations of printed piezoceramic sensors. This includes the use of a finite element simulation to estimate the generated electric charge from sensors on three locations on the tool holder, induced by transient mechanical loading. The design is validated under controlled mechanical loading and tested across various cutting conditions and tool-wear states. Signal information content from each sensor location, relative to different machining conditions, is assessed through recursive feature elimination and validated using dimensionality reduction. Finally, tool-wear progress is evaluated using the selected features.

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Influence Estimation In Multi-Step Process Chains Using Quantum Bayesian Networks

Influence Estimation In Multi-Step Process Chains Using Quan...

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2022 Informatik in den Naturwissenschaften, INFORMATIK 2022 - 2022 Computer Science in the Natural Sciences, INFORMATIK 2022

作者： Selch, Maximilian Müssig, Daniel Hänel, Albrecht Lässig, Jörg Ihlenfeldt, Steffen Fraunhofer Institute for Machine Tools and Forming Technology IWU Department Digital Production Twin Nöthnitzer Straße 44 Dresden01187 Germany Fraunhofer IOSB Branch Advanced System Technologies IOSB-AST Cognitive Energy Systems Wilhelmsplatz 11 Görlitz02826 Germany

ISBN: (纸本)9783885797203

Digital representatives of physical assets and process steps play a decisive role in analysing properties and evaluating the quality of the process. So-called digital twins acquire all relevant planning and process data, which provide the basis, for example, to investigate path accuracies in manufacturing. Each single process step aims to perform an ideal machining after the specification of a target geometry. However, the practical implementation of a step usually shows deviations from the targeted shape. The machine-learning based method of probabilistic Bayesian networks enables the quality estimation of the holistic process chain as well as improvements by targeted considerations of single steps and influence factors. However, the handling of large-scale Bayesian networks requires a high computational effort, whereas the processing with quantum algorithms holds potential improvements in storage and performance. Based on the issue of path accuracy, this paper considers the modelling and influence estimation for a milling operation including experiments on superconducting quantum hardware. © 2022 Gesellschaft fur Informatik (GI). All rights reserved.

关键词： Bayesian networks

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Vacuum gripper without central compressed air supply

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Procedia CIRP 2021年 97卷 76-80页

作者： Robert Schaffrath Erik Jäger Georg Winkler Jan Doant Marcel Todtermuschke Fraunhofer Institute for Machine Tools and Forming Technology IWU 09126 Chemnitz Germany

Compressed air operated industrial equipment has been always an important part of car body production. Advantages of compressed air powered tools are their robust construction, low-cost manufacturing as well as high performances especially forces at a minimum of construction size. Disadvantages are high operating costs, due to pressure losses in case of leakage, high installation costs and intricate cabling especially at highly flexible manufacturing systems. As a result, many automobile manufacturers aiming for a reduction of air powered production tools or even air free automobile manufacturing systems. Against this background a new concept of a vacuum grippers will be presented, which does not need central compressed air supply. Results of the development of suction cups will be shown, which are based on mechanical air displacement inspired by artificial muscles. Furthermore, a control of clusters of new suction cups with artificial intelligence is given.

关键词： Automotive Body shop End of arm tooling Gripper Vacuum Sucktion cups Compressed air supply

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Data Acquisition Framework for spatio-temporal analysis of path-based welding applications 57

Data Acquisition Framework for spatio-temporal analysis of p...

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18th IFAC Workshop on Time Delay Systems, TDS 2024

作者： Safronov, Georgij Theisinger, Heiko Sahlbach, Vasco Braun, Christoph Molzer, Andreas Thies, Anabelle Schuba, Christian Shirazi, Majid Reindl, Thomas Hänel, Albrecht Engelhardt, Philipp Ihlenfeldt, Steffen Mayr, Peter BMW AG Petuelring 130 München80788 Germany Technical University of Munich Materials Engineering of Additive Manufacturing Freisinger Landstraße 52 Garching bei München85748 Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Nöthnitzer Straße 44 Dresden01187 Germany Nebumind GmbH Willy-Messerschmitt-Straße 1 Taufkirchen82024 Germany

The use of digital technologies in industrial manufacturing reduces operational costs and improves production quality. The "Framework for Spatiotemporal Production Data Acquisition" (PathSense) aims to improve access and usability of production data by applying a common data ecosystem. Through integrating operational technology (OT) and information technology (IT), PathSense supports decision-making and process optimization. The framework uses the concept of digital shadows to collect critical information from sensors within the continuous manufacturing processes, e.g., welding or gluing lines. Spatial and temporal digital shadows are developed in accordance with human spatial cognition to support sophisticated-yet intuitive-human-computer interactions without the need for advanced data science skills. The backbone of the framework consists of robust data pipelines with a setup incorporating modern IT protocols, such as OPC UA and MQTT, to support the efficient acquisition and management of data. The paper addresses the challenges associated with the combination of IT and OT in cyber-physical systems, stressing modern complex data-intensive manufacturing as one exemplary domain to be tackled by scalable and secure data architectures. The paper identifies two major future directions: refining data integration processes and embedding advanced machine learning algorithms to enable automated data analysis and improve process quality monitoring. In summary, PathSense proposes a data-driven approach for quality inspection in manufacturing, which may eventually enhance industry practices and move towards data-driven decisions and increased operational flexibility. © 2024 The Authors.

关键词： Spatio-temporal data

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forming Limit of Dual Phase Steel: An Experimental and Numerical Investigation 14th

Forming Limit of Dual Phase Steel: An Experimental and Numer...

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14th International Conference on technology of Plasticity, ICTP 2023

作者： Müller, Martina Fehlemann, Niklas Herrig, Tim Lenz, David Könemann, Markus Bergs, Thomas Münstermann, Sebastian Laboratory for Machine Tools and Production Engineering WZL of RWTH Aachen University Campus-Boulevard 30 Aachen52074 Germany Fraunhofer Institute for Production Technology IPT Steinbachstrasse 17 Aachen52074 Germany Institute of Metal Forming IBF RWTH Aachen University Intzestrasse 10 Aachen52074 Germany

ISBN: (纸本)9783031409196

forming limit diagrams and forming limit curves are used to determine the failure limits of sheet metal materials by conducting a forming limit analysis. The aim is to enable the selection of suitable materials, geometries and process parameters at an early stage in the component development. In this way, engineering time and costs can be reduced. In addition to experimental forming limit analyses, different models and model approaches exist to numerically predict damage and failure. All have in common that calibration is necessary based on experimental investigations. The correspondingly determined parameters specify when ductile damage initiation begins, how it evolves, and how the material finally fails. Thus, the calibration and the parameters determined have a significant impact on the models’ accuracy. The present work focuses on the numerical prediction of DP 800 dual phase steel in a Nakajima test using a modified Bai-Wierzbicki model. Besides the calibration influence of the damage model coming from a non-unique parameter selection is investigated. A sensitivity analysis of the experimentally determined parameters of the damage model is carried out with the aim of predicting the crack initiation with high accuracy and to determine the influence of the calibrated parameters, especially the range between the damage initiation locus, the failure locus and the damage evolution rate. The objective is to determine which damage model parameters possess a high influence on the failure prediction, in order to be able to make a risk assessment with regard to the prediction accuracy for later applications. © 2024, The Author(s), under exclusive license to Springer Nature Switzerland AG.

关键词： Calibration

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The RaRe2 Attempt as a Holistic Platform for Decision Support in Rapidly Changing Process Chains 9th

The RaRe2 Attempt as a Holistic Platform for Decision Suppor...

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Production Processes and Product Evolution in the Age of Disruption - Proceedings of the 9th Changeable, Agile, Reconfigurable and Virtual Production Conference CARV2023 and the 11th World Mass Customization and Personalization Conference MCPC2023

作者： Teicher, Uwe Ben Achour, Anas Selbmann, Erik Demir, Ozan Emre Arabsolgar, Dena Cassina, Jacopo Ihlenfeldt, Steffen Colledani, Marcello Fraunhofer Institute for Machine Tools and Forming Technology IWU Pforzheimer Straße 7a Dresden01189 Germany Department of Mechanical Engineering Politecnico di Milano Via La Masa 1 Milan20156 Italy Syxis VSI Europos pr. 122 Kaunas46351 Lithuania Institute of Mechatronic Engineering Technische Universität Dresden Dresden01069 Germany

ISBN: (纸本)9783031348204

The trend towards globalization is increasingly being questioned or put under the microscope for social, political, and economic policy reasons. Due to the closely net-worked trade relations unpredictable events like pandemics, natural disasters, technical disruptions of supply chains and political conflicts can have considerable economic and social consequences. However, the central point is the constantly and rapidly changing market conditions to which it is necessary to react, or which must be shaped in order to adequately and successfully counter new technologies or new competitors. Within this paper it is worked out that based on targeted support of decision makers from top management to lower management and of the executing staff, the economic consequences for companies can be lowered with data-driven approaches and furthermore the. The objective of this paper is to help tackling reconfiguration needs via a holistic approach with the human being in the centre. The central hypothesis consists of the fact that with standards and defined methods, data-driven tools such as the digital twin or dedicated software applications for decision support specifically for information-based decisions, it is possible to deal more robustly and resiliently with rapid changes in the business environment. Based on exemplary use cases of automotive and medical technology as well as precision manufacturing of optical components, a holistic ecosystem platform RaRe2 will be developed, which will be disseminated as a reference for innovative software concepts on an industrial scale. © 2023, The Author(s), under exclusive license to Springer Nature Switzerland AG.

关键词： Supply chains

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Increasing Energy Efficiency in Hot forming Processes Through Multivalent Data Use 9

Increasing Energy Efficiency in Hot Forming Processes Throug...

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9th International Conference on Hot Sheet Metal forming of High-Performance Steel, CHS2 2024

作者： Polster, Stefan Boesler, Martin Straube, Oliver Lösch, Siegfried Brenne, Thomas Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Str. 88 Chemnitz09126 Germany Gestamp Autotech Engineering Deutschland GmbH August-Thyssen-Str. 1 Ludwigsfelde14974 Germany AutoForm Engineering Deutschland GmbH Joseph-von-Fraunhofer-Straße 13a Dortmund44227 Germany

ISBN: (纸本)9780930767303

The energy policy requirements help to make industrial production more sustainable and environmentally friendly, reduce energy consumption and lower the overall costs for businesses. There is a great need for action to increase energy efficiency in production in press hardening processes through efficient technologies along entire process chains. In such production processes and process chains, data accumulates from a wide variety of sources, including machine controls, sensors, material data and simulation data from process design. The logical next step is to utilize this data along with machine learning and optimization methods to control the process and pursuing objectives like optimal quality, minimal energy, or fast cycle times. This is where the proposed method of this work comes in. The main contribution of this work is a methodology to schematically describe and handle process optimizations model-based. In addition, this method is demonstrated on a hot forming process using hybrid (simulation and experimental) data. It is shown that the process can be optimized regarding its energy consumption while complying with additional technical and quality boundary conditions. © CHS2 2024 . All rights reserved.

关键词： Energy efficiency

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Vacuum gripper without central compressed air supply 8

Vacuum gripper without central compressed air supply

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8th CIRP Conference of Assembly technology and Systems, CATS 2020

作者： Schaffrath, Robert Jäger, Erik Winkler, Georg Doant, Jan Todtermuschke, Marcel Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz09126 Germany

关键词： Compressed air

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Efficient data acquisition for traceability and analytics

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Procedia CIRP 2024年 122卷 73-78页

作者： Heiner Reinhardt Mahtab Mahdaviasl Bastian Prell Anton Mauersberger Philipp Klimant Jörg Reiff-Stephan Steffen Ihlenfeldt Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Chemnitz Germany Technical University of Applied Sciences Wildau Hochschulring 1 15745 Wildau Germany Professorship Virtual Technologies Hochschule Mittweida - University of Applied Sciences Technikumplatz 17 09648 Mittweida Germany Institute of Machine Tools and Control Engineering Technische Universität Dresden 01062 Dresden Germany

Implementing processes for traceability is required in various industries to assure product quality during manufacturing, provide evidence on required processing conditions or facilitate product recalls. Commonly, radio-frequency identification (RFID) or code recognition techniques (e.g. Data Matrix) are applied to track the flow of workpieces through a manufacturing system and link processing data accordingly. Although the analysis of tracking data is well-examined, we still see a gap in the research on the trade-off between data acquisition, data analytics and data quality. Here, we present a framework to increase the value of existing data by enabling data analytics while addressing common pitfalls and reducing the costs of data management.

关键词： Identification Knowledge management Manufacturing system Process control Quality assurance Sustainable development Decision making Complexity Analysis Design

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Shaping of Sharp-Edged Design Elements by Electromagnetic forming 13th

Shaping of Sharp-Edged Design Elements by Electromagnetic Fo...

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13th International Conference on the technology of Plasticity, ICTP 2021

作者： Psyk, Verena Scheffler, Christian Stalmann, Albrecht Goede, Martin Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz Germany Volkswagen AG Wolfsburg Germany

ISBN: (纸本)9783030753801

Modern car body design includes parts with sharp-edged elements, which are challenging for conventional sheet metal forming technologies. This is especially critical when implementing aluminum parts in order to consider lightweight design requirements. Applying high strain rates allows increasing formability for numerous materials, including typical aluminum alloys used in the automotive industry. Therefore, integrating high-speed forming into a conventional process can help to extend forming limits. The feasibility of locally sharpening a deep-drawn radius by integrated electromagnetic forming was proved in the literature, but up to now, the investigated target radii were much larger compared to the sheet thickness. The presented paper shows that target radii in and below the size of the sheet thickness are possible by this process combination. Based on a simplified 2D component geometry, complementary experimental and numerical investigations served for developing different variants of a modular test tool and analyzing the influence of important process and tool parameters on the forming result. © 2021, The Minerals, Metals & Materials Society.

关键词： Automotive industry

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