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A survey on modeling and forecasting the energy consumption in discrete manufacturing

Procedia CIRP 2020年 90卷 443-448页

作者： Heiner Reinhardt Jan-Peter Bergmann Marc Münnich David Rein Matthias Putz Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz 09126 Germany

The manufacturing industry faces environmental challenges due to its high electrical energy demand. Measures for improving the energy efficiency of manufacturing processes are applied to reduce the total energy consumption while eco-friendly renewable energy sources are harnessed increasingly. However, the volatile nature of renewables drives a change in energy allocation and the electrical grid. Both energy efficiency and energy allocation may benefit from accurate energy consumption modeling and forecasting. In this paper we constitute the state of the art of existing modeling techniques in the domain of discrete manufacturing and derive future research activities.

关键词： Energy Energy efficiency Forecast Manufacturing Modeling

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Single point incremental forming of large sheet metal components

Single point incremental forming of large sheet metal compon...

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ASME 2019 International Mechanical Engineering Congress and Exposition, IMECE 2019

作者： Schieck, Frank Mauermann, Reinhard Weise, Dieter Demmler, Matthias Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Saxony Germany

ISBN: (纸本)9780791859377

The production of complex, large-scale cladding parts made of metal in small quantities for a wide range of applications in architecture, power generation, shipbuilding, but also rail vehicle construction, mobile work machines and, last but not least, automotive sector is a major challenge in terms of principled manufacturability, but also in terms of manufacturing costs. Appropriate components are often produced in small quantities by hand, whereby the reproducibility and achievable quality depend largely on the experience and craftsmanship of the employer. The incremental forming using CNC-controlled machine tools or robots offers a good alternative for an efficient and reproducible production of sheet metal components with batch size one. There are already a large number of research work, studies and examples of applications worldwide regarding principled incremental forming strategies, process layout, FE simulation and optimization strategies. The fraunhofer iwu works with the claim of applied research, that is, to transfer results from basic research into an industrial application. This also applies to the field of incremental sheet metal forming. Especially in the area of large-scale, 3-dimensional components, there is a very great need on the part of the industry. The paper provides an overview of current research results in the field of incremental forming of industrially relevant large-scale structures up to dimensions of approximately 4 x 2 meters, which are carried out in the single point process on a modified large milling machine. The topic of shape storage (molds), flexible clamping frames and heating equipment for temperature-supporting incremental forming of light metals is also addressed. The outlook identifies application and development potential aimed at both the further development of the technology and the associated equipment technology. Copyright © 2019 ASME.

关键词： machine tools

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Bin Picking Pneumatic-Mechanical Gripper for Industrial Manipulators

Bin Picking Pneumatic-Mechanical Gripper for Industrial Mani...

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2021 International Conference on High technology for Sustainable Development, HiTech 2021

作者： Ivanov, Vladislav Aleksandrov, Angel Bdiwi, Mohamad Popov, Aleksander Rashid, Aquib Pershina, Zhanna Kolker, Aleksey Dimitrov, Lubomir Technical University of Sofia Dept. for Machine Elements and Non-Metallic Constructions Sofia Bulgaria Line 3: Fraunhofer Institute for Machine Tools and Forming Technology Robot System Department Chemnitz Germany Novosibirsk State Technical Universirty Falulty of Automation Russia

ISBN: (纸本)9781665448734

The human body is an advanced and complex machine. A simple task like grasping an object, which is done intuitively, has puzzled researchers for decades. For each object, humans have a suitable grip to grab it optimally and safely. Even for objects which we have never seen before, we can choose the best possible grip and can adapt as the environment changes to get a better grip based on cognition and experience. One of the main capabilities of humans is their ability to learn about unfamiliar things and processes. This capability helps us adapt to different situations and still be able to solve a problem. This works focuses on developing a self-learning robotic system which can replicate the human learning capabilities in a handing-over task. The proposed system consists of two submodules: 1) Vision analysis and environment monitoring, which provides accurate global and local information about the area in which the robot has to hand over the specific object;2) Safe and flexible bin-picking gripper, which handles various objects with complex geometries. The work is a consortium of 3 partners: iwu Chemnitz (Germany), Novosibirsk State Technical University (Russia) and Technical University of Sofia (Bulgaria) under European program *** RUS PLUS 2017 © 2021 IEEE.

关键词： Industrial manipulators

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Automated design of product-flexible car body fixtures with software-supported part alignment using particle swarm optimization

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Procedia CIRP 2020年 88卷 157-162页

作者： Rayk Fritzsche Eric Voigt Robert Schaffrath Marcel Todtermuschke Marcel Röber 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 Head of dep. Assembly systems at Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz 09126 Germany

The fraunhofer iwu has been developed specialized clamping robots for production of different car-models on one fixture. As a base for the fixture design, a method for optimal part alignment has been developed. For handling multitude of possibilities regarding the alignment of parts from different car-models, a specific software tool using particle swarm optimization has been created. The objective was to achieve similar travels for all clamping robots in this fixture. To facilitate the integration of the automated part alignment into fixture design, a further software tool for automatically designing a flexible fixture was modelled.

关键词： Body in white Automated device design Particle swarm optimization Product flexibility

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Retrieving properties of manufacturing systems from traceability data for performance evaluation and material flow simulation 54

Retrieving properties of manufacturing systems from traceabi...

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54th CIRP Conference on Manufacturing Ssystems, CMS 2021

作者： Reinhardt, Heiner Münnich, Marc Prell, Bastian Arnold, Roman Krippner, Fabian Weber, Marek Seifert, Frank Putz, Matthias Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany Technical University of Applied Science Wildau Hochschulring 1 Wildau15745 Germany Volkswagen Sachsen GmbH Motorenwerk Chemnitz Kauffahrtei 47 Chemnitz09120 Germany Chemnitz University of Technology Straße der Nationen 62 Chemnitz09111 Germany

The operation of manufacturing systems is increasingly accompanied by data-driven continuous improvement processes and product traceability is required. Commonly, radio-frequency identification (RFID) technology is applied to track the flow of a uniquely-identifiable workpiece along various stations or waypoints within a factory. Based on an automotive use case, this paper describes how to analyze the resulting traceability data in order to identify several properties of a manufacturing system. The acquired knowledge can support performance evaluation and facilitate model building for material flow simulation as a foundation for digital twins and cyber-physical production systems. © 2021 Elsevier B.V.. All rights reserved.

关键词： Knowledge management

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Ultrasonic Vibration assisted Silver Integration by Powder Mixed EDM for Antibacterial Surfaces

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Procedia CIRP 2024年 123卷 410-415页

作者： Viet D. Bui André Martin Thomas Berger Karsten Harnisch Joachim Döring Jessica Bertrand Andreas Schubert Chemnitz University of Technology Professorship Micromanufacturing Technology Reichenhainer Str. 70 09126 Chemnitz Germany Otto-von-Guericke University Magdeburg Institute of Materials and Joining Technology Universitätsplatz 2 39106 Magdeburg Germany Otto-von-Guericke University Magdeburg Department of Orthopaedic Surgery Leipziger Str. 44 39120 Magdeburg Germany Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Str. 88 09126 Chemnitz Germany

Powder mixed electrical discharge machining (PMEDM) with silver nano-powder has demonstrated its potential capability in antibacterial surface modification. Analyses in the cross-sectional layer showed that silver was mainly integrated near the topmost surface layer, and its content is reduced within the layer towards the substrate. However, to achieve a long-term antibacterial efficacy, silver needs to be deeply integrated in the modified layer. Previous studies indicated that ultrasonic vibration (UV) assisted PMEDM can homogenize the silver content in the deposited layer. In this study, the effect of UV on the silver distribution within the modified layer is investigated. Ti6Al4V workpieces were stimulated by UV with a frequency of 22.3 kHz and an amplitude of 2.5 µm. Hydrocarbon-based dielectric fluid, mixed with silver nano-powder with concentrations up to 15 g/L, were internally flushed through a hollow tool with a pressure of 4 bar. PMEDM without UV was investigated for comparison. The layer thickness, micro-cracks and the cross-sectional distribution of deposited silver were analysed by confocal microscopy, scanning electron microscopy, and energy-dispersive X-ray spectroscopy. Results indicate that applying UV leads to the highest silver content in the middle region of the layer, a significant decrease of micro-cracks and a slight reduction of the layer thickness.

关键词： powder mixed EDM ultrasonic vibration silver distribution modified layer antibacterial effect

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High performance machining of continuous metal fibers with cascaded multi-stage profile tools

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Procedia CIRP 2021年 101卷 334-337页

作者： Uwe Teicher Tristan Lange Steffen Ihlenfeldt Fraunhofer Institute for Machine Tools and Forming Technology IWU Dresden 01187 Germany Technische Universität Dresden Institute of Manufacturing Technology Dresden 01062 Germany Technische Universität Dresden Institute of Mechatronic Engineering Dresden 01062 Germany

Metallic fibers are essential for applications in the chemical industry, the automotive industry for brake pads and, more recently, for the air conditioning modules. The most productive process to date for producing continuous fiber lines with fiber cross-sections between 50 and 150 µm is the application of cascaded multi-stage profile tools for cutting from semi-finished wire products. One challenge is the development of a technology for highly ductile materials made of aluminium, which are used as fiber materials in the area of refrigeration adsorbers. Preliminary studies have shown that high cutting speeds are necessary for machining. For this reason, a highly manually operated machine system was advanced to meet the requirements of high cutting speeds and to integrated a process monitoring system. For the first time, experimental investigations were able to show the interrelationships between set technology values and the effective machining forces for this process. Further investigations were done using the example of aluminium alloys 5019 for an analysis of a control system for wire breakage detection on the basis of force sensors.

关键词： machining aluminium metal fiber optimization

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Evaluation of augmented reality supported approaches for product design and production processes

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Procedia CIRP 2021年 97卷 160-165页

作者： Marco Schumann Christian Fuchs Christian Kollatsch Philipp Klimant Institute for Machine Tools and Production Processes Chemnitz University of Technology Reichenhainer Straße 70 09126 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Straße 88 09126 Chemnitz Germany

Augmented Reality (AR) has been a focus of research in the field of production for many years with the goal to improve e.g. monitoring and maintenance processes. Although the benefits have been well researched, the AR technology has not been widespread yet in the industry. This article discusses reasons why existing approaches have not become established outside the research context. Following this, solutions are examined for three identified problematic areas. First, this article presents a theoretical method to create use cases for AR applications in the product design process based on the Double Diamond design process model. The second main part discusses which device properties are relevant for a production environment. A catalogue of criteria is presented, weighting properties according to their importance. Third, a discussion is described regarding data integration concepts, problems and solutions for AR design and production use cases.

关键词： Augmented reality Production Design Double Diamond design process model

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Holistic animation and functional solution for digital manikins in context of virtual assembly simulations

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Procedia CIRP 2021年 97卷 15-20页

作者： Christian Fuchs Christoph Allmacher Philipp Klimant Matthias Putz Institute for Machine Tools and Production Processes Chemnitz University of Technology Reichenhainer Straße 70 09126 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Straße 88 09126 Chemnitz Germany

Assembly simulations in virtual reality were used increasingly in recent years. Even though a multitude of solutions exists in the commercial market, research is focusing on improving soft factors like usability and financial accessibility. Therefore, this paper proposes a holistic solution for animation and integration of functionality of a digital manikin in Unity. The solution is using Unity's integrated inverse kinematics system and physics engine. The result is a fully animated human manikin based on the tracking data of a head-mounted display and its two controllers, which is extrapolating motion data for untracked body parts. Furthermore, the solution enables the user to manipulate objects and explore the virtual environment. The solution is validated in comparison to established motion capture methods using joint error analysis.

关键词： Virtual reality Digital manikins Motion capture Inverse kinematics Animation Assembly simulation

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Laser structuring with DLIP technology of tungsten carbide with different binder content

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Procedia CIRP 2022年 111卷 601-604页

作者： Uwe Teicher Robert Baumann Yasmine Bouraoui Anas Ben Achour Andrés Fabián Lasagni Steffen Ihlenfeldt Fraunhofer Institute for Machine Tools and Forming Technology IWU Nöthnitzer Straße 44 01187 Dresden Germany Institute for Manufacturing Technology Technische Universität Dresden George-Baehr-Str. 3c 01069 Dresden Germany Fraunhofer Institute for Material and Beam Technology IWS Winterbergstraße 28 01277 Dresden Germany Institute of Mechatronic Engineering Technische Universität Dresden Helmholtzstraße 7a 01069 Dresden Germany

In machining, tool wear is one of the main influence factors for the resulting quality of the product. Several wear mechanisms have to be addressed to prevent unwanted deterioration of the tool integrity. For aluminium alloys, adhesion of the workpiece material on the cutting tool is one of the most challenging wear mechanisms. Engineering surface microtopographies has been proved as a convenient strategy to tackle this issue. Particularly, the direct laser interference patterning (DLIP) technique enables the integration of periodic structures on the micrometer or sub-micrometer scale. In this study the structuring of tungsten carbide with different cobalt content is presented. The interference of two laser beams leads to periodic line-like structures with a spatial period of 5.5 µm. A maximum structure depth of 2.2 µm is reached by controlling the processing parameters. Moreover, the wettability of the structured samples was analyzed by contact angle measurements with selected cooling lubricants, revealing a hydrophilic behavior with a decreased contact angle of 10°. This work gives an insight into the possibilities of structuring tungsten carbide materials with a picosecond laser source in combination with an innovative beam shaping setup from the point of view of an analysis to explore the formation of structured surfaces and their wetting behavior with cooling lubricants.

关键词： Laser structuring cutting tool DLIP Surface modification tungsten carbide

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