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International Conference on Emerging Technologies and Factory Automation (ETFA)

作者： Ole Kroeger Felix Wollschläger Jörg Krüger Fraunhofer Institute for Production Systems and Design Technology IPK Berlin Germany University of Stuttgart Stuttgart Germany

ISBN: (数字)9781728189567

ISBN: (纸本)9781728189574

In this work we present our first prototype of a modular, low-cost end-of-arm concept for industrial robot applications. The goal is a faster, more flexible and cost-effective alternative compared to current industrial solutions. We use an embedded single-board computer and three cameras as a sensor base for the new system. The scope of robot application is supposed to as wide as possible (e.g. object detection, bin picking, assembly tasks and quality control tasks). We discuss some industry and low-cost-hardware solutions, introduce our system and deliver a proof of concept. Furthermore we use the system to accomplish a vision based pick and place task.

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Investigation of the gap bridgeability at high-power laser hybrid welding of plasma-cut thick mild steels with AC magnetic support 10

Investigation of the gap bridgeability at high-power laser h...

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10th International Conference on Beam Technologies and Laser Applications, BTLA 2021

作者： Üstündag, Ömer Bakir, Nasim Gumenyuk, Andrey Rethmeier, Michael Unter den Eichen 87 Berlin12205 Germany Fraunhofer Institute for Production Systems and Design Technology Pascalstraße 8-9 Berlin10587 Germany Institute of Machine Tools and Factory Management Technische Universität Berlin Pascalstraße 8-9 Berlin10587 Germany

One of the challenges of the high-power hybrid laser welding of thick steels is the sensitivity of the process of the process to manufacturing tolerances. This usually leads to a time-consuming preparation of the welding edges, such as milling. The study deals with the influence of the edge quality of milled and plasma-cut steel made of S355J2 with a wall thickness of 20 mm on the laser hybrid welded seam quality. Furthermore, the gap bridgeability and the tolerances towards edge misalignment was investigated. An AC magnet was used as backing support to prevent sagging and positioned under the workpiece, to generate an upwards directed electromagnetic pressure. The profiles of the edges and the gap on the top and root side were measured using a digital camera. Single-pass laser hybrid welds of plasma-cut edges could be welded using a laser beam power of just 13.7 kW. A gap bridgeability up to 2 mm and misalignment of edges up to 2 mm could be achieved successful. Additionally, the independence of the cutting side and the welding side was shown, so that samples were welded to the opposite side to their cutting. For evaluation of internal defects or irregularities, X-ray images were carried out. Charpy impact strength tests were performed to determine the toughness of the welds. © 2021 institute of Physics Publishing. All rights reserved.

关键词： High power lasers

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Laser welding of L-PBF AM components out of Inconel 718

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Procedia CIRP 2022年 111卷 92-96页

作者： Christian Brunner-Schwer Juan Simón-Muzás Max Biegler Kai Hilgenberg Michael Rethmeier Fraunhofer Institute for Production Systems and Design Techology IPK Pascalstraße 8-9 10587 Berlin Germany Bundesanstalt für Materialforschung und –prüfung Unter den Eichen 87 12205 Berlin Germany Institute of Machine Tools and Factory Management Technische Universität Berlin Pascalstraße 8-9 10587 Berlin Germany

With regard to efficient production, it is desirable to combine the respective advantages of additively and conventionally manufactured components. Particularly in the case of large-volume components that also include filigree or complex structures, it makes sense to divide the overall part into individual elements, which afterwards have to be joined by welding. The following research represents a first step in fundamentally investigating and characterizing the joint welding of Laser Powder Bed Fusion (L-PBF) components made of Inconel 718. For this purpose, bead-on-plate welds were performed on plates manufactured using the L-PBF process and compared with the conventionally manufactured material. Conventional laser beam welding was used as welding process. The weld geometry was investigated as a function of the L-PBF build-up orientation. It was found that the welding depth and weld geometry differ depending on this orientation and in comparison to the conventional material.

关键词： Laser Welding L-PBF Inconel 718 Weld geometry Bead-on-plate welds

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Concept for a modular system model for energy-efficiency monitoring of factory supply systems

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AIP Conference Proceedings 2024年第1期2989卷

作者： Stefan Sigg Gregor Thiele Marvin Trapp Jörg Krüger Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstr. 8-9 10587 Berlin Germany Institute for Machine Tools and Factory Management Technische Universität Berlin Pascalstr. 8-9 10587 Berlin Germany

Companies in the manufacturing industry are facing the challenges of both reducing energy costs as well as driving decarbonization. As a result, energy efficiency optimization of factory operations is gaining importance. Due to their high share in the energy consumption of a factory, industrial supply technology is of interest for these optimizations. Particularly cooling systems used in factories often offer considerable potential for energy efficiency improvements, some of which can be realized through optimized control strategies. Optimization based on control technology in particular requires a high level of energy consumption transparency in order to identify potentials and measure efficiency improvements. However, industrial supply systems are often complex and interconnected facilities composed of a combination of various individual assets. Consequently, the energy efficiency monitoring and analysis of such systems typically require a high manual effort. To reduce this effort, we propose the development of a modular system model which decomposes complex, interconnected energy systems to individual, recurring assets. The system model consists of a standardized data exchange format, a standardization of structural and behavioral models in the form of a model library for industrial supply systems at different hierarchy levels, and a standardized interface for using the data model on a target platform such as an energy management software. The data model of the data exchange format maps data points such as the control and media interfaces as well as energy performance indicators of the individual assets in a standardized and consistent way. Similar to the concept of digital twins, the knowledge of manufacturers and operators about the system is to be seamlessly combined and utilized. By connecting the interfaces of the individual asset models, an aggregate structural model of a factory supply system is built. The aggregate structural model enables the calculation

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Inertial Measurement Unit based Human Action Recognition for Soft-Robotic Exoskeleton

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IOP Conference Series: Materials Science and Engineering 2021年第1期1140卷

作者： Jan Kuschan Moritz Burgdorff Hristo Filaretov Jörg Krüger Fraunhofer Institute for Production Systems and Design Technology IPK Germany

Absence from work caused by overloading the musculoskeletal system lowers the life quality of the worker and gains unnecessary costs for both the employer and the health system. Exoskeletons can present a solution. Typically, such systems struggle with stiffness and discomfort and primarily a lack of battery lifetime. Soft-robotic exoskeletons offer a possibility to overcome these problems by increasing the system flexibility, not limiting the supported DoF and being actuator and joint together. Since soft-robotic exoskeletons can be designed only using power when supporting the wearer, it is possible to increase the battery lifetime by only acting on those actions for which the wearer needs support. Dealing with controls for soft-robotic exoskeleton one major difficulty is to find a compromise between saving energy and supporting the wearer. Having an action-depending control can reduce the supported actions to cover only relevant ones and increase the lifetime of the battery. The system conditions are to detect the user actions in real-time and distinguish between actions which require support and those which do not. We contribute an analysis and modification of human action recognition (HAR) benchmark algorithms from activities of the daily living, transferred them onto industrial use cases containing short and mid-term action and reduce the models to be compatible using embedded computers for real-time recognition on soft exoskeletons. We identified the most common challenges for inertial measurement units based HAR and compare the best-performing algorithms using a newly recorded data set overhead car assembly for industrial relevance. As a benchmark data set we focused on the 'Opportunity' data set. By introducing orientation estimation, we were able to increase the F1 scores by up to 0.04. With an overall F1 score without a Null-class of up to 0.883, we were able to lay the foundation to use HAR for action dependent force support.

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Generating annotated training data for 6D object pose estimation in operational environments with minimal user interaction

arXiv

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arXiv 2021年

作者： Koch, Paul Schlüter, Marian Thill, Serge Radboud University Nijmegen6525 HR Netherlands Fraunhofer IPK Institute for Production Systems and Design Technology Pascalstr. 8-9 Berlin10587 Germany Donders Institute for Brain Cognition and Behaviour Radboud University Nijmegen6525 HR Netherlands

Recently developed deep neural networks achieved state-of-the-art results in the subject of 6D object pose estimation for robot manipulation. However, those supervised deep learning methods require expensive annotated training data. Current methods for reducing those costs frequently use synthetic data from simulations, but rely on expert knowledge and suffer from the domain gap when shifting to the real world. Here, we present a proof of concept for a novel approach of autonomously generating annotated training data for 6D object pose estimation. This approach is designed for learning new objects in operational environments while requiring little interaction and no expertise on the part of the user. We evaluate our autonomous data generation approach in two grasping experiments, where we archive a similar grasping success rate as related work on a non autonomously generated data set. © 2021, CC BY-NC-SA.

关键词： Deep neural networks

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production environment of tomorrow (ProMo): Partially automated repair process of small tool moulds, forming tools, injection moulding tools and sand casting tools

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IOP Conference Series: Materials Science and Engineering 2021年第1期1140卷

作者： Jan Kuschan Vinzenz Müller Stephan Monchinger Oliver Heimann Carsten Niebuhr Oday Kabha Fraunhofer Institute for Production Systems and Design Technology IPK Germany

Small defects in the grain or major damage to a moulded part or tool can bring production to a standstill. SMEs in particular have neither the personnel nor the equipment to repair such damage on their own, so they send it to specialised contractors. The repair process is carried out manually, depending on the accuracy requirements, and is usually completed by a finishing process. This work requires qualified personnel and, at the same time, requires a lot of time in case of larger damages. In this paper we present a way to map the Maintenance, Repair and Operations (MRO) process chain in a partially automated manner. The symbiosis of individual technologies results in a significantly increased efficiency of the MRO process chain, which continues to focus on people and their process knowledge. While Directed Energy Deposition (DED) for the MRO of moulded parts is used widely, usually a high manual effort in measuring the component geometries and teaching of the machine tool paths is necessary. However, there are clear advantages compared to the manufacture of new parts or manual laser welding repair. At the same time, the resource and energy requirements can often be significantly reduced compared to new part production. Promo focuses on automating the time-consuming machine programming by reducing the number of necessary work steps in CAD/CAM-based program creation. Based on a subsequent robot-guided scan, a digital actual 3D model is generated. Due to intelligent path planning algorithms, no manual programming of the robot is necessary and at the same time it is possible to detect components of different sizes, shapes and covers in this system with a minimum of effort. In addition, the operator passes on elementary information, such as the approach path of the milling head, to the subsequent processes by means of finger gestures and can thus significantly reduce tedious CAM programming steps. Now, the scanned component is transferred to a 3D-CAD model and a target

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Modeling of the wet immersed tumbling process with the Discrete Element Method (DEM)

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Procedia CIRP 2021年 102卷 1-6页

作者： E. Uhlmann J.-P. Fürstenau Y. Kuche S. Yabroudi J. Polte M. Polte Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Pascalstr. 8-9 Berlin 10587 Germany Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstr. 8-9 Berlin 10587 Germany CADFEM GmbH Pelikanstr. 13 Hannover 30177 Germany

Immersed tumbling is an industrially established process for finishing of components made of metal, ceramic or plastic. In this process, the components are completely surrounded by a wet, abrasive medium, which allows burrs to be removed and surfaces to be polished. In order to gain specific insights into the influence and flow properties of the abrasive media used in this process, numerical approaches using the Discrete Element Method (DEM) with the Rocky DEM software are presented within these investigations. A complete process simulation could be realised by means of a digital machine tool. The immersed tumbling process with cone-shaped polymer abrasive media is implemented by use of a liquid bridge model. The results were validated by experiments with an industrially used immersed tumbling machine tool and for the first time allow sound statements about the contact conditions and interactions of the abrasive media with the workpiece.

关键词： discrete element method DEM immersed tumbling liquid bridge facetted particles

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SyProLei-A systematic product development process to exploit lightweight potentials while considering costs and CO2 emissions 32

SyProLei-A systematic product development process to exploit...

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32nd CIRP design Conference, CIRP design 2022

作者： Kaspar, Jerome König, Kristian Scholz, Johannes Quirin, Steven Kleiner, Sven Fleischer, Jürgen Herrmann, Hans-Georg Vielhaber, Michael Em Engineering Methods Ag Rheinstr. 97 Darmstadt64295 Germany Institute Of Engineering Design Saarland University Campus E2 9 Saarbrücken66123 Germany Wbk Institute Of Production Science Karlsuhe Institute Of Technology Kaiserstraße 12 Karlsruhe76131 Germany Lightweight Systems Saarland University Campus E3 1 Saarbrücken66123 Germany Fraunhofer Institute For Nondestructive Testing Izfp Campus E3 1 Saarbrücken66123 Germany

In lightweight design, developers are used to face the conflicting objectives of functional fulfillment, economic performance, and sustainability. Against this background, however, a clearly structured approach for the satisfied use of specific lightweight engineering methods within the product development is still missing. Thus, this contribution deals with the fundamental conception and first implementation of a systematic development methodology covering the disciplines of mechanics, electrics/electronics and software just like the focus on an integrated view on product, production and material aspects. To ensure an application-specific manifestation of the product development process for three exemplary use cases from small and medium-sized enterprises but also large corporations in the area of prosthetics, bike construction and plant engineering, the individually developed methods and tools are first generalized in order to make them adaptable to a wide variety of industries. As a result, one lightweight-specific method or tool (e.g., function mass analysis, "PPM solution correlator"or "2D layout & weight drafting") is introduced in more detail for all stages of the technically extended RFL(T)P approach derived from model-based systems engineering (MBSE). © 2022 The Authors.

关键词： Product development

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Process behaviour of micro-textured CVD diamond thick film cutting tools during turning of Ti-6Al-4V

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Procedia CIRP 2020年 87卷 25-30页

作者： Eckart Uhlmann Danny Schröter Institute for Machine Tools and Factory Management (IWF) Technische Universität Berlin 10587 Berlin Germany Fraunhofer Institute for Production Systems and Design Technology (IPK) 10587 Berlin Germany

Currently, an efficient machining of high-performance materials, such as titanium alloy Ti-6Al-4V, represents a challenge in manufacturing. For the reduction of high cutting temperatures, micro-textured CVD diamond thick film cutting tools establish new potentials regarding the process productivity. The application of micro-textures allows a reduced contact area between chip and tool in order to decrease the generation of heat. Furthermore, a direct application of lubricant into the cutting zone is possible. The present study investigates the influence of micro-textured CVD diamond thick film cutting tools on the resulting process forces, chip formation as well as maximum cutting volumes during turning process. Part of the investigations was a variation of micro-texture trajectory with micro-textures parallel to the major cutting edge, perpendicular to the bisector of corner angle ε and curved along the cutting edge. The analyses showed that both positive and negative effects occur using micro-textures. The forces can be reduced by 14 % whereas the use of micro-textures leads to higher feed forces F f by 21 % as well as an additional notch effect in the micro-texture bottom.

关键词： CVD diamond thick film micro-texture Ti-6Al-4V turning

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