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4th IFAC Workshop on Mining, Mineral and Metal Processing, MMM 2015

作者： Birkhold, M. Friedrich, C. Lechler, A. Institute for Control Engineering of Machine Tools and Manufacturing Units Seidenstrasse 36 Stuttgart70174 Germany

Automation of the casting process in foundries is most commonly limited to foundry lines for series manufacturing. The employed teach-in method for programming the process is time-consuming and, therefore, only suited for large lot sizes. Thus, manufacturing of small lot sizes or single parts still necessitates the handwork and expertise of workers pouring the molten metal into the mould. This creates a dangerous environment for the worker. In recent years researchers have developed a model-based process control, which allows precise casting control without having to previously teach the process. Usage of these process models has been limited to special process control systems, specifically designed for a certain machine. In this paper, a novel approach is presented, in which a NC (Numerical control) system is enhanced by process models. Instead of programming the NC in kinematic coordinates, it will be shown that programming in process coordinates allows robust and flexible casting, even for small lot sizes. The paper will prove the feasibility of the approach by evaluation of the processing time of the model. © 2015, IFAC (International Federation of Automatic control) Hosting by Elsevier Ltd. All rights reserved.

关键词： Foundries

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New Coordination Software for Parameter Identification Applied to Thermal Models of an Actuator Strut

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Journal of Computational engineering 2017年第1期2017卷

作者： Burkhard Hensel Steffen Schroeder Klaus Kabitzsch Chair for Technical Information Systems Dresden University of Technology 01062 Dresden Germanytu-dresden.de Institute of Machine Tools and Control Engineering Dresden University of Technology 01062 Dresden Germanytu-dresden.de

The practical worth of models of technical processes depends on their accuracy, that is, the difference between model outputs and real measurements. For minimizing these differences, process identification methods are used. In this article, coordination software for process identification is presented which has the unique feature that it allows the integration of models that have been created with external tools, for example, Matlab or Python scripts. There is no need to transform the models into another type of software format to use the common identification coordinator. The concept of the software is described and two examples for the coupling with external simulation software are given. Additionally, this article contains a detailed case study of the parameter identification of two models using that identification coordination software. This highlights the benefit of the new coordination software regarding similar work flow for different model types. The modeled physical subject is the thermal behavior of an actuator strut.

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Selective rotor Assembly Using Fuzzy Logic in the Production of Electric Drives

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Procedia CIRP 2015年 33卷 550-555页

作者： Daniel Coupek Aybike Gülec Armin Lechler Alexander Verl Institute for Control Engineering of Machine Tools and Manufacturing Units (ISW) Seidenstraße 36 70174 Stuttgart Germany

The growing sector of sustainable mobility requires an increasing number of electric drives for automobiles, thus increasing the need for their efficient mass production. In current production scenarios, End-Of-Line (EOL) inspection is applied to determine the quality of the assembled final product. The work presented in this paper is developed in the project MuProD, which aims at developing an innovative quality control system to change the current concept of EOL quality control. The case under investigation is the production of electric drives where the rotor is composed of several magnetized stacks. The magnetic properties of each stack differ due to variations of the single magnets and the magnetization process itself. In addition, handling of the magnets within the production line may cause cracks that decrease the strength of the magnetic field. This paper proposes a new solution for deviation compensation in the production of electric drives by selective assembly based on a crisp classification and a Mamdani style fuzzy inference system. The magnetic field of each stack is measured after the magnetization stage, yielding a discrete space-resolved magnetic profile. This magnetic profile is transformed into another feature space through a combination of feature selection and feature extraction to reduce the dimension. Based on these new features, the stacks can be classified into crisp sets. In the second part, an appropriate fuzzy rule base for the matching of the stacks is developed to obtain a uniform magnetic field of the rotor. By applying this assembly strategy, the rotor and consequently the final motor reaches desired quality targets although deviations in the single stacks are present. The benefits of the approach are validated within an industrial context.

关键词： Assembly Fuzzy logic Drive Selecvtive assembly Feedforward control

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Using game physics engines for hardware-in-the-loop material flow simulations: benefits, requirements and experiences

Using game physics engines for hardware-in-the-loop material...

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IEEE/ASME (AIM) International Conference on Advanced Intelligent Mechatronics

作者： Philipp Neher Armin Lechler Institute for Control Engineering of Machine Tools and Manufacturing Units (ISW) University of Stuttgart Stuttgart Germany Chief Engineer for Institute for Control Engineering of Machine Tools and Manufacturing Units (ISW) University of Stuttgart Stuttgart Germany

Object of this paper is the proposal of using existing physics engines mainly deployed in video games and movie animations for simulating material flow applications with a high degree of reality. Since the actual control systems are supposed to be tested and verified using this simulation it has to possess real-time capabilities for usage with a hardware-in-the-loop simulation setup. This paper illustrates why such a simulation is necessary concerning the considered application. In addition, the required work items to achieve this approach are presented. During the realization, encountered problems and obstacles are commented on as well.

关键词： Engines control systems Real-time systems Kinematics Mathematical model Kernel

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Flexible and Modular control and manufacturing System

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Procedia CIRP 2015年 33卷 115-120页

作者： Jens Friedrich Stefan Scheifele Alexander Verl Armin Lechler Institute for Control Engineering of Machine Tools and Manufacturing Units (ISW) University of Stuttgart Seidenstraße 36 70174 Stuttgart Germany

The trend in production industry is going away from mass-produced products, towards individual products, which are adapted to the customer requirements. Thus flexible, modular production systems that can be adapted to individual use-cases are necessary. Within this paper, a flexible and modular control for a modular production system with the ability to use manufacturer-independent functions and modules is proposed. A new approach for a standardized description and an open interface for functions and modules is developed. This includes a decentralized control system architecture. The self-configuring control system identifies all functions and modules automatically and a specifically defined memory set (the CIMory data) is used to enable the self-configuration of the control system. Combining a real-time bus system and a SOA-based communication enables the decentralized approach of a future cloud based control system architecture.

关键词： customized products flexible and modular production system (FMPS) self-configuring control system

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Automation of the Casting Process using a model-based NC Architecture

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IFAC-PapersOnLine 2015年第17期48卷 195-200页

作者： M. Birkhold C. Friedrich A. Lechler Institute for Control Engineering of Machine Tools and Manufacturing Units Seidenstrasse 36 70174 Stuttgart DE (Tel: +49-711-685-84502)

关键词： Casting process model-based control pouring control

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Contour Error Analysis of Precise Positioning for Ball Screw Driven Stage Using Friction Model Feedforward

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Procedia CIRP 2015年 26卷 712-717页

作者： N.A. Rafan Z. Jamaludin T.H. Chiew L. Abdullah M.N. Maslan Control Systems of Machine Tools Research Group Faculty of Manufacturing Engineering Universiti Teknikal Malaysia Melaka Hang Tuah Jaya76100 Durian Tunggal Melaka Malaysia

This paper presents contouring error analysis using various classical feedforward controllers. A circular motion is performed using an XY positioning stage with specified amplitude and velocities. This study applied single Static friction model, Generalized Maxwell Slip (GMS) model and combination of both models together with feedforward Proportional-Integral-Derivative (PID) controller. Contour error in term of quadrant glitch is measured by respective angle in each quadrant of circular motion. Due to stick slip motion during velocity reversal generate glitches near zero velocity. Root-mean-square error (RMSE) is calculated based on radial error of circular motion to show variance of errors towards average. The results are experimentally shown that glitches have higher reduction in lower velocity by comparing between applied with and without friction feedforward controller. Better reduction in contour errors improves precision of machine tools and hence increases productivity.

关键词： ball screw driven system friction compensation contouring motion quadrant glitches feedforward

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Heavy-duty omni-directional Mecanum-wheeled robot for autonomous navigation: System development and simulation realization

Heavy-duty omni-directional Mecanum-wheeled robot for autono...

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International Conference on Mechatronics (ICM)

作者： Li Xie Christian Scheifele Weiliang Xu Karl A. Stol Department of Mechanical Engineering University of Auckland Auckland New Zealand Institute for Control Engineering of Machine Tools and Manufacturing Units University of Stuttgart Stuttgart Germany

A Mecanum-wheeled robot benefits from great omni-direction maneuverability. However it suffers from random slippage and high-speed vibration, which creates electric power safety, uncertain position errors and energy waste problems for heavy-duty tasks. A lack of Mecanum research on heavy-duty autonomous navigation demands a robot platform to conduct experiments in the future. This paper introduces AuckBot, a heavy-duty omni-directional Mecanum robot platform developed at the University of Auckland, including its hardware overview, the control system architecture and the simulation design. In particular the control system, synergistically combining the Beckhoff system as the controller-PC to serve low-level motion execution and ROS as the Navigation-PC to accomplish highlevel intelligent navigation tasks, is developed. In addition, a computer virtual simulation based on ISG-virtuos for virtual AuckBot has been validated. The present status and future work of AuckBot are described at the end.

关键词： Wheels Navigation Mobile robots Robot sensing systems Mathematical model Vibrations

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EcoBotics: Advantages and challenges of building a bamboo robot arm

EcoBotics: Advantages and challenges of building a bamboo ro...

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IEEE International Conference on Industrial Technology (ICIT)

作者： Akos Csiszar Philipp Sommer Armin Lechler Graduate School of Excellence University of Stuttgart Stuttgart Germany Institute for Control Engineering of Machine Tools and Manufacturing Units University of Stuttgart Stuttgart Germany

Sustainability and sustainable development concepts are frequently the driving force for research related to optimizing energy consumption and material use in order to reduce the carbon footprint for different products. EcoBotics aims to analyse the question of sustainability in the area of robotics. In this paper, as a first example of EcoBotics, it is examined what are the advantages and challenges of exchanging the aluminium structure of lightweight robot arms with a sustainable material. Bamboo is used in order to exemplify a sustainable material, but the challenges and the proposed solutions for open problems are valid for any material causing a robot structure with low stiffness.

关键词： Service robots Robot kinematics Aluminum Couplings Payloads Carbon

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Method for Selecting Improvement Measures for Discrete Production Environments Using an Extended Energy Value Stream Model

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Procedia CIRP 2015年 26卷 133-138页

作者： J. Fischer N. Weinert C. Herrmann Siemens AG Corporate Technology Systems Engineering Munich Germany Sustainable Manufacturing and Life Cycle Engineering Research Group Institute of Machine Tools and Production Technology (IWF) Technische Universität Braunschweig Germany

Improving energy efficiency in discrete manufacturing environments has been one of the key goals of recent research and industrial activities in production management, leading to a large and still increasing amount of different methodologies and improvement measures in that field (here called “Solution Elements”). Despite the growing interest, most of these are rarely applied, or are implemented in an improper manner instead of identifying and realizing the most appropriate ones from a holistic, factory wide perspective. For coping with these challenges a flexible, multi criteria and multi step selection process is introduced by which the applicability of solution elements is evaluated for a specific discrete production environment. The selection process is based on an approach taking multiple criteria derived from the current (as-is) situation in a factory as well as from user preferences into account. For data gathering an extended energy value stream approach is utilized that allows the derivation of value stream specific energy and cost drivers. The approach was tested in an industrial use-case, which is introduced in this paper.

关键词： Energy efficient production Sustainable roduction Lean production Decision support

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