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Synchronized online simulation at field level for virtual sensing of web tension

Discover Applied Sciences 2025年第6期7卷

作者： Deubert, Darius Schultze, Stephan Selig, Andreas Verl, Alexander Institute for Control Engineering of Machine Tools and Manufacturing Units University of Stuttgart Seidenstraße 36 Stuttgart70174 Germany Bosch Rexroth AG Bgm.-Dr.-Nebel-Straße 2 Lohr am Main97816 Germany

In industrial automation, online simulation should reflect a real mechatronic system as accurate as possible. However, the simulation could drift away from the real manufacturing process due to imprecise modeling or changing system behavior. While in literature, some methods are already used to synchronize digital twins or online simulations of processes to their real counterpart, this article systematically describes the comprehensive field of synchronizing online simulations of manufacturing systems by defining several types of synchronization, explaining their functions, and indicating exemplary realization methods in this context. Subsequently, the concepts are applied to a newly presented use case of online simulation at field level for the demonstration of the proposed concepts. In particular, an exemplary synchronized online simulation is implemented that serves as a virtual sensor for web tension in an imitated web transport system. For this use case, an individual synchronization strategy based on the described methods is presented. The results are validated and discussed based on an experiment, where the behavior of the web transport system is rapidly changing and the synchronized online simulation is adapting accordingly. The findings of this research contribute to the aim of using existing simulation models for online simulation in the operation phase of manufacturing systems. © The Author(s) 2025.

关键词： Factory automation

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Monitoring the Evolution of Dimensional Accuracy and Product Properties in Property-controlled Forming Processes

SSRN

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SSRN 2023年

作者： Stebner, Sophie Charlotte Martschin, Juri Arian, Bahman Dietrich, Stefan Feistle, Martin Hütter, Sebastian Lafarge, Rémi Laue, Robert Li, Xinyiang Schulte, Christopher Spies, Daniel Thein, Ferdinand Wendler, Frank Wrobel, Malte Vasquez, Julian Rozo Dölz, Michael Münstermann, Sebastian Integrity of Materials and Structures RWTH Aachen University Aachen Germany Institute of Forming Technology and Lightweight Components Dortmund University Dortmund Germany Forming and Machining Technology Paderborn University Paderborn Germany Institute for Applied Materials - Material Science Karlsruhe Institute of Technology Karlsruhe Germany Fraunhofer Institute for Casting Composite and Processing Technology Garching Germany Institute of Materials and Joining Technology Otto-von-Guericke University Magdeburg Germany Forming and Machining Processes Technische Universität Dresden Dresden Germany Institute for Machine Tools and Productions Processes Virtual Production Engineering Chemnitz University of Technology Chemnitz Germany Institute of Metal Forming RWTH Aachen University Aachen Germany Institute of Automatic Control RWTH Aachen University Aachen Germany Institute for Production Engineering and Forming Machines Technical University of Darmstadt Darmstadt Germany Institut für Geometrie und Praktische Mathematik RWTH Aachen University Aachen Germany Measurement and Sensor Technology Chemnitz University of Technology Chemnitz Germany Digital Process Engineering Group Institute for Mechanical Process Engineering and Mechanics Karlsruhe Institute of Technology Karlsruhe Germany Materials Test Engineering Dortmund University Dortmund Germany

As recent trends in manufacturing engineering disciplines show a clear development in the sustainable as well as economically efficient design of forming processes, monitoring techniques have been gaining in relevance. In terms of monitoring of product properties, most processes are currently open-loop controlled, entailing that the microstructure evolution, which determines the final product properties, is not considered. However, a closed-loop control that can adjust and manipulate the process actuators according to the required product properties of the component will lead to a considerable increase in efficiency of the processes regarding resources and will decrease postproduction of the component. For most forming processes, one set of component dimensions will result in a certain set of product properties. However, to successfully establish closed-loop property controls for the processes, a systematic understanding of the reciprocity of the dimensions after forming and final product properties must be established. This work investigates the evolution of dimensional accuracy as well as product properties for a series of forming processes that utilize different degrees of freedom for process control. © 2023, The Authors. All rights reserved.

关键词： Process control

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Connected production planning and control systems – implementation and the optimization process for subcontracting

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Procedia CIRP 2020年 88卷 191-196页

作者： Carsten Ellwein Anja Elser Marcel Vollmer Oliver Riedel Institute for Control Engineering of Machine Tools and Manufacturing Units University of Stuttgart Seidenstr. 36 D-70174 Stuttgart Germany University of Stuttgart Kepplerstr.7 D-70174 Stuttgart Germany

Production planning and control (PPC) systems are used to organize operating materials. In order to address connectivity demands of interacting PPC systems a new software architecture has been presented in prior work. This software architecture provides a basis for data exchange in-between such systems. It is up to this paper to describe an implementation approach realizing the theory. Furthermore, a new optimization process which targets subcontracting, dynamics and communication of interconnected PPC systems is presented. As a result, the mandatory and optional content of an order enquiry as well as of a response message is discussed.

关键词： Planning control systems Software architecture Industry 4.0 Cloud manufacturing

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Motion superimposition for machine tool trajectories using asynchronous axis interpolation ⁎

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IFAC-PapersOnLine 2019年第10期52卷 300-305页

作者： T. König A. Verl A. Lechler Institute for Control Engineering of Machine Tools and Manufacturing Units (ISW) University of Stuttgart Germany

This paper presents a method for reducing non-productive times in the planning and interpolation of lift movements during 2.5D machining. At the moment, this mostly vertical lift movement is executed separately from the position changing in the operating plane. This sequential processing of motions increases the non-productive time in processes with frequent changes of operating height, such as laser cutting. The reduction is realized by superimposing the planar path movements with lift motion. An asynchronous axis interpolation is applied to make use of the maximum machine dynamics. In addition, known obstacles can be taken into account by further parameters in the planning.

关键词： machine tools productivity simultaneous processing lift movement path optimization non-productive time reduction asynchronous interpolation

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A two-step digitalization level assessment approach for manufacturing companies

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Procedia Manufacturing 2021年 54卷 25-30页

作者： Günther Schuh Thomas Scheuer Gábor Nick Ádám Szaller Tamás Várgedő Laboratory for Machine Tools and Production Engineering (WZL) RWTH Aachen University Aachen 52074 Germany Fraunhofer Institute for Production Technology Aachen 52074 Germany Széchenyi University Research Center of Vehicle Industry Győr 9026 Hungary EPIC InnoLabs Ltd. Budapest 1111 Hungary Institute for Computer Science and Control Budapest 1111 Hungary Department of Manufacturing Science and Engineering Budapest University of Technology and Economics Budapest 1111 Hungary

Manufacturing companies are facing the fourth industrial revolution, which concerns itself with the real-time data-based communication and connection between cyber-physical systems and people. To initiate a successful digital transformation, many organizations turn to Industry 4.0 maturity models for orientation and advice. This paper aims to enable companies to find the model that suits them best. Therefore, several existing models are introduced and two of them, a quick-assessment model ( CCMS ) and a more extensive approach ( Industry 4.0 Maturity Index ), are described in detail. These two complementing models are combined into a new resource-efficient approach to assessing Industry 4.0 maturity.

关键词： Industry 4.0 Maturity model Readiness assessment Digitalization

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Securing the Data Flow for Blockchain Technology in a Production Environment ⁎

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IFAC-PapersOnLine 2019年第10期52卷 125-130页

作者： Tobias Korb David Michel Oliver Riedel Armin Lechler Institute for Control Engineering of Machine Tools and Manufacturing Units University of Stuttgart 70174 Stuttgart Germany

For several years, blockchain technology have been used and tested in various prototypes for production environments. The main focus of these approaches is the feasibility of different applications. It is usually simply assumed that data in a blockchain is stored immutably. However, the path from data generation to entry into a blockchain is usually neglected. Exactly this topic is discussed in this paper and a solution proposal for a secure data flow from the machine to the blockchain is presented. For this, the hardware and software architecture of the solution is shown, followed by measurements of the operational capability of the solution.

关键词： Blockchain Manufacturing Immutability Trust Microcontroller Digitization

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DMME: Data mining methodology for engineering applications – a holistic extension to the CRISP-DM model

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Procedia CIRP 2019年 79卷 403-408页

作者： Steffen Huber Hajo Wiemer Dorothea Schneider Steffen Ihlenfeldt Technische Universität Dresden Institute for Machine Tools and Control Engineering 01062 Dresden Germany

The value of data analytics is fundamental in cyber-physical production systems for tasks like optimization and predictive maintenance. The de facto standard for conducting data analytics in industrial applications is the CRISP-DM methodology. However, CRISP-DM does not specify a data acquisition phase within production scenarios. With this work, we present DMME as an extension to the CRISP-DM methodology specifically tailored for engineering applications. It provides a communication and planning foundation for data analytics within the production domain. We show the feasibility of our methodology for engineering applications within a case study in the field of work piece detection.

关键词： Data mining machine learning Manufacturing data management Data driven process optimisation

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A model-based and software-assisted safety assessment concept for reconfigurable PnP-systems

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Procedia CIRP 2020年 93卷 359-364页

作者： C.H. Koo S. Schröck M. Vorderer J. Richter A. Verl Corporate Sector Research and Advanced Engineering Robert Bosch GmbH Robert-Bosch-Campus 1 71272 Renningen Germany Institute for Control Engineering of Machine Tools and Manufacturing Systems (ISW) University Stuttgart Seidenstraße 36 70174 Stuttgart Germany

In times of volatile market situations, the deployment of Plug-and-Produce (PnP) technology for reconfigurable systems contributes to better responsiveness to satisfy changing production demands. However, the possibility for rapid system (re-)configuration raises safety uncertainties and complicates the required safety assessment procedure. In accordance to the legislative requirements, safety engineers must conduct a thorough safety assessment for the system under consideration, which is highly time-consuming and demands extensive evaluations to ensure error-free results. This publication proposes a model-based safety assessment concept (MBSAFE), utilizing the concept of digital representations, simulations and semantic modeling to facilitate safety engineers during safety assessment and decision-making.

关键词： safety assessment reconfigurable manufacturing systems plug-and-produce systems model-based approach digital representations

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Comparative Analysis of Factory Simulation Description Models for Comprehensive Description of Model Design

Comparative Analysis of Factory Simulation Description Model...

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IEEE Eurasia Conference on IOT, Communication and engineering (ECICE)

作者： Daniella Brovkina Annika Kienzlen Oliver Riedel Graduate School of Excellence advanced Manufacturing Engineering (GSaME) University of Stuttgart Stuttgart Germany The Institute for Control Engineering of Machine Tools and Manufacturing Units University of Stuttgart Stuttgart Germany Fraunhofer Institute for Industrial Engineering IAO Stuttgart Germany

ISBN: (数字)9781728180601

ISBN: (纸本)9781728180618

Simulation models are used during the entire life cycle of a factory. Because of a factory's complexity, different simulation tools with different scope emerged over time. The holistic mapping requires coupled simulations that consider the factory from different perspectives. Each simulation requires a new tool and simulation model, which, up to now, has usually been created manually. This paper presents an analysis of existing approaches and data models for factory simulation description. These approaches allow data exchange between single simulation models, but do not provide dynamic coupling and model generation, and often cannot include all relevant information for the factory simulation. To achieve a continuous and comprehensive factory simulation, a concept for a metamodel for factory simulation description is outlined. Its goal is not only to describe a skeleton of the factory and provide simulation coupling and data exchange but also to provide a dynamic model generation.

关键词： Modeling Data models Unified modeling language Analytical models Production facilities Computational modeling tools

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Graph-based Data Model for Assembly-Specific Capability Description for Fully Automated Assembly Line Design

Graph-based Data Model for Assembly-Specific Capability Desc...

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IEEE Eurasia Conference on IOT, Communication and engineering (ECICE)

作者： Daniella Brovkina Oliver Riedel Graduate School of Excellence advanced Manufacturing Engineering (GSaME) University of Stuttgart Stuttgart Germany The Institute for Control Engineering of Machine Tools and Manufacturing Units University of Stuttgart Stuttgart Germany Fraunhofer Institute for Industrial Engineering IAO Stuttgart Germany

ISBN: (数字)9781728180601

ISBN: (纸本)9781728180618

Assembly systems are an essential component of industrial production. However, due to a lack of tools for decision-making support, these systems are usually planned and designed manually or with a low degree of automation. In this paper, a data model and a fully automated system for the design of assembly lines in the context of Model-based System engineering (MBSE) are presented. This system uses a graph-based description of the product and production capabilities, matches the product requirements to the available capabilities and resources, and enables an appropriate design generation using the Model-in-the-Loop and Software-in-the-Loop simulations. Explicit semantics and high flexibility of the graph-based data model allow a fine-grained description of the highly complex system. A particular focus is on the assembly-specific capability and product description, and generalizability of assembly systems through the use of the presented data model. For the data model evaluation, several scenarios are presented, where the production capabilities are being matched to a product description to form a logic assembly line structure.

关键词： Data models Communication cables Layout Force Parallel robots Creep Virtual manufacturing

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