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Design and Evaluation of In-line Product Repair Strategies for Defect Reduction in the Production of Electric Drives

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Procedia CIRP 2014年 21卷 159-164页

作者： M. Colledani D. Coupek A. Verl J. Aichele A. Yemane Politecnico di Milano Mechanical Engineering Department Via la Masa 1 20156 Milano Italy Institute for Control Engineering of Machine Tools and Manufacturing Units (ISW) Seidenstraße 36 70174 Stuttgart Germany Corporate Research Robert Bosch GmbH Postfach 300240 70442 Stuttgart Germany

Manufacturing companies are continuously facing the challenge of operating their manufacturing processes and systems in order to deliver the required production rates of high quality products of increasing complexity, with limited use and waste of resources. This aspect is particularly critical in emerging sectors, such as the e-mobility industry, where state of the art quality and process control technologies show strong limitations. This paper proposes new solutions for implementing in-line product repair strategies in the production of electric drives for the automotive industry. Moreover, it develops an innovative quantitative tool to estimate the impact of the proposed strategies on the overall process-chain performance. The benefits of the approach are validated within a real industrial context.

关键词： Product Repair Electric Drives Assembly Zero-defect Manufacturing

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Investigations of a small machine tool with CFRP-frame 13

Investigations of a small machine tool with CFRP-frame

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13th International Conference of the European Society for Precision engineering and Nanotechnology, EUSPEN 2013

作者： Hoffmeister, H.-W. Gerdes, A. Verl, A. Wurst, K.-H. Heinze, T. Batke, C. TU Braunschweig Institute of Machine Tools and Production Technology Braunschweig Germany Universität Stuttgart Institute for Control Engineering of Machine Tools and Manufacturing Units Stuttgart Germany

ISBN: (纸本)9780956679024

Experimental investigations regarding energy consumption in cooperative mode show a reduction of kinetic energy of about 50 %. However the power consumption increases in cooperative mode due to necessary additional drive and electric losses. Numerical Results show a maximum thermal deformation of 5 μm of the test workpiece due to the clamping process. The CFRP-frame shows a high stiffness and low dynamic magnitudes and is suitable for use as machine tool frame also due to its thermal stability and subsequently higher precision of the machine tool.

关键词： machine tool kinetic energy Power consumption Electric losses energy consumption

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Integrated object and path demonstration for industrial robots in adaptive handling applications

Integrated object and path demonstration for industrial robo...

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International Conference on Emerging Technologies and Factory Automation (ETFA)

作者： C. F. Wu S. K. Lin J. Lambrecht T. D. Nguyen A. Vick M. Kleinsorge J. Krüger Division of Intelligent System Engineering Industrial Technology Research Institute Mechanical and Systems Research Laboratory Hsinchu Taiwan National Chiao Tung University Institute of Electrical Control Engineering Hsinchu Department Industrial Automation Technology Technische Universität Berlin Insitute for Machine Tools and Factory Management Berlin Germany

We propose an approach for integrated object and path demonstration. The main idea is to choose the motion of the robot depending on the object it grabs. When programming, an object is fixed at the robot's gripper. Path programming is done using haptic guidance. Afterwards, if a robot is handed over an object it knows before, it reproduces the path assigned to the object. Path programming and object recognition can be done with a single force/torque sensor. In our opinion, this way of programming is especially suited for creating pick and place tasks in frequently changing production environments where (re-)programming has to be done frequently.

关键词： Robot sensing systems Programming Service robots Force Grippers Training

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Introducing an automated reconfiguration mechanism for flexible metal forming systems using a web service-based architecture approach 22

Introducing an automated reconfiguration mechanism for flexi...

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22nd International Conference on Production Research, ICPR 2013

作者： Birkhold, M. Abel, M. Verl, A. Institute for Control Engineering of Machine Tools and Manufacturing Units Seidenstraße 36 Stuttgart70174 Germany

Classic mechanical presses limit the flexibility of metal forming systems due to their fixed sinusoidal motion. Servo presses are no longer limited to a fixed sinusoidal motion, combining the free motion capability of hydraulic presses with the speed of classic mechanical presses. This new freedom of the press motion allows the integration of peripheral processes into the forming tool, reducing the necessity of follow-up processes. However, this new capability comes at the cost of increased complexity of the tool, which needs its own control system. Current techniques for the integration of peripheral systems lack granularity and need tedious hand tweaking. Therefore, many tool manufacturers have yet to embrace the new capabilities of servo presses. In this paper we introduce a novel approach, in which a press tool uses a middleware to automatically set-up the fieldbus configuration, during reconfiguration of the press. The considered peripheral system consists of three transfer modules which combine two forming parts in the tool for welding. The access to additional system data is necessary for the sophisticated transfer motions in this tool. Additionally, the necessity of manually tweaking the synchronization of the transfer is eliminated by this new approach. The capabilities of the new approach are demonstrated using state of the art controllers of a production system.

关键词： Presses (machine tools)

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Industrial powerline communication for machine tools and industrial robots

Industrial powerline communication for machine tools and ind...

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2013 IEEE 17th International Symposium on Power Line Communications and Its Applications, ISPLC 2013

作者： Joao, Lopes Karl-Heinz, Wurst Alexander, Verl Institute for Control Engineering of Machine Tools and Manufacturing Units University of Stuttgart Seidenstraße 36 70174 Stuttgart Germany

ISBN: (纸本)9781467360166

machine manufactures are facing a challenging moment: on one hand the need to lower the prices, on the other hand the need for more machine flexibility and availability. In this context, Industrial Powerline Communication (IPLC) can play a capital role, by reducing the costs and increasing flexibility. In this paper the requirements and constraints of Powerline Communication (PLC) and Industrial Communication are merged and a solution to this problem proposed. This solution consists of a ferrite filtering, with the task of building a Daisy Chain Network topology on top of a PLC bus. © 2013 IEEE.

关键词： Industrial robots

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Analysis and evaluation of collision detection libraries for collision monitoring of multichannel control applications 22

Analysis and evaluation of collision detection libraries for...

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22nd International Conference on Production Research, ICPR 2013

作者： Hoher, Simon Neher, Philipp Verl, Alexander University of Stuttgart Institute for Control Engineering of Machine Tools and Manufacturing Units Seidenstraße 36 Stuttgart70174 Germany

The main objective of this paper is to evaluate collision detection libraries for collision monitoring of multichannel control applications. First, the requirements for collision monitoring of multi-channel control will be presented. On this basis suitable collision detection libraries will be analyzed and selected considering the required feature range. The assumed libraries are then evaluated in regard to their runtime characteristics. In particular the time-intensive memory accesses at runtime and the time deterministic and efficient execution times during different experiments are examined in more detail on a real-time platform.

关键词： Libraries

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Adaptive spindle speed variation to improve process stability 22

Adaptive spindle speed variation to improve process stabilit...

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22nd International Conference on Production Research, ICPR 2013

作者： Friedrich, J. Verl, A. Institute for Control Engineering of Machine Tools and Manufacturing Units University of Stuttgart Seidenstr. 36 StuttgartD-70174 Germany

A limiting factor of the performance of machine tools is the dynamic process behavior. Suppression of chatter is still an important measure to increase productivity. Spindle speed variation is a known possibility to reduce chatter vibrations without changes to the machine tool using the degree-of-freedom of the spindle speed. In this paper the new adaptive spindle speed variation (ASSV) method is presented. The ASSV algorithm automatically adapts the amplitude and the frequency of the spindle speed variation due to the current process stability conditions taking into account the machine capability and the process technology. A simulation model of the milling process is used to analyze and verify the functionality of the ASSV. With just using a simple P-or PI-controller in combination with the ASSV algorithm the depth of cut and thus the productivity can be increased to 150% in comparison to cutting with constant spindle speed with respect to the displacement of the tool tip.

关键词： machine tools

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Increasing the energy efficiency in metal cutting manufacturing through a demand based coolant filtration 20

Increasing the energy efficiency in metal cutting manufactur...

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20th CIRP International Conference on Life Cycle engineering, LCE 2013

作者： Rahäuser, Raphael Klemm, Peter Verl, Alexander Kircher, Christian Graduate School of Excellence Advanced Manufacturing Engineering University of Stuttgart Germany Institute for Control Engineering of Machine Tools Manufacturing Units University of Stuttgart Germany Robert Bosch GmbH Germany

ISBN: (纸本)9789814451475

The coolant supply uses in typical applications of metal cutting manufacturing on average 50 % of the electrical energy. A main optimization option is the retrofit of demand-based control strategies in the supply system. Previous studies showed that a high saving potential remains in pressure filter plants for coolant cleaning. The plants are operated constantly on an excessive power level, independent on the coolant demand. A concept of a demand-based control is introduced and evaluated in simulations using the example of precoat filters. The analysis at an existing plant shows an energy saving potential of up to 73 %.

关键词： Energy efficiency

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Realizing Energy Reduction of machine tools Through a control-integrated Consumption Graph-based Optimization Method

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Procedia CIRP 2013年 7卷 640-645页

作者： Philipp Eberspächera Alexander Verla Institute for Control Engineering of Machine Tools and Manufacturing Units (ISW) Seidenstraße 36 70174 Stuttgart Germany

Industrial manufacturing has started focusing on the topic of energy efficiency already some years ago. Nowadays, even machine controls are equipped with possibilities to switch the machine into energy saving modes or even to shut it down entirely based on fixed time intervals or manually. The developed combination and modification of state-based consumption modeling with graph- based optimization theory enables the control to choose the energy-optimal state sequence for given unproductive times. The approach is presented in detail and its saving potential is demonstrated by a usage scenario from an industrial setup.

关键词： Energy efficiency Energy optimal control Consumption modeling Operating state-based optimization ECOMATION

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On the development of transformable sheet metal forming tools

On the development of transformable sheet metal forming tool...

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16th IFAC Symposium on Automation in Mining, Minerals and Metal Processing, MMM 2013

作者： Birkhold, M. Pauli, F.-B. Lechler, A. Verl, A. Institute for Control Engineering of Machine Tools and Manufacturing Units Seidenstrasse 36 70174 Stuttgart DE Germany Franz Pauli Gmbh and Co KG Hauptstrasse 24 59469 Ense-Parsit DE Germany

ISBN: (纸本)9783902823427

Freed from the strict sinusoidal motion of classic mechanical presses, the servo press allows new tool designs This free motion capability of the servo press can be used to integrate follow-up processes into the sheet metal forming tool With this approach, specialized equipment like dedicated welding stations becomes unnecessary Moreover, by introducing transformability to the design, this integration can be made reversible Depending on the production situation, it is possible to run the process integrated or externally This tool design allows the manufacturer to adapt to demand more easily, thus increasing its competitiveness However, the complexity of such sheet metal forming tools is significantly increased But tool manufacturers have yet to embrace the new capabilities of the servo press In this paper we will show the design for a transformable sheet metal forming tool The tool will produce a clamp, consisting of a ring and a holder Ring and holder are formed, combined and welded within the tool We will discuss the issues concerning mechanical and control systems design and show how we have solved them We will put a special emphasis on the challenges we faced with handling of forming parts, synchronization, placement and power supply of the integrated welding station Copyright © 2013 IFAC.

关键词： Presses (machine tools)

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