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18th IFAC Workshop on Time Delay Systems, TDS 2024

作者： Ranke, Daniel Trierweiler, Michael Berkhan, Patricia Münnich, Marc Bauernhansl, Thomas Fraunhofer Institute for Manufacturing Engineering and Automation IPA Nobelstr. 12 Stuttgart70569 Germany Institute of Industrial Manufacturing and Management IFF Nobelstr. 12 Stuttgart70569 Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany

The industry's use of adaptable production systems, such as matrix production, is increasing. However, these systems vary in their specific details. The lack of a unified definition, delimitation, and description hinders comparability and the transfer of lessons learned between different systems. This paper aims to propose a comprehensive definition of matrix production and differentiation between different implementation forms. To achieve this, the paper first examines existing approaches to define and describe production systems and their manifestations. Various frameworks and models have been proposed in the literature, but they often focus on specific aspects of production systems, neglecting the complexity of matrix production. The paper identifies common elements and challenges in defining and describing production systems by analyzing these approaches. A second investigation analyzes various existing descriptions of matrix production from the scientific literature. While some definitions focus on the organizational structure, others emphasize operational aspects. By synthesizing these definitions, the paper proposes a comprehensive definition of matrix production encompassing both dimensions. Furthermore, the paper includes cases of industrial implementations as a third investigation. These cases provide insights into the practical application of matrix production systems across different industries. The paper identifies common characteristics, challenges, and benefits associated with matrix production by analyzing these implementation examples. Finally, all three investigations are combined to create a unified definition and a complementary descriptive model. The proposed framework provides a systematic approach to define and describe matrix production systems. It allows for a better understanding and comparison of different implementations, facilitates the transfer of lessons learned, and promotes the exchange of best practices. This framework will enable r

关键词： Production efficiency

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Tool-holder integrated printed piezoceramic sensors for process state classification and tool-wear progress evaluation in turning

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Procedia CIRP 2025年 133卷 382-387页

作者： Miguel Panesso Jan Berthold Lucas Hamm Zongshuo Li Welf-Guntram Drossel Thomas Bergs Fraunhofer Institute for Machine Tools and Forming Technology Nöthnitzer Str. 44 01187 Dresden Germany Manufacturing Technology Institute (MTI) of RWTH Aachen University Campus-Boulevard 30 52074 Aachen Germany

Tool condition monitoring strategies in turning processes, using multiple sensor sources to measure dynamic quantities (e.g., force, acoustic emissions, acceleration), has gained significant attention in conjunction with machine learning methods. As a novel approach, the introduction of printed piezoceramic thick films in machine tools allows the customization of sensor shape and placement, optimized to fit the tool holder’s geometry and process boundary conditions. This work proposes integration concepts using two configurations of printed piezoceramic sensors. This includes the use of a finite element simulation to estimate the generated electric charge from sensors on three locations on the tool holder, induced by transient mechanical loading. The design is validated under controlled mechanical loading and tested across various cutting conditions and tool-wear states. Signal information content from each sensor location, relative to different machining conditions, is assessed through recursive feature elimination and validated using dimensionality reduction. Finally, tool-wear progress is evaluated using the selected features.

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Automated shop floor reconfiguration and process integration: towards product driven manufacturing systems

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Procedia CIRP 2025年 134卷 49-54页

作者： Marcel Albus Florian Duewel Katharina Barbu Jan Eric Huebner Christian Keilig Christian Gollee Fraunhofer Institute for Manufacturing Engineering and Automation IPA Nobelstraße 12 70569 Stuttgart Germany Fraunhofer Institute of Optronics System Technologies and Image Exploitation IOSB Fraunhoferstraße 1 76131 Karlsruhe Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Pforzheimer Straße 7a 01189 Dresden Germany

Flexible manufacturing systems are crucial in today’s rapidly evolving manufacturing landscape, characterized by supply chain disruptions, shorter product lifecycles, and diverse customer demands. Introducing new products necessitates extensive planning efforts, including price estimates, production cost evaluation and ensuring resilience. This paper presents a comprehensive approach through an integrated digital toolchain for reconfiguration planning in manufacturing companies, from production feasibility to shop floor execution. The solution leverages data space connectors to facilitate information exchange between customers and Modular Production (MP) environments. Key features include the STEP decomposition, resource capability matching, automated assembly line reconfiguration and balancing, as well as the automated integration and execution of manufacturing processes on the shop floor. This toolchain aims to enable automated data exchange, coordinated order planning, and efficient shop floor operations, allowing manufacturers to adapt to market changes while maintaining cost-effectiveness and resilience.

关键词： Shop Floor Reconfiguration Automated Process Execution Assembly Line Balancing

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Robotic Visual Servoing for Tracking Structureless Moving Parts

Robotic Visual Servoing for Tracking Structureless Moving Pa...

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Iberian Robotics Conference (ROBOT)

作者： Christian Schroder Marco Schumann Rico Loser Philipp Klimant Martin Dix Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Professorship Virtual Technologies Hochschule Mittweida - University of Applied Sciences Mittweida Germany Institute for Machine Tools and Production Processes Chemnitz University of Technology Chemnitz Germany

ISBN: (数字)9798350376364

ISBN: (纸本)9798350376371

The European Union has committed to achieving the 1.5-degree Celsius limit set by the Paris Climate Agreement, emphasizing the necessity for substantial energy savings across various sectors, particularly in industry. This ambitious goal requires a delicate balance between reducing energy consumption and maintaining economic strength. Concurrently, there is a noticeable shift from mass production to mass customization, driven by the need for more flexible and adaptable manufacturing processes. Cognitive robotics emerges as a pivotal technology in this context, offering enhanced capabilities for flexible production lines. One significant advantage is the ability to assemble moving parts which optimizes cycle times and therefore contributes to energy savings. This paper presents a novel approach to object tracking using NC robot-based position control, demonstrating its potential to support the industry's transition towards more sustainable and efficient manufacturing practices. The image processing algorithm, which consists of a fused methodology merging an iterative 2D image registration and stereo vision-based point cloud registration, demonstrates the ability to track an object with a mean L2-error of 3.5 mm in a dynamic environment.

关键词： Industries Point cloud compression Service robots Heuristic algorithms Energy conservation Position control Production Visual servoing Object tracking Meteorology

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forming Limit of Dual Phase Steel: An Experimental and Numerical Investigation 14th

Forming Limit of Dual Phase Steel: An Experimental and Numer...

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14th International Conference on technology of Plasticity, ICTP 2023

作者： Müller, Martina Fehlemann, Niklas Herrig, Tim Lenz, David Könemann, Markus Bergs, Thomas Münstermann, Sebastian Laboratory for Machine Tools and Production Engineering WZL of RWTH Aachen University Campus-Boulevard 30 Aachen52074 Germany Fraunhofer Institute for Production Technology IPT Steinbachstrasse 17 Aachen52074 Germany Institute of Metal Forming IBF RWTH Aachen University Intzestrasse 10 Aachen52074 Germany

ISBN: (纸本)9783031409196

forming limit diagrams and forming limit curves are used to determine the failure limits of sheet metal materials by conducting a forming limit analysis. The aim is to enable the selection of suitable materials, geometries and process parameters at an early stage in the component development. In this way, engineering time and costs can be reduced. In addition to experimental forming limit analyses, different models and model approaches exist to numerically predict damage and failure. All have in common that calibration is necessary based on experimental investigations. The correspondingly determined parameters specify when ductile damage initiation begins, how it evolves, and how the material finally fails. Thus, the calibration and the parameters determined have a significant impact on the models’ accuracy. The present work focuses on the numerical prediction of DP 800 dual phase steel in a Nakajima test using a modified Bai-Wierzbicki model. Besides the calibration influence of the damage model coming from a non-unique parameter selection is investigated. A sensitivity analysis of the experimentally determined parameters of the damage model is carried out with the aim of predicting the crack initiation with high accuracy and to determine the influence of the calibrated parameters, especially the range between the damage initiation locus, the failure locus and the damage evolution rate. The objective is to determine which damage model parameters possess a high influence on the failure prediction, in order to be able to make a risk assessment with regard to the prediction accuracy for later applications. © 2024, The Author(s), under exclusive license to Springer Nature Switzerland AG.

关键词： Calibration

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A case study on the use of open source hardware in mechanical engineering 34

A case study on the use of open source hardware in mechanica...

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34th CIRP Design Conference, CIRP 2024

作者： Veliu, Cäcilia Petzold, Valentin Reichelt, Dirk Stange, Maximilian Ihlenfeldt, Steffen Dresden University of Applied Sciences Friedrich-List-Platz 1 Dresden01069 Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Strasse 88 Chemnitz09126 Germany Institute of Mechatronic Engineering Technical University Dresden Helmholtzstr. 7a Dresden01069 Germany

Open Source Hardware (OSH) enables innovative developments and business models. The OSH approach creates new forms of cross-company product development and community-based innovation processes. Open source has been state of the art in software industry for years. When it comes to OSH projects, however, the focus is primarily on the consumer sector. The use of OSH for industrial products, especially in mechanical engineering, is still in its early stages. The paper presents a case study on the development of an application module based on OSH components in a R&D testbed. The developed module is intended to enable electronic functional testing. For this purpose, the development process involved, among other things, creating solutions for a tool changing system. Using the case study, we analyse the advantages and disadvantages of the open source licenses used and derive implications for the R&D process. Building on this, various concepts for the use, adaptation and expansion of OSH components and the resulting implications for development processes and business models are presented. The case study is used to analyse which established open source software concepts can be transferred to material assets, but also which additional requirements arise from OSH components, e.g. in the area of safety. © 2024 The Authors. Published by Elsevier B.V.

关键词： Software testing

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Incorporating Shape Knowledge into Regression Models

arXiv

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arXiv 2024年

作者： Poursanidis, Miltiadis Link, Patrick Schmid, Jochen Teicher, Uwe Fraunhofer Institute for Industrial Mathematics ITWM Kaiserslautern67663 Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz09126 Germany

Informed learning is an emerging field in machine learning that aims to compensate for insufficient data with prior knowledge. Shape knowledge covers many types of prior knowledge concerning the relationship of a function's output with respect to input variables, for example, monotonicity, convexity, etc. This shape knowledge - when formalized into algebraic inequalities (shape constraints) - can then be incorporated into the training of regression models via a constraint problem formulation. The defined shape-constrained regression problem is, mathematically speaking, a semi-infinite program (SIP). Although off-the-shelf algorithms can be used at this point to solve the SIP, we recommend an adaptive feasible-point algorithm that guarantees optimality up to arbitrary precision and strict fulfillment of the shape constraints. We apply this semi-infinite approach for shape-constrained regression (SIASCOR) to three application examples from manufacturing and one artificial example. One application example has not been considered in a shape-constrained regression setting before, so we used a methodology (ISI) to capture the shape knowledge and define corresponding shape constraints. Finally, we compare the SIASCOR method with a purely data-driven automated machine learning method (AutoML) and another approach for shape-constrained regression (SIAMOR) that uses a different solution algorithm. © 2024, CC BY.

关键词： Contrastive Learning

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Coupled CFD model of tool environment and workspace to determine the convective heat transfer in jet cooling of milling processes in machine tools

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Procedia CIRP 2025年 133卷 280-285页

作者： Steffen Brier Alexander Geist Janine Glänzel Christian Naumann Joachim Regel Martin Dix Steffen Ihlenfeldt Chemnitz University of Technology Professorship Production Systems and Processes Reichenhainer Str. 70 09126 Chemnitz Germany Fraunhofer-Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 09126 Chemnitz Germany Technical University Dresden Institute for Machine Tools Development and Adaptive Controls Helmholtzstraße 10 01069 Dresden Germany

The responsible use of resources is an essential part of the manufacturing of industrial products. This includes the economical use of cooling lubricant and requires precise knowledge of the cooling mechanisms and their effect on the accuracy of the machine tool and thus the thermal error. A temporal and spatial resolution of the dynamic coolant flow near the tool and in the entire workspace in a single model would require a large simulation time. Therefore, a composite model was developed, that consists of a near-tool model and a larger surrounding workspace model. The required static near-tool cooling lubricant distribution is obtained via data discretization methods from a separate static simulation that resolves the turbulence of the cooling lubricant created by the tool rotation. The identified coolant distribution is integrated into a CFD near-tool model (with simplified tool geometry) which is coupled with a surrounding CFD workspace model. The workspace model is thus able to identify the effects of the coolant wetting on the machine surface temperature and finally, using thermo-elastic FEM simulations, on the resulting thermal error. This approach allows the composite model to simulate the entire workspace with reduced simulation effort and map the coolant-influenced heat transfer coefficients on the machine surface.

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Influence of the cutting edge preparation of carbide punching tools for punching of ultra-high strength steel strips

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Procedia CIRP 2024年 123卷 268-273页

作者： Nermin Redžić Sven Winter Elmar Galiev Sarah Baron Christian Stein Markus Höfer Joachim Regel Verena Kräusel Martin Dix Chemnitz University of Technology Institute for Machine Tools and Production Processes IWP Reichenhainer Str. 70 09126 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 09126 Chemnitz Germany Fraunhofer Institute for Surface Engineering and Thin Films IST Riedenkamp 2 38108 Braunschweig Germany

In order to ensure a robust punching process of ultra-high strength steel spring strips using carbide punching tools, a high stability of the cutting edge is required. Here the cutting edge preparation process has a significant influence. In the presented study, high-pressure abrasive water jet technology for cutting edge preparation was designed, investigated and analysed. For defining the optimal cutting edge shape regarding stresses, a numerical analysis using LS-DYNA was conducted. Within this analysis, the influence of the cutting edge rounding and symmetry was numerically tested and evaluated. Based on the results, two cutting edge shapes were selected and prepared using the high-pressure abrasive water injection jet technology. The tools were applied in the punching process up to 50,000 strokes in order to analyse the cutting performance and tool wear. With regard to a highly wear resistant tool for punching, a combination of the abrasive water injection jet preparation routine and a CVD diamond coating are under further investigation and first insights are presented additionally.

关键词： Punching Carbide Tool geometry Waterjet machining Ultra-high strength steel

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Investigation of Surface Characteristics in Magnetic Field assisted Electrical Discharge Machining

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Procedia CIRP 2024年 123卷 416-421页

作者： Viet D. Bui André Martin Thomas Berger Andreas Schubert Chemnitz University of Technology Professorship Micromanufacturing Technology Reichenhainer Str. 70 09126 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Str. 88 09126 Chemnitz Germany

Electrical discharge machining (EDM) has demonstrated its promising potential for surface modification. The integration of materials from tool electrode or powder that is mixed into the dielectric fluid has proven to modify the workpiece surface to enhance its mechanical properties, realize antibacterial effects, or increase biocompatibility. Recent EDM studies showed that due to non-contact forces, properties of the modified surface such as roughness values and the thickness of modified layer were significantly influenced when using magnetic field assisted EDM. Consequently, in this study, an external magnetic field with a strength of 0.66 T is used to assist the material transfer from tool electrode to workpiece surfaces during the EDM process. Pure silver and copper tools with a diameter of 2 mm are used to modify surfaces of Ti6Al4V workpieces at a discharge energy of 125 µJ with different polarities. Results show that the assistance by magnetic field significantly increases the content of transferred material from tool electrode to the workpiece surface. Additionally, it increases material removal rate and reduces the modified layer thickness. Magnetic field assisted EDM is a potential technology for improving the efficacy of the EDM surface modification.

关键词： EDM magnetic field deposition modified surface

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