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International Electric Drives Production Conference (EDPC)

作者： Jakob Bonart Philipp Hümmer Welf-Guntram Drossel Technology development E-Drive BMW AG MunichGermany Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz Germany

ISBN: (纸本)9781665418102

Production lines for electric drives consist of successive assembly steps. The highly integrated topology of the unit can lead to complex faults caused by poor components or incorrect assembly. To minimize the added value of a bad motor, a noise-vibration-harshness (NVH) measurement is performed on an in-line test bench (IL). Following the IL, other components (gearbox, inverter, …) are assembled, resulting in a finished electric drive unit. The final state is again tested by a NVH measurement on an end-of-line (EOL) test bench. A novel approach is presented that combines the results of both test benches into an overall picture, thus creating a contextual environment for the EOL. Depending on the interaction of the two test benches, different implications are derived. An identified defect on the EOL can be further classified by deviations already present in the IL test. Deviations that are not present on the IL also indicate processes between the two test stands and thus increase the ability to correctly classify defects on the EOL. If deviations are present on the IL, an indicator of significant testability is derived. This can be further used to accurately detect defects that were previously only detected on the EOL.

关键词： Vibrations Location awareness Electric variables measurement Production Manuals Vibration measurement Topology

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Everting of tubular net structures based on Shape Memory Alloys

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Engineering Research Express 2021年第2期3卷

作者： Hensel, Sebastian Boxberger, Lukas Weisheit, Linda Schellnock, Julia Thielsch, Juliane Riedel, Frank Drossel, Welf-Guntram Fraunhofer Institute for Machine Tools and Forming Technology IWU Dresden01187 Germany Professorship for Adaptronics and Lightweight Design Chemnitz University of Technology Chemnitz09126 Germany

Foldable technical structures can be used to provide a temporary additional volume. In nature, a tubular folding application is the extension of the snail eye. The present study uses this approach. A transformation into a technical application is only successful if the high eversion loads are considered. The study aims to develop a method to realize such structures based on a metallic wire net structure. The tube consists of Shape Memory Alloy (SMA) pieces connected by developed crimp elements produced by additive manufacturing. Additive manufacturing was used to provide a fast and effective way to make several crimp element geometries available to define a preferred variant. In a preliminary building study, the printing parameters for crimp element production were improved. The tubular structure development is assisted by numerical simulation of the eversion process. The SMA material model parameters were identified with experimental tension tests. A feasible way to connect additively manufactured crimp elements with SMA wire was found within a joining method study. Tension tests of the connections protect against pull-out failure. The eversion process was investigated using a high-speed camera system. Multiple eversion of the developed structure is possible without failure. © 2021 The Author(s). Published by IOP Publishing Ltd.

关键词： 3D printers

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Data Acquisition Framework for spatio-temporal analysis of path-based welding applications

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Procedia CIRP 2024年 130卷 1644-1652页

作者： Georgij Safronov Heiko Theisinger Vasco Sahlbach Christoph Braun Andreas Molzer Anabelle Thies Christian Schuba Majid Shirazi Thomas Reindl Albrecht Hänel Philipp Engelhardt Steffen Ihlenfeldt Peter Mayr BMW AG Petuelring 130 80788 München Germany Technical University of Munich Chair of Materials Engineering of Additive Manufacturing Freisinger Landstraße 52 85748 Garching bei München Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Nöthnitzer Straße 44 01187 Dresden Germany nebumind GmbH Willy-Messerschmitt-Straße 1 82024 Taufkirchen Germany

The use of digital technologies in industrial manufacturing reduces operational costs and improves production quality. The “Framework for Spatiotemporal Production Data Acquisition” (PathSense) aims to improve access and usability of production data by applying a common data ecosystem. Through integrating operational technology (OT) and information technology (IT), PathSense supports decision-making and process optimization. The framework uses the concept of digital shadows to collect critical information from sensors within the continuous manufacturing processes, e.g., welding or gluing lines. Spatial and temporal digital shadows are developed in accordance with human spatial cognition to support sophisticated–yet intuitive–human-computer interactions without the need for advanced data science skills. The backbone of the framework consists of robust data pipelines with a setup incorporating modern IT protocols, such as OPC UA and MQTT, to support the efficient acquisition and management of data. The paper addresses the challenges associated with the combination of IT and OT in cyber-physical systems, stressing modern complex data-intensive manufacturing as one exemplary domain to be tackled by scalable and secure data architectures. The paper identifies two major future directions: refining data integration processes and embedding advanced machine learning algorithms to enable automated data analysis and improve process quality monitoring. In summary, PathSense proposes a data-driven approach for quality inspection in manufacturing, which may eventually enhance industry practices and move towards data-driven decisions and increased operational flexibility.

关键词： PathSense digital twin welding process data acquisition spatiotemporal analysis defect detection OPC UA MQTT AI

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Reaming of carbon fibre reinforced plastics: Influence of tool geometry on process forces and tool wear

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Procedia CIRP 2021年 99卷 409-413页

作者： Konstantin Sauer Matthias Putz Chemnitz University of Technology Reichenhainer Strasse 70 09126 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Strasse 88 09126 Chemnitz Germany

Due to the high abrasive wear and the tendency to workpiece damages, the manufacturing of high-quality bores in carbon fibre reinforced plastics (CFRP) is still one of the major goals in tool development. In this work, reaming tests are performed on CFRP in order to characterise the relationship between tool geometry, process forces and tool wear. After a preliminary investigation of a taper reamer, diverse carbide tools have been tested which exhibit different values of rake and clearance angle. The forces measurement took place using a rotating dynamometer, while the evaluation of the tool wear has been realised by microscopic images via structured light projection. Different forms of wear appear, while hardly any differences in the force curves can be detected when applying different angles of the cutting wedge.

关键词： Drilling Reaming CFRP Bore quality Tool wear

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Hybrid approach to evaluate surface integrity based on grinding power and Barkhausen noise

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Procedia CIRP 2022年 108卷 489-494页

作者： Jonas Heinzel Rahel Jedamski Maximilian Rößler Bernhard Karpuschewski Jérémy Epp Martin Dix MAPEX Center for Materials and Processes University of Bremen Bibliothekstr. 1 28359 Bremen Leibniz Institute for Materials Engineering IWT Badgasteiner Str. 3 Bremen 28359 Germany Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Straße 88 09126 Chemnitz Germany

In this paper the potential of a reliable characterization of surface and subsurface properties is presented by measurement of process forces for determining the specific grinding power Pc” and the micromagnetic Barkhausen noise in cylindrical grinding trials. Therefore different dressing conditions by grinding with conventional wheel with varying process parameters are investigated. It is shown that an identified lower thermal limit in a Pc” - ∆t -diagram (contact time ∆t ) to prevent tempering zones in the ground surface and subsurface area of case hardened steel is applicable even if the condition of the grinding wheel is intentionally influenced by dressing. Finally a soft sensor concept for the use of the specific grinding power and in perspective also the use of the Barkhausen noise for process control is derived.

关键词： grinding burn detection surface integrity process control

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Synergy Analysis and verification of connected Cyber Physical Systems using virtual commissioning

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Procedia CIRP 2021年 99卷 639-644页

作者： Christoph Allmacher Anna Seiderer Philipp Klimant Michael Kuhl Institute for Machine Tools and Production Processes Chemnitz University of Technology Reichenhainer Str. 70 09126 Chemnitz Germany Mittweida University of Applied Sciences Technikumplatz 17 09648 Mittweida Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 09126 Chemnitz Germany

The design of cyber physical systems in today’s production and intralogistics is influenced by the increasing availability and exchange of data. On the one hand, synergies between connected systems can be used to develop lightweight applications by sharing and reusing data. On the other hand, the possible combinations between these systems increase the complexity and design options. This paper presents a method to structure possible design options systematically and proposes virtual commissioning as solution for their analysis and verification to enable early design decisions. The method is demonstrated using an automated guided vehicle combined with a tactile warning device.

关键词： Virtual commissioning Automated guided vehicle Tactile warning device

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Digital innovation hubs for robotics – TRINITY approach for distributing knowledge via modular use case demonstrations

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Procedia CIRP 2021年 97卷 45-50页

作者： Minna Lanz Jan Reimann Aleš Ude Niki Kousi Roel Pieters Morteza Dianatfar Sotiris Makris Tampere University Tampere Finland Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Jožef Stefan Institute Ljubljana Slovenia University of Patras Patras Greece

Robots are no longer stand-alone systems on the factory floor. The demand for industrial robots (market) is anticipated to be growing to 65 billion euros by the year 2023. Within all areas of robotics, the demand for collaborative and more flexible systems is rising as well. The level of desired collaboration and increased flexibility will only be reached if the systems are developed as a whole, e.g. perception, reasoning and physical manipulation. The rising need for collaborative robots in the automation industry is acting as a driver for this market and is expected to serve as a market opportunity for future growth. However, at the same time especially smaller companies have difficulties to formulate a concrete vision and strategies for the uptake of robotics, finding skilled workforce to develop and deploy the robot systems and/or work in the manufacturing industry. A number of Digital Innovation Hubs (DIHs) have been developed to enhance the knowledge and technology transfer from laboratories to factory floors, mitigating the skills gap and supporting the formulation of innovation ecosystems with the specific focus on small and medium-sized companies around Europe. The main aim of this paper is to introduce the concept and approach taken in H2020 TRINITY-project that aims to develop a Robotics Innovation Hub focused on Agile Production. The paper will introduce the concept and technical approach of the project, and discusses the preliminary results, challenges and opportunities of these kind of DIHs.

关键词： Digital innovation hub Modular Robotics ICT IIoT

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Application of Fourier-related data reduction methods in sheet metal forming

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Procedia CIRP 2021年 99卷 260-265页

作者： Christian Schwarz Patrick Link Steffen Ihlenfeldt Welf-Guntram Drossel Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Strasse 88 Chemnitz 09126 Germany Institute of Mechatronic Engineering TU Dresden Helmholtzstrasse 7a Dresden 01062 Germany Institute for Machine Tools and Production Processes TU Chemnitz Reichenhainer Strasse 70 Chemnitz 09126 Germany

Due to the increasing digitalization, modern solutions are needed to work effectively with rapidly growing amounts of data in the automotive production. This paper shows two potential fields of application for the practical use of data reduction methods. In particular, the combination of Fourier-related transformation methods (e.g. discrete Fourier transform) and surrogate models for the useful 3D visualization of complex interrelationships is shown using the example of press hardening and deep drawing.

关键词： Press hardening Deep drawing FEM Sensitivity analysis Discrete Fourier Transform (DFT) Discrete Cosin Transform (DCT)

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Usage-based leasing of complex manufacturing systems: A method to transform current ownership-based into pay-per-use business models

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Procedia CIRP 2022年 107卷 1238-1244页

作者： Mohaned Alaluss Chris Drechsler Robin Kurth Anton Mauersberger Steffen Ihlenfeldt Michael Marré Rainer Labs Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Strafβ 88 09126 Chemnitz Germany Institute of Mechatronic Engineering Technische Universität Dresden Helmholtzstr. 7a 01069 Dresden Germany South Westphalia University of Applied Sciences Frauenstuhlweg 31 58644 Iserlohn Germany

Manufacturing technology with its cost- and resource-intensive manufacturing machines like machine tools, whose amortization often takes several years, is characterized by a high degree of individualization. Here, the need for increasingly complex as well as individualized products leads to the demand for high flexibility and resilience in complex manufacturing systems. The increasing uncertainty and volatility in the markets pose high economic risks for machine operators with ownership-based business models to enter new technologies. Consequently, this restrains the innovative and creative power of manufacturing companies. Although leasing models exist in various industry sectors like printing industry or compressed air supply, their implementation is still challenging due to the high degree of complexity regarding machine system, process, and services of the leasing product. In this paper, a novel method, with increased consideration of technical-technological aspects, to transform current ownership-based into usage-based business models like pay-per-use, is proposed. The resulting method also considers the pay-per-use readiness through an initial assessment of the existing manufacturing system.

关键词： perfomance-based contracting pay-per-use method business models manufacturing machines machine tools industry 4.0 agile production

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Impact of shape irregularity in medial sphenoid wing meningiomas on postoperative cranial nerve functioning, proliferation, and progression-free survival

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Brain and Spine 2023年 3卷 101857-101857页

作者： Wach, Johannes Block, Greta-Aimée Vychopen, Martin Grunert, Ronny Güresir, Erdem Arlt, Felix University Hospital Leipzig Germany Fraunhofer Institute for Machine Tools and Forming Technology Zittau Germany

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