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International Workshop on Robot Sensing (ROSE)

作者： Jayanto Halim Mohamad Bdiwi Steffen Ihlenfeldt Group Collaborative Robot Systems Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz Germany Department of Production System and Factory Automation Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz Germany

ISBN: (数字)9798350362367

ISBN: (纸本)9798350362374

Agile manufacturing paradigms have revolutionized a new era of production processes, offering unparalleled flexibility and adaptability to the ever-changing landscape of product variations and smaller batch sizes. In response to this dynamic environment, the robotic industry has undergone a significant transformation, presenting a range of versatile robotic systems capable of swiftly deploying diverse applications. This transformative shift accelerates manufacturing processes and showcases the ability to accommodate product specifications and batch size variations. Welding is a notable example of robotics playing a crucial role in agile production. This work presents a novel approach combining no-code robot programming and an intelligent vision-based welding system. By leveraging this framework, even non-expert users can seamlessly instruct welding trajectories through intuitive interactions. These trajectories are meticulously crafted using advanced welding seam extraction algorithms, considering various welding joint types and inputs from heterogeneous sensors. Consequently, robot-specific parameters can be parametrized, and the generated robot code can seamlessly translate into robotic movements in the real world. Validation of this approach through real-world experiments underscores its potential for deployment in agile welding applications. The promising results affirm this novel methodology's efficacy, paving the way for its practical implementation in real-world scenarios. By effectively bridging the divide between advanced robotics and agile manufacturing, this approach can potentially elevate industrial robotic applications to new levels of efficiency and adaptability.

关键词： Agile manufacturing Service robots Welding Semantics Production Robot sensing systems Mathematical models

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Novel method for manufacturing herringbone gears by power skiving 15

Novel method for manufacturing herringbone gears by power sk...

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15th CIRP Conference on Intelligent Computation in Manufacturing Engineering, ICME 2021

作者： Bauer, Ruben Dix, Martin Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenainer Str. 88 Chemnitz09126 Germany

Due to the symmetrical flank configuration, herringbone gears have no resulting axial forces and a smaller tooth width than helical gears. Because of existing manufacturing limitations, currently only double helical gears with wide center space or assembled herringbone gears are applied. In the present work, a novel machining method for herringbone gears by power skiving is presented. For this purpose, tool and technology are designed using a mathematical process model and tested subsequently. It is shown that the process can produce the required geometry with significant improvements on productivity and accuracy. Additionally, the unused center area can be eliminated. © 2022 The Author(s).

关键词： Helical gears

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Computer-based design and development of a fully automated assembly of aircraft doors made of thermoplastic composite material

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Procedia CIRP 2024年 126卷 805-810页

作者： Rayk Fritzsche Erik Jäger Head of group Adaptable assembly systems at Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz 09126 Germany Scientific employeeat Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz 09126 Germany

For production of aircraft doors using innovative lightweight materials, a fully automated assembly process was developed. Therefor a door structure of an overwing-exit-door is to be joined from thermoplastic composite material components. The innovative material enable the use of new joining concepts. The assembly process was virtually simulated in order to forecast production time, process sequence, provision of operating resources and investment costs. Relevant manufacturing equipment was designed and accessibilities of the clamping and joining tools as well as collision areas were determined and optimized. To quality management, process control concept was developed with which geometric deviations of the components can be automatically compensated.

关键词： process automation aircraft production thermoplastic composite material assembly process virtual simulation manufacturing equipment

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Effects of abrasive waterjet cutting on surface properties of hardened steel 16

Effects of abrasive waterjet cutting on surface properties o...

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16th CIRP Conference on Intelligent Computation in Manufacturing Engineering, CIRP ICME 2022

作者： Redžic, Nermin Kieweg, Philipp Regel, Joachim Dix, Martin Chemnitz University of Technology Institute for Machine Tools and Production Processes Reichenhainer Str. 70 Chemnitz09126 Germany Franke GmbH Obere Bahnstraße 64 Aalen73431 Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 Chemnitz09126 Germany

The importance of cutting hardened materials without influencing their structural properties makes abrasive waterjet machining a favorable choice in certain applications in comparison with other manufacturing technologies. Using this technology, faulty surface structures and errors caused by high thermal loads such as burrs, burns and cracks, can be avoided. In this paper, the results of applying the abrasive waterjet technology for cutting of hardened steel and its advantageous properties in comparison with cut-off grinding will be presented. The influence of process parameters on surface properties and burr formation has been determined by experimental analysis. © 2023 Elsevier B.V.. All rights reserved.

关键词： Grinding (machining)

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Bioinspired approaches for resource-efficient material flow in production – an innovative actuator concept for peristaltic-based transport

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Procedia CIRP 2024年 125卷 249-254页

作者： Henriette Kunze Marcel Lorenz Scientific employee at Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Chemnitz Germany

In automated material flow, in a wide variety of areas, the primary goal is usually to handle a wide spectrum of components as time- and cost-efficiently as possible. In view of the current and future challenges in industrial production, it is becoming apparent that ecological requirements are becoming increasingly important in automation solutions. For example, in form of resource efficiency, transformability and material efficiency. In this context, especially materials handling technology is subject of various optimization approaches, as no value is added to the part handled. The question: "How does material flow occur in nature?" thus offers biologically inspired approaches to thinking about transport in the industrial sector. This paper first presents a selection of concepts or existing mechanisms that are adaptable in materials- handling technology and have been developed based on a biological model. In the second part of this paper, a new concept is presented that is modeled on peristalsis as a transport mechanism. The approach presented here uses tensegrity-structures for assembly, which are characterized by their high material efficiency and flexibility. The transport movement is achieved by peristaltic typical contraction or relaxation of the respective structure parts.

关键词： tensegrity biotensegrity assembly technologies

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Intelligent dressing for continuous generating grinding with convolutional neural networks and knowledge distillation

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Procedia CIRP 2024年 126卷 513-518页

作者： Martin Boesler Marco Schumann Philipp Klimant Martin Dix Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz 09126 Germany Institute for Machine Tools and Production Processes Chemnitz University of Technology Reichenhainer Str. 70 09126 Chemnitz Germany

Continuous generating grinding is a highly productive and precise way to finish hardened gears. However, the dressing of the tool has a huge potential for optimization. Detecting the optimal point to stop the dressing process would save cost and reduce machine downtime. This paper provides a proof of concept of how machine learning models can achieve these goals based on acoustic emission data. Therefore, different ML-Classifiers were trained and compared. Particular emphasis was placed on the robustness of the models. In addition, the trade-off between fast and robust models was examined.

关键词： Continuous generating grinding Dressing machine learning Convolutional neural network Distillation

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Intelligent parameter determination and quality control of an injection molding process

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Procedia CIRP 2024年 126卷 721-726页

作者： Sina Nahvi Marco Schumann Martin Dix Philipp Klimant Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Chemnitz Germany Institute for Machine Tools and Production Processes Chemnitz University of Technology Reichenhainer Str. 70 09126 Chemnitz Germany

One of the most extensively utilized techniques for material processing is injection molding, which is used to manufacture highly accurate and complex plastic items. In order to produce qualified items and ensure quality of the products, process parameter determination is crucial. We propose and compare two approaches for intelligently determining the parameters and controlling the quality within the injection molding process while aiming towards zero defects. These approaches are combinations of the process model trained using Automated machine Learning (AutoML) with optimization techniques based on Bayesian and genetic algorithms.

关键词： Injection molding Process parameter determination Quality control Optimization machine Learning

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Case Study of Robot Machining at Different Working Space Locations

Case Study of Robot Machining at Different Working Space Loc...

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MECHATRONIKA International Symposium

作者： Mikuláš Szabari Jan Berhold Jan Vetiška František Bradáč Michal Holub Martin Dix Institute of Production Machines Systems and Robotics Brno University of Technology Brno Czech Republic Cutting Technology Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany

ISBN: (数字)9798350394900

ISBN: (纸本)9798350394917

Machining, 3d printing and robot welding require a minimum difference between simulated and real position of robot (TCP) to facilitate high quality surface finish and fulfil dimension and form tolerance. The solution is the absolute robot calibration, which increases positional accuracy. In this paper, a calibrated direct-measuring robot is used to machine the sample part. In the experiment, the sample part is positioned at different location and machined by different machining processes. Then the produced part is measured on a coordinate measuring machine (CMM). The quality of the surface finish, dimensions and geometric tolerances are evaluated. This experiment showed the effect of calibration on the machining process. Based on the obtained results, further activities will be directed in the field of increasing the geometric accuracy of industrial robots.

关键词： Drilling Accuracy Coordinate measuring machines Service robots Robot kinematics Machining Kinematics Surface finishing Robots Surface treatment

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Methods for the environmental and economic assessment in early product design – a case study-based overview for wind turbines in urban areas

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Procedia CIRP 2024年 122卷 789-794页

作者： Martin Zumpe Maximilian Stange Ahmet Burak Ertem Marian Süße Steffen Ihlenfeldt Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Institute of Mechatronic Engineering Technische Universität Dresden Dresden Germany

The assessment of environmental impacts has become an inevitable necessity for many manufacturing companies – not only from a mere retrospective viewpoint but also for product design decisions. At the same time, economic feasibility must be constantly considered throughout all product design phases. For both dimensions, many different decision-support methods exist. However, there is a lack of combined assessment methods especially in early product design phases, when product characteristics, manufacturing technologies and corresponding data are still uncertain. The paper provides an overview and qualitative evaluation of different methods for economic and ecological assessment in product design stages. Based on this, a generalized procedure for combined economic and ecological decision-making during product design is derived, highlighting possible coping mechanisms for uncertain or insufficient data. Both, the evaluation of available assessment methods as well as the derived procedure are transferred to the specific requirements of wind turbines in urban areas. As a result, open research aspects and the next steps for method development are derived.

关键词： Eco-design methodology LCA Evaluation Environment Wind Turbines

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Combining material flow simulation and optimization for sustainable manufacturing – application in automotive paint shops

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Procedia CIRP 2024年 122卷 659-664页

作者： Marian Süße Xinyi Xie Steffen Ihlenfeldt Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Institute of Mechatronic Engineering Technische Universität Dresden Dresden Germany

The necessity for sophisticated decision support in industrial manufacturing has been described manifoldly and simulation approaches as well as optimization methods are continuously developed. This can be especially promising when it comes to decision-making with multidimensional requirements of economic and ecological efficiency. However, due to the required expert knowledge, there is still a gap between theoretically applicable and industrially applied methods. The paper therefore presents results of two use cases as part of the European project ECOFACT where different approaches for the combination of simulation and (heuristic) optimization were applied with industry partners. An overview of recent works and systematic literature reviews of sustainable manufacturing and the approaches for combining simulation and optimization is given. Correspondingly, the investigated use cases of automobile paint shops refer to the reduction of environmental impacts by optimized heating processes and an improved batching process to minimize paint waste. In the first case, setup times for heating color pools and ovens were shifted to avoid load peaks in a calculation time of less than one minute. In the second use case batch size was increased by around 25%.

关键词： Sustainable manufacturing Energy Simulation Optimization

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